fluxmotor

Introducing Multiphysics Workflows to Accelerate the Design of Electric Motor Driven Systems

Electrification is everywhere! It brings energy efficiency into systems and also helps add new smart functionalities to products. The electric motor is a key element of such systems, converting electricity into mechanical power. It is multiphysics by nature. Electric machine engineers need to take into account various constraints from the early stage of the design, looking at electromechanical performance, as well as respecting thermal and NVH constraints. Simulations need to integrate these multiple physics and also coupling effects. Dedicated tools and streamlined multiphysics workflows are developed in order to reduce complexity and speed up the design. Speakers: Limin Huang, Electromechanical Engineer, Altair Samia Saaidi, Senior Technical Specialist - Electromechanical Solutions, Altair Duration: 20 minutes

Conference Presentations

Electric Motor Design through Simulation Driven approach

This presentation is an overview of Rizel Automotive’s R&D journey towards developing an efficient and cost-effective Motor Platform with optimum characteristics for the automotive EV Space using Altair’s tools to solve electromagnetic, structural, NVH, and Thermal challenges and validate the Digital Designs and through Physical Testing. All the way through the design process, Altair tools helped us in solving the complex problems which solve the core electric motor problems; like inductances calculation, cogging torque optimization, D axis conditioning, model analysis, transient thermal analysis which helped us in understanding and validating our analytical design and research. With the help of Altair tools, we were able to implement and validate our novel ideas related to thermal design and come up with a unique motor architecture without compromising on electromagnetics. In this process, we have designed one of the lightest and compact radial flux motors in the industry. Easy to use software from Altair, with a simple interface and automation tools; helped us to iterate, fine-tune our motors with high accuracy and a much quicker pace. And helped us to engineer a powerful yet silent and cooler but efficient motor. From our recent dyno testing at ARAI, we were able to match the simulated data to dyno test results with a deviance of less than 5%, giving us great confidence in our Simulation Techniques and Altair’s tools, helping us decrease the Time to Enter the Market.

India ATC 2021

eMotor Director - A paradigm shift for the multi-physics design of e-motors

In this workshop you will discover the key features and benefits of simulation- and data-driven development and representation of e-motors in eMotor Director. The holistic and multi-physical development of e-motors requires a new way of thinking and a new development strategy. At Altair, we meet this challenge with simulation and data-driven development. Simulation and optimization are key development tools to ensure that all technical requirements can be met at minimal cost and time.

Webinars

Technology-Ecosystem-to-Accelerate-EV-Product-Development

Altair has collaborated with Startup India, Automotive Research Association of India (ARAI), Confederation of Indian Industry - CII, and IIT Madras Incubation Cell for Altair Start-up Challenge 2021 - For EVs. This is an initiative to create awareness of appropriate cutting-edge technologies, relevant processes, enable the start-ups to accomplish their goals of product development in a structured manner. This facilitates competency building and the development of competitive products.

Webinars

ATCx E-Powertrain - E-Motor Panel Discussion

A recording of the electric motor development panel discussion as part of the ATCx Electric Powertrain virtual event in March 2021. The panel features insight from Cleef Thackwell, Lead Motor Design Engineer at Jaguar Land Rover; Dr. Lars Fredriksson, VP Global Automotive at Altair; James Eves, Team Manager at Altair; Jonathan Stevens, Senior Development Engineer at Equipmake; Andy Jones, Innovation Program Manager at HiETA Technologies; Sergi Riba, Design Engineer at Safran Ventilation Systems; and Vincent Leconte, Senior Director of Global Business Development, Electromechanical Solutions at Altair.

Conference Presentations

Electric Machine Noise and Vibration Assessment Using MASTA / Flux

Andrew Lawton, Principal Research Engineer at Smart Manufacturing Technology. Andrew has worked at SMT for almost 10 years with a focus on the dynamic analysis of drivetrains, including the effect of excitation forces from the electric machine as well as the gears. Andrew’s presentation will cover NVH analysis of an EV drivetrain, specifically with regard to response to electric machine forces generated by Altair Flux.  He will illustrate this by looking at how the presence of unbalanced magnetic pull can affect the NVH response by importing the forces from Flux into MASTA.

