Company:

McMaster University

Products:

Actran Acoustics

Industries:

汽车

Actran Induces Optimization of Electric Motor Drive Design

Overview:

The transportation industry is facing various new technological changes. Among them, the replacement of traditional internal combustion engines by electric powertrains makes new vehicles quieter. Still, new challenges in noise and vibration are rising, in particular during the design of electric motors. In order to develop efficient architectures meeting the expectations both in terms of performance and acoustic comfort, engineers need to access new methods and tools.

Motor design generally starts with the torque as the main purpose of an electric motor is to deliver the required torque at a given speed range. Then, the dimensions of the motor start becoming apparent and efficiency analysis, radial force analysis, structural analysis, and acoustic analysis enter the loop.

“Acoustics analysis should be part of the process and not applied at the end of it” explains Dr. Berker Bilgin, Research Program Manager and Chief Engineer of Canada Excellence Research Chair in Hybrid Powertrain program at McMaster University. If not, it will become difficult to reduce acoustic noise from the motor once the motor design is finalized. Electric motor noise is mainly due to the impact of electromagnetic radial forces (see Figure 1) that excite the stator structure.

Results Validation:

By including Actran in their design process, McMaster researchers developed current control techniques to limit acoustic noise: “Without making any changes in the motor we can actually reduce the acoustic noise just by optimizing the current, because the radial forces are also related to stator excitation, and we experimentally verified drastic noise reduction in switch reluctance motors”, said Dr. Berker Bilgin.

The use of simulation tools has reduced significantly the cost of prototyping and allowed a more advanced analysis of the designed product. Another added value of simulation is of course the attention paid to details thanks to 3D acoustic modelling capabilities. In addition, Actran’s visualization capabilities offer a great possibility for students to train and dig deeper in their research.

In the future, CERC in Hybrid Powertrain team plan on working on how to modify the structural modes without affecting the torque performance of the motor, focusing on current controls of the motors, or modelling the damping ratio of the motor for accurate estimation and reduction of acoustic noise in electric motors.


 
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Company:

Hyundai Motor Company

Products:

Actran Acoustics

Industries:

汽车

Actran Helps Reduce Time to Optimize Design of Active Pedestrian Alerting System by 50%

Overview:

At moderate to high speeds, the only external noises typically generated by electric vehicles are caused by wind resistance or tire noise. As a consequence, electric vehicles present a risk to pedestrians and cyclists, especially those who are visually or hearing impaired or listening to headphones.

Hyundai active pedestrian alerting system Regulations have been issued in both the United States and the European Union requiring that newly manufactured electric vehicles make an audible noise when traveling at low speeds. These regulations have differing requirements for the amplitude and frequency content of the warning sound.

Results Validation:

The simulation results were validated by conducting a 1-volt sine sweep test for both the actual speaker and the simulations. As shown in the figure above, the spectral behavior of sound at 1 meter from the speaker predicted by simulation matches the physical measurements nearly perfectly.

By using Actran to optimize cavity and duct resonances, Hyundai engineers were able to design the speaker to handle low, mid and high frequencies as needed to meet both US and EU regulations while at the same time minimizing speaker size and power consumption. “The simulation results provided by Actran were much more comprehensive than information generated by physical testing, which helped Hyundai engineers quickly iterate to an optimized design in about half the time that would have been required using traditional build and test methods,” Lee said.


 
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Company:

Major automotive OEM

Products:

Digimat

Industries:

汽车

Simulating SMC part response with greater confidence using Digimat

Overview:

While Sheet Molded Compound (SMC) materials have been widely used in the automotive industry for some time, recently there has been a move to apply SMCs on more structurally demanding components. Though the material has long been considered quasi-isotropic with relative success, it has become apparent in industry that due to the complex manufacturing process, optimal structural design is not possible without considering the real anisotropic nature of the material.. With growing demand from the market, now is the time to leverage advanced SMC modeling capabilities targeting crash performance.

Results Validation:

Static and crash FEA simulations can now attain an excellent level of accuracy in stiffness and can capture peak load and displacement trends for typical part load cases.

The inner seat part illustrates the proposed workflow from process simulation to structural application. The Digimat simulation achieves a much better fit with respect to test data for most load cases, including head impact (puncture) and provide a good indication of hot spot localizations.


 
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Company:

Products:

Simufact Forming

Industries:

Simufact Forming helps Demshe Forge Inc. to get Forging Process Design Right at the First Try

 
 
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Company:

Products:

Simufact Additive

Industries:

LightHinge+: An innovation project of EDAG engineering, voestalpine Additive Manufacturing Center and Simufact

 
 
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Company:

Products:

Simufact Forming

Industries:

Forming simulation streamlines manufacturing process of large forgings

 
 
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Company:

Products:

Simufact Additive

Industries:

Flexibility through additive manufacturing: How simulation supports 3D prototyping

 
 
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Company:

Products:

Simufact Forming

Industries:

LuK innovates manufacturing processes through forming simulation with Simufact

 
 
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Company:

Products:

Simufact Additive

Industries:

Design validation for highly efficient Additive Manufacturing

 
 
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Company:

Products:

Simufact Forming

Industries:

Innovative joining process developed with Simufact Forming

 
 
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Company:

Products:

Simufact Additive

Industries:

Simufact Additive: Collaborative Simultaneous Engineering Tool for Additive Manufacturing

 
 
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Company:

Products:

Simufact Forming

Industries:

Omni-Lite Industries reduces development costs and time in cold forming tool design with Simufact Forming

 
 
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Company:

Products:

Simufact Additive

Industries:

Simufact Engineering provides the GreenTeam & Renishaw with a complete AM Process Simulation Solution

 
 
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Company:

Products:

Simufact Forming

Industries:

Process optimization through forming simulation

 
 
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Company:

Products:

Simufact Additive

Industries:

Overcome additive manufacturing issues by process simulation

 
 
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