Event

Electric Drivetrain Innovation: Component to System Level Design

UKMagSoc

EDISON

Feb 23rd 2022 - Feb 23rd 2022

Updated 22 February 2022

Please register at the bottom of this page

The UK’s EDISON Project is developing the first ferrite magnet motor with potential to be used in an automotive ePowertrain.

In this ‘X-motor’, the rotor features a ‘3D flux focusing’ layout for the magnets, where a ‘circumferentially magnetised’ assembly positioned in spokes interacts with two sets of ‘axially magnetised’ magnets in rings at each end. This arrangement delivers a resulting performance matching that of a conventional IPM.

This seminar will report the findings of the project, looking at materials, topologies, and machine modelling, optimisation, construction and testing.

The seminar will be a hybrid event with both in-person and online parts, although the event may be run wholly virtually if Covid restrictions change:

  • The in-person part will be held at Jaguar Land Rover, Castle Bromwich, UK.
  • The online part will include the presentations and its own networking opportunities. We will also be trialling cross-over activities between in-person and virtual delegates.

CHAIR

  • Annabel Shahaj, Romax

IN-PERSON EVENT

The in-person event will be held at Jaguar Land Rover, Castle Bromwich, UK. More details will be added when we have them.

COVID MEASURES

If you’re attending in person, you will need to follow Covid measures as a condition of entry:

  1. Please complete a Lateral Flow test at home, no more than 48 hours prior to the arrival at the venue. You will be required to show proof of a negative result.
  2. Please wear a mask or face covering when entering and walking round.

SITE TOUR

A tour of the manufacturing facilities at Castle Bromwich will be part fo the in person agenda.

VIRTUAL EVENT PLATFORM

The virtual part of the event will be hosted on Zoom. As well as the talks presented, you can also:

  • visit and talk with exhibitors in the Breakout rooms
  • Ask questions of speakers and send comments during the whole event via Chat

CONTINUING CONTACT / GDPR

Please note, by providing contact details during registration, you authorise us to

  • use these contact details to let you know details of this event, and
  • add your contact details to our contact database to let you know about future events that may be of interest.

Please let us know at enquiries@ukmagsoc.org at any time if you do not wish to be contacted in this way. Also, we can remove you from our contact schedule at any point in the future.

SPONSORS

Hexagon

Dassault Systemes UK

GRM consulting

NPL

University of Sheffield

Jaguar Land Rover

 


Speakers

Metrology of Magnetic Materials in Motors
by Daniel Brunt of NPL

With the drive towards electrification of vehicles, there is a growing demand for more accurate datasets that are more representative of a material, while in operation. Throughout the Edison project NPL has been extending our measurement capabilities and been building the metrology around these operational conditions. In this presentation I show the work NPL has been doing to perform this magnetic characterisation on the permanent magnets and soft magnetic materials used in the construction of the novel ferrite motor.

Building and Modal Testing a Prototype Radial Flux Machine
by Riza Jamaluddin of Hexagon System Dynamics

As the ferrite motor was assembled into the final integrated drive unit that was tested; modal tests were carried out on each key component and sub assembly.  This presentation describes how those tests were performed and details the test results.  Suitability of simulation to predict these results is assessed.  Concluding in a proven methodology for predicting dynamic behaviour of an automotive e-powertrain.

High Performance Ferrite Machine Experimental Validation
by Khoa Hoang of University of Sheffield

The presentation illustrates the experimental evaluation of a novel 12,000rpm, 80kW Ferrite IPM machine for traction applications. For IPM machine validation, accurate information about IPM machine parameters is essential. In practice, IPM machine dq-axis parameters (dq-axis inductances/dq-axis stator flux linkages) exhibit a highly nonlinear relationship with dq-axis currents, thus, they are often defined as a function of dq-axis current. Therefore, for characterizing the Ferrite IPM machine prototype, a parameter identification method employing stator flux linkage and torque maps as a function of dq-axis current is presented. Based on the obtained stator flux linkage and torque maps, current reference look-up table (LUT) as a function of torque-speed operation could be generated. It is shown that a good agreement in efficiency between FEA and measurement could be achieved using the defined current reference LUTs.