Conference Presentations

Creating the World’s Most Power Dense Electric Motor

James Eves, Team Manager at Altair, Jonathan Stevens, Senior Development Engineer at Equipmake and Andy Jones, Innovation Program Manager at HiETA Technologies, discuss AMPERE, a joint project to produce an extremely lightweight, efficient but low-cost electric motor with an extremely high continuous power density. The consortium will present some of the engineering challenges that designing such a high performance motor has posed, and how these challenges have been overcome through advanced manufacturing technology and simulation driven design.

Conference Presentations

Electric Machines for Aerospace - Technology Needs for Aircraft’s Energy Transition

Sergi Riba, Design Engineer at Safran Ventilation Systems, with a brief introduction by Vincent Leconte, Senior Director of Global Business Development - EM Solution at Altair. Together they discuss the development of electric machines for the aerospace sector.

Conference Presentations

Delivering the Electric Revolution with Intelligent Simulation Technologies

Dr. Royston Jones, CTO and Dr. Anthony Hahnel, Technical Director, give their keynote presentation during the ATCx Driving Innovation in Electric Powertrain 2021.

Conference Presentations

Streamline your e-Motor Design with Multiphysics Optimization at Early Concept Level

Altair FluxMotor™ is a software dedicated to the design of e-Motor concepts. It enables designers to build machines within minutes, quickly run multiphysics tests to assess machine performance, and select most promising concepts. Coupled with Altair HyperStudy™, more design exploration and optimization can be accomplished. Using these tools confidence can be established in meeting requirements, even at this early design stage.

Product Overview Videos

Simulation-Driven Design of Synchronous Motors

Simulation-Driven Design of Synchronous Motors

Webinars

Predesign Methodologies In Motor Development Projects

Predesign Methodologies In Motor Development Projects

Webinars

Purpose Driven Electric Motor Modeling for Multi-physics System Simulation

Purpose Driven Electric Motor Modeling for Multi-physics System Simulation

Webinars

Accelerating Upright Scooter Mechatronic Development

Integrate models for mechanical, electrical, and controller subsystems to simulate your mechatronic product holistically as a system-of-systems. Exchange models and/or co-simulate with other CAE tools either from Altair (such as Altair MotionSolve® and Altair Flux®) or from 3rd parties through the Functional Mockup Interface (FMI) open standard.

Use Cases

Electric Vehicle Drivetrain Optimization & System of System Simulation

Simulate electric powertrains for various types of vehicles (e.g., cars, trucks, buses, trains, scooters, drones, aircraft, etc.) combining mechanical plant models with motors, batteries, & controllers together with realistic drive cycles. Then optimize the overall performance of your electric vehicles.

Product Overview Videos

Cool Runnings: E-Motor Design at DEF

The idea for its cooling technology for electric motor systems was born at high-tech start-up Dynamic E flow (DEF), when the founders first experienced an overheated engine of an electrical car. The existent development process at DEF used analytical methods and physical testing to confirm results. With increasing customization, that process was not flexible enough to handle various design possibilities. With the need for a simulative design approach, DEF employed Altair software to tackle its multi-physical design challenges, and to meet all the customer requirements for their unique motors, test hundreds of variants, and to check the feasibility of the customized product.

Customer Stories

Rethinking the e-Motor Design Process to Maximize Vehicle Range

In this article, appearing in the Fall 2020 issue of Engine + Powertrain Technology International, Altair outlines how a holistic approach to propulsion system design is enabling manufacturers to meet performance requirements while maximizing vehicle range.

Technical Document

Using Altair Software for Electromagnetics

Altair software is used across industries to solve a broad range of electromagnetic problems from static to low and high frequencies. Whether your application requires multiple frequency and time-domain techniques with true hybridization to enable the efficient exploration of a broad spectrum of electromagnetic performance, other the simulation of magneto static, steady-state and transient conditions, we have the tools you need.

Learn more at altair.com/electromagnetics.

Use Cases

Using Altair Software for Multiphysics

Altair provides an industry-leading portfolio of multiphysics-enabled software to simulate a wide range of interacting physical models including fluid-structure interaction, flexible bodies, aeroacoustics, and thermomechanical simulation. Together with Altair’s multidisciplinary optimization and scalable high-performance computing you can solve real world engineering problems quickly and effectively.

Learn more at altair.com/multiphysics.

