Analytical Design Method Vs FEA
Analytical Design Method Vs FEA
Analytical Design Method Vs FEA
The success of this design method has been validated and improved by
calibration adjustments from actual machine testing.
Analytical methods using classic magnetic field equations for calculating the
magnetic flux magnitude and distribution within the magnetic circuit can only
be estimated. Leakage and the effects in changes in material permeability due
to flux densities can not be accounted for using classic field equations.
However these design methods are very useful because they are fast and re-
iterative solutions can be rapid. This process is used for initial designs and
sizing of machines. Over the years charts of typical data for average current
densities & average circuit flux densities are available to speed up this process.
Expert designers have developed and validated special solution methods as
mentioned earlier.
These classic field equations are also used with all FEA solvers for post
processing the field distribution results to accurately predict current densities,
inductances, torque output, losses, efficiencies as well as thermal conditions.
By solving the field equations for each bit rather than the major circuit
components such as the yokes, the teeth, the magnets, the coils, (and
usually ignoring the fame and shaft parts), the open circuit air gap flux
distribution can be accurately studied including the flux leakage details as
a function of phase current (for both motoring & generating).
Two very efficient design simulation tool choices are called MOTORSOLVE or SPEED
G (air-gap)
N (turns)
Ag
Certain NI
produces Each steel
certain flux, section has
cross section certain cross
determines flux section area
L
density
(Length of path)
ϕ Magnetic flux
Analytical calculation methods have been used for about 75 years for
electric machine design with perhaps hundreds of millions machines
operating successful without the use of FEA analysis.
High saturation
Distorted flux circuit sections
distribution
Tapered
teeth
IPM machines can be initially sized with analytical methods but FEA must be used
Mod 7 Copyright: JR Hendershot 2012 8
Cogging torques
Cogging torques or open circuit shaft torques are associated with PM
machines only. (Not to be confused with torque ripple under load).
Can be estimated by analytical methods and useful for relative
analysis for comparing slot pole combinations and pole angles
FEA methods are necessary when the current density is not uniform.
Equal sharing of parallel strands or parallel circuits.
High frequency causes of current concentrations in certain
conductors or on certain portions of individual conductors.
Proximity effects & Litz wire requirements
FEA methods are necessary top predict eddy current losses in phase
conductors
Until about one decade ago very little was available in the literature much
less any technical books on the thermal analysis of electrical machines.
(The technology of this topic was kept secret by suppliers)
Fortunately for us all Dave Staton of the UK has changed this for all time.
He has published may articles on this topic and also offers an analytical
thermal solver product that utilizes a lumped parameter model with motor
templates. This product filled a significant thermal analysis gap.
The lumped parameter method offers somewhat faster solution times but
the 3D FEA thermal solver offers the potential of more accuracy