Electromechanical Effects of Eccentricity in a Geared EDU
by Chris Riley, Bartosz Lukasik of Dassault Systemes (Opera), Hexagon System Dynamics

One of the major goals of the Edison project was to develop software tools that allowed accurate system simulation of a complete electric drive unit (EDU). A typical EDU consists of an electric motor, bearings, shafts, gears, electronics and casing. Due to their interaction, all of these may be subject to vibration leading to excessive noise – although the individual components operate quietly in isolation. Two independent simulation software packages, SIMULIA Opera for electromagnetic modelling of the motor and Romax Evolve for mechanical simulation of the system, were coupled to achieve the software tools needed for accurate NVH (noise, vibration and harshness) simulation. This presentation describes the procedures developed by the Opera and Evolve teams to give a sufficient level of accuracy and highlights areas where numerical noise in the simulation can lead to spurious, non-physical mechanical response if not treated carefully. A further aim of the project was to use these simulation tools to identify the types of mechanical deformation to the motor, resulting from its interaction with the drive system, that lead to excessive NVH. Among the sensitivity studies performed, using an 8-pole, internal permanent magnet (IPM) motor in the EDU, were: • static • stator ovalling • tooth rocking • rotor tilt • rotor eccentricity • dynamic • tooth rocking • forward rotor whirl The presentation will discuss some of the results, in particular showing how the stator tooth forces are affected and what the resulting mechanical response is. The partners will also discuss how they “closed the loop”, so that deflections calculated in Evolve could be applied to the Opera model for the dynamic tooth rocking simulation.

Reduced Order Modelling for Electromagnetic Analysis of Electrical Machines
by Bilquis Mohamodhosen of Dassault Systemes (Opera)

During motor conception, it is usually desired to generate results over the entire operating range of the machine. This can be very time consuming when running Finite Element (FE) models, and hence a faster way would be more practical. Reduced Order Modelling (ROM) is an efficient way to capture the behavior of the model over the operating range into a meta/analytical model at the expense of slightly less accurate results. A methodology to generate a sufficiently accurate reduced order model has been developed throughout the EDISON project using two coupled SIMULIA tools: Opera and Isight. Opera was used to run the FE models, and Isight to create a Design of Experiment for the entire operating range. The intention was to output the radial and tangential forces in the stator teeth of the machine for different values of direct and quadrature currents (Id & Iq). An analytical model as a function of these inputs and outputs was then derived, so that forces could be easily calculated at each operating point.

A Co-Simulation Method for True System Optimisation of EDUs
by Kyle Grubb of GRM Consulting

Since 2008, GRM Consulting Ltd have worked with major OEMs to develop innovative new methods and processes which enable multiple attributes of performance to be optimised for simultaneously. During this time, we have investigated the development of gearbox, motor and EDU casings and mounting points to deliver noise, stiffness and strength requirements, allowing an EDU and its gear train to achieve the best performance possible. The EDISON project brought together Romax Technology, Jaguar Land Rover, Dassault Systemes, The National Physical Laboratory and The University of Sheffield with GRM to investigate the field of transmission optimisation but with a particular focus on electric vehicle applications. The primary aim of this project was to reduce vehicle emissions by developing novel ferrite motor technology for a passenger vehicle application. GRM and Romax supported engineers by enabling the electromagnetic, structural strength and dynamic transmission performance of a particular concept to be optimised for concurrently. This presentation will provide an insight into the methods we’ve employed and provide case studies and potential valuable learnings for attendees that GRM have developed in partnership with major OEMs—such as Jaguar Land Rover, Tata Motors and a multitude of academic institutions throughout the UK. GRM shall explore how the EDISON project has delivered the integration and optimisation of multiple physics for electric drive design problems. Furthermore, the application of the ‘EDISON’ coupled optimisation method to a wind turbine casing to ensure planetary gear misalignment will be presented.

Jaguar Land Rover in the Move to Electrification and Sustainability in the Automotive Industry
by Max Wilhelm of JLR

Hear about Jaguar Land Rover’s electrification strategy goals, the challenges this presents on magnets and their supply chain and how the EDISON project aimed to address these issues.