Use Cases

EM and EDA, from Concept to Production

Altair’s portfolio of simulation-driven design solutions covers – amongst many other disciplines – electromagnetics (EM) and electronic design automation (EDA).

Conference Presentations

Altair FluxMotor - Thermal Design, Test, and NVH Evaluation

The latest release of FluxMotor, Altair's software product for electric machines design, adds several functionalities in the area of thermal design, test, and NVH evaluation. This short video illustrates some of the major updates.

Use Cases

Altair Flux and FluxMotor - Electric Motor Optimization

Designing an efficient motor has always been a complicated set of tasks. Altair's multidisciplinary optimization platform is a solution that allows considering multiphysics parameters and conflicting constraints.

Use Cases

Online Workshop - Simulation-Driven Innovation for e-Mobility

Simulation-Driven Innovation for e-Mobility with SRM university

Webinars

Online Workshop - Electromagnetic and Thermal Simulation of PMSM (IPM) Motor

Electromagnetic and Thermal Simulation of PMSM (IPM) Motor

Webinars

Training - Rated Torque Simulation of IPM Motor Using Altair Flux

Rated Torque Simulation of IPM Motor Using Altair Flux

Webinars

Infographic: The Impact of Multiphysics Optimization on e-Motor Development

Simulation helps you validate at the end of a product design cycle, but deployed early and throughout a development process, it can actually allow you to explore more potential solutions, collaborate more effectively and optimize the design for cost, performance, weight, and other important criteria. This infographic provides a framework for developing and implementing your own simulation-driven process to help you produce more efficient e-motors and shorten development times. 

Technical Document

Electric Motors Multidisciplinary Optimization Platform

The design of a high-performance e-Motor is a complex undertaking. Engineers have conflicting constraints to consider including efficiency, temperature, weight, size and cost. To explore more ideas, better understand their designs and improve performance, Altair HyperWorks™ has a workflow to guide motor designers through an efficient process of Simulation-Driven Design. This analysis and optimization solution supports multi-disciplinary teamwork and reduces design times.

Use Cases

The Multi Physics Optimization of an e-Motor Rotor

Vincent Leconte, Director of Business Development - EM Solutions at Altair presents at the 2019 UK e-Mobility Seminar. Optimization of e-Motors, Case Studies: Jaguar Land Rover & Porsche. Cooling Simulation of the eMotors.

Conference Presentations

Meet your Energy Efficiency Goals in your Electrification Projects with Simulation

Electrification is one of the main means of creating a low-carbon economy, allowing to use renewable energies and energy efficient technologies. Electric power enters many industries and also impacts our everyday lives, especially with the electric mobility. The use of power electronics and control systems allows offering better reliability, safety and low maintenance costs, and also brings additional innovative functions. Learn how Altair simulation and optimization tools can help designing highly efficient electric machines, as well as advanced control strategies to help you build innovative and energy efficient electric solutions.

Conference Presentations

An Efficient and Automated Design Strategy for Multi-physics E-Motor Development

This presentation introduces an application of a unique, highly automatic, multi-physics design strategy for E-motors, based on a current program at Mercedes-AMG GmbH. The strategy considers essential development requirements including electromagnetics and thermal requirements, NVH, stress and durability. It accommodates for DOE, multi-objective optimization and design exploration methods to be used to explore and find feasible motor designs. The presentation will show how the strategy adds efficiency to the E-motor development process and how it impacts the total costs of development.

Conference Presentations

Using Machine Learning and Optimization to Develop e-Motor

The Altair Multiphysics platform provides a broad portfolio of solvers and tools to help engineers develop e-motor design requirements by using simulation and optimization methods. This presentation provides examples, using Altair Machine Learning and optimization solutions, of the e-motor requirements by leveraging in data available, which is key for e-motor designers to reduce time-to-market.

Conference Presentations

Modeling the Thermal Runaway Behavior of Li-ion Batteries upon Mechanical Abused Loading

This presentation demonstrates Altair’s capability of simulating the behavior of a mechanically damaged battery from a cell to a pack integrated in a vehicle, based on collaborative research previously conducted with MIT. An innovative approach of applying electromagnetics loss to predict rising temperature due to short circuit effects during an impact is discussed, along with the development of a software tool, Battery Design, which enables OEMs and suppliers to design battery applications using multiphysics optimization, including mechanical-electrical-electrochemical-thermal behaviors.

Conference Presentations

Conceptual Design and optimization of an Electric Motor

Presentation by Koby Ingram, Gevasol BV. Conceptual Design and optimization of an Electric Motor using Altair Flux and HyperStudy. The customized electric machine with high level demands and efficiency is a challenging topic requiring top level of expertise and best in class simulation tools. This work focuses on the usage of Flux and Hyperstudy as tools for bettering the design and design process of e-motors. Presentation at the ATCx in Israel, Netanya on October 30, 2019.

Conference Presentations

e-Motor Concept Quick Design with Altair FluxMotor

Altair FluxMotor is a straightforward platform dedicated to the pre-design of electric rotating machines. It enables the designer to build a machine from standard or customized parts, add windings and materials to quickly run a selection of tests and easily compare the machine performance. In addition, they can predict the machine performance at one or more working points, and also for complete duty cycles. By coupling FluxMotor to Altair HyperStudy design exploration and optimization solution, Altair offers designers a unique process to optimize their motor concept at an early design stage. They can select and focus on the topologies that fulfill the main specifications before going further in their EM design with Altair Flux and perform Multiphysics analysis.

Quick Start

Automated Tests and Reports with Altair FluxMotor

Altair FluxMotor is a straightforward platform dedicated to the pre-design of electric rotating machines. It enables the designer to build a machine from standard or customized parts, add windings and materials to quickly run a selection of tests and easily compare the machine performance. In addition, they can predict the machine performance at one or more working points, and also for complete duty cycles. By coupling FluxMotor to Altair HyperStudy design exploration and optimization solution, Altair offers designers a unique process to optimize their motor concept at an early design stage. They can select and focus on the topologies that fulfill the main specifications before going further in their EM design with Altair Flux and perform Multiphysics analysis.

Quick Start

Discover Altair FluxMotor: Easy-to-Use Software Dedicated to e-Motor Concept Design

Altair FluxMotor is a straightforward platform dedicated to the pre-design of electric rotating machines. It enables the designer to build a machine from standard or customized parts, add windings and materials to quickly run a selection of tests and easily compare the machine performance. In addition, they can predict the machine performance at one or more working points, and also for complete duty cycles. By coupling FluxMotor to Altair HyperStudy design exploration and optimization solution, Altair offers designers a unique process to optimize their motor concept at an early design stage. They can select and focus on the topologies that fulfill the main specifications before going further in their EM design with Altair Flux and perform Multiphysics analysis.

Quick Start

e-Motor Concept Optimization Coupling with Altair FluxMotor and Altair HyperStudy

By coupling Altair FluxMotor for e-Motor concept design with Altair HyperStudy, more design exploration and optimization can be accomplished, while considering duty cycles. Further information are available on Altair connect.

Quick Start

Traction Motors Design & Multidisciplinary Optimization

Traction Motor play key role in the electric vehicle/hybrid electric vehicle (EV/HEV) development process. The design of a High-Performance e-Motor is a complex undertaking. Engineers have conflicting constraints to consider including efficiency, temperature, weight, size, and cost. To explore more ideas, better understand their designs and improve performance, Altair HyperWorks™ has a workflow to guide motor designers through an efficient process of Simulation-Driven Design. This analysis and optimization solution supports multi-disciplinary teamwork and reduces design times.

Webinars

Multi-Fidelity E-Motor Drive Solution

Presenters: Ulrich Marl, Key Account Manager for Electric Vehicle Motor-Feedback Systems, Lenord+Bauer & Andy Dyer, MBD Sr Technical Specialist, Altair

This presentation shows a modeling process to quantify the position/speed sensor (e.g, encoder) effects on an e-motor, and corresponding control system for a concept traction motor similar to the Nissan Leaf. The integrated solution of the e-drive is carried in Altair Activate as a system builder, using other Altair solutions e-motor solutions in FluxMotor and Flux to generate data for the e-motor itself, as well as the optimal current values for the Field-Oriented Contoller. The inverter is driven with efficient space vector pulse width modulation. The integrated solution also supports different levels of modeling fidelity for the system components, for example for the e-motor where either direct co-simulation with Flux for detailed finite element analysis or a reduced order model (ROM) using look-up tables. In this way, sensor design parameters can be evaluated within an accurate system of the e-drive to improve performance and efficiency.

