A​bstract

Globally, there is a significant emphasis on electrification in multiple industries. Automotive companies regularly announce programs for expansion of their hybrid and electric fleet. Hybrid and electric airplanes have been a topic for research and development in the aerospace industry. Other industries have increased usage or invested on improving performance of electric motors for pumps, compressors and household appliances. Design of an electric motor involves a complicated process including initial electromagnetic design, optimization of electromagnetic performance, thermal design as well as design for controlled vibration and noise. In this work, we focus on two highly used traction motors, namely, induction and permanent magnet. In the first part of this study, a complete simulation methodology is demonstrated using an induction machine where analytical equations are initially solved for a quick electromagnetic analysis of the motor. This study refines the design space and is followed by 2D or 3D Finite Element Analysis (FEA) of electromagnetics. To define the thermal performance, electromagnetic heat losses are then mapped to a Computational Fluid Dynamics (CFD) solver where the flow and heat transfer inside the motor are studied. Temperature and coolant flow fields are obtained from the CFD study and are validated against existing experimental data. To identify the fatigue lifetime of a critical component, temperatures from the CFD study are mapped to a FEA mesh to obtain thermal stresses. Using the stress calculations, a fatigue solver calculates the lifetime of the component. In part two of this study, electromagnetic forces from an interior permanent magnet machine are transferred to a mechanical FEA solver to study motor vibration and acoustics. For electromagnetic, thermal and mechanical studies, ANSYS Maxwell, Fluent and Mechanical solvers are utilized, respectively. This comprehensive multiphysics study provides significant insight into motor design and facilitates improved performance. High performance electric motors are one of the key pillars in electrification research and development.