Introducing the EDISON Project and Ferrite Motor Design
by Annabel Shahaj, Khoa Hoang of Hexagon System Dynamics, University of Sheffield

The EDISON project is a collaboration between Jaguar Land Rover, Romax Technology (now Hexagon System Dynamics), University of Sheffield, Dassault Systemes, GRM Consulting and National Physical Laboratory. The project has delivered a prototype demonstrator of a novel ferrite magnet motor with performance matching a conventional IPM. Details of the ferrite motor concept and construction will be given here. Understanding of electromechanical interactions in e-powertrain units, structural optimisation for improved geartrain durability and improved magnet material characterisation where also achieved by the consortium partners and will be introduced in this presentation.

Performance Comparison between a Rare Earth IPM Machine and a Novel Ferrite Magnet Machine
by Giorgio Valente of Hexagon Applied Solutions

An important objective of the Edison project was to develop a machine concept that was not only rare earth free but also had an efficiency comparable with more conventional rare earth IPM machine topologies. Therefore, as part of the project the proposed ferrite machine has been compared to a benchmark rare earth IPM machine for different key performances such as energy consumption for a given driving cycle (WLTP), material costs and power density. Although the power density is reduced, the proposed ferrite machine presents benefits in terms of material costs and drive cycle efficiency with lower energy consumption in the considered drive cycle compared to the benchmark rare earth machine.

Partial Discharge Conditioning and Degradation Measurements in Twisted Wire Pairs
by Martin Wickham of NPL

Partial discharge is a known phenomenon in high voltage applications such as switch gear, transformers and generators. The electrification of transport systems, which have traditionally relied on non-electrical or lower voltage power solutions, has led to a new range of higher voltage applications which have low mass and small size as critical to system performance and market acceptance. These applications require reductions in insulation thicknesses, alternative lightweight dielectric materials and increased proximity of electrical conductors to make them viable. The National Physical Laboratory has recently developed a multi-channel partial discharge conditioning and measurement system. Early work has been conducted on twisted wire pairs of motor windings specification, to better understand when PD occurs (inception voltage), how it can cause degradation in the wire insulation and over what timescales. The presentation will detail the system concept, design, early results and plans for the future.


Programme

TimeSession TitleSession Host
10:55WelcomeAnnabel Shahaj, Hexagon
11:00Jaguar Land Rover in the Move to Electrification and Sustainability in the Automotive IndustryMax Wilhelm, JLR
11:25Introducing the EDISON Project and Ferrite Motor DesignAnnabel Shahaj, Hexagon System Dynamics and Khoa Hoang, University of Sheffield
11:55High Performance Ferrite Machine Experimental ValidationKhoa Hoang, University of Sheffield
12:20Performance Comparison between a Rare Earth IPM Machine and a Novel Ferrite Magnet MachineGiorgio Valente, Hexagon Applied Solutions
12:45Lunch and Tours
13:00 Tour 1
13:45Tour 2
14:30Metrology of Magnetic Materials in MotorsDaniel Brunt, NPL
14:55Building and Modal Testing a Prototype Radial Flux MachineRiza Jamaluddin, Hexagon System Dynamics
15:20Electromechanical Effects of Eccentricity in a Geared EDUChris Riley, Dassault Systemes (Opera) and Bartosz Lukasik, Hexagon System Dynamics
15:45Coffee
16:00A Co-Simulation Method for True System Optimisation of EDU'sKyle Grubb, GRM Consulting
16:25Reduced Order Modelling for Electromagnetic Analysis of Electrical MachinesBilquis Mohamodhosen, Dassault Systemes (Opera)
16:50Partial Discharge Conditioning and Degradation Measurements in Twisted Wire Pairs Martin Wickham, NPL
17:15Closing Remarks
17:20Light Buffet and networking

Registration

Type Standard Fee Group Discount
(3+ delegates)
In-Person Member £69.00 N/A
In-Person Non-Member £99.00 N/A
In-Person Member Student £39.00 N/A
In-Person Non-Member Student £69.00 N/A
Online Member £39.00 N/A
Online Non-Member £79.00 N/A
Online Member Student £19.00 N/A
Online Non-Member Student £49.00 N/A
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