Conference Presentations

Advanced e-Motor Design Dedicated Environment - Altair Flux FeMT

Designing an e-Motor has never been a simple task. Altair Flux, the solution for accurate electromagnetic detailed design, not only enables to quickly generate 2D and 3D motor models with its Overlays. Its new module now produces efficiency maps and automatic reports in the same appreciated FluxMotor supportive environment. Flux captures the complexity of electric motors and electromechanical equipment to optimize their performance, efficiency, dimensions, cost or weight with precision, bringing better innovation and value products to end users. Flux simulates magneto static, steady-state and transient conditions, along with electrical and thermal properties.

Quick Start

e-Motor Concept Optimization Coupling with Altair FluxMotor and Altair HyperStudy

Designers starting with a blank page face an unlimited number of configurations and need to quickly select machines types. By coupling Altair FluxMotor to Altair HyperStudy design exploration and optimization solution, Altair offers designers a unique process to optimize their motor concept at an early design stage, defining their constraints and their objectives. A typical objective is to reach maximum global efficiency across a given duty cycle. Then, designers can select and focus on the topologies that fulfill the main specifications before going further in their design.

Quick Start

e-Motors Comparison and Ranking with Altair FluxMotor

Quickly design and optimize concept machines while offering efficient comparison capabilities, Altair FluxMotor enables designers to make informed early strategic choices to select the most appropriate topologies.

Product Overview Videos

The Multiphysics Optimization Platform for e-Motor Innovation

Altair develops multiphysics simulation technologies that allow you to accelerate next generation mobility solutions development. From smart control design to powertrain electrification and vehicle architecture studies, our solutions enable optimization throughout the development cycle, all backed up by a global team of engineering consultants.

Product Overview Videos

E-motor Design using Multiphysics Optimization

Today, an e-motor cannot be developed just by looking at the motor as an isolated unit; tight requirements concerning the integration into both the complete electric or hybrid drivetrain system and perceived quality must be met. Multi-disciplinary and multiphysics optimization methodologies make it possible to design an e-motor for multiple, completely different design requirements simultaneously, thus avoiding a serial development strategy, where a larger number of design iterations are necessary to fulfill all requirements and unfavorable design compromises need to be accepted.

The project described in this paper is focused on multiphysics design of an e-motor for Porsche AG. Altair’s simulation-driven approach supports the development of e-motors using a series of optimization intensive phases building on each other. This technical paper offers insights on how the advanced drivetrain development team at Porsche AG, together with Altair, has approached the challenge of improving the total design balance in e-motor development.

White Papers

Coupled Electro-Magnetic and Acoustic Simulation of an In-Wheel Electric Motor

At Elaphe, the engineers have been facing the NVH challenges from the very beginning. The topology of this electric motor, which on the one hand enables the team to use the otherwise empty space inside the wheel, can on the other hand, result in some new and unexplored NVH challenges. The experience over the years has proven that NVH is a bottleneck in the design cycle of Elaphe's motors and this was the main motivation for a more automated and more user-friendly NVH simulation workflow. Within the NVH, noise radiation was the area Elaphe was most interested in.

Webinars

Flux & Flux Motor: A Preview from the Inside

This presentation was given on April 11, 2019 at ATCx Electromechanical Applications in Troy, MI.

Conference Presentations

Using Multiphysics Optimization to Design High Performance Rotating Machines

Light-weight, low cost, compact, high efficiency are some of the many objectives and constraints that have to be considered when designing a rotating machine. To meet these various challenges it is necessary to take into account several physical aspects: - electromagnetic - structural - thermal This presentation shows how Altair HyperStudy can involve several Altair solvers to consider different requirements into a single optimization and will be illustrated through various examples.

Webinars

Considering Temperature Constraints in the Design of Electric Machines

Because of always more compact and high efficiency systems, temperature is a critical constraint in electric machine design. Depending on the design stage, different levels of modeling can be proposed: - 1D for fast pre-design, to - full 3D CFD models for the validation stage. This presentation shows, through a complete example how the Altair platform for innovation helps machine designers to manage temperature distribution and evolution.

Webinars