Program

Main propulsion of today’s commercial aircraft is gas engines. It is envisioned that next step is to hybridize or use full electric propulsion systems to minimize the emissions, increase the reliability, and reduce the cost of flying. This talk will have two sections. In first section, Dr. Sarlioglu will present the most recent developments in electric and hybrid propulsion of aircraft. In the second section, the needs, requirements, and power densities for motor topologies will be addressed. New material technologies and design approaches along with challenges and opportunities will be presented to achieve aerospace-grade high power density and high efficiency motors.

The environment temperature for an in-vehicle motor becomes severe enough, and the importance of thermal design increases.
Taking estimation via simulating the generation of heat from a motor can also be advantageous for magnet design. Highly accurate loss data is important in guaranteeing the accuracy of thermal fluid analysis, but there is a hurdle such as that MILS models using JMAG-RT plant models are also necessary. However, since it became possible to build an SILS environment in JMAG from version 17.1, we tried a coupled analysis with harmonic loss calculation using this new function and thermal fluid analysis FloTHERM.

The design of a high-speed induction motor poses several challenges as it to has consider electromagnetic, thermal, mechanical and acoustic effects. Theoretically, several combinations of stator slot and rotor bar numbers are possible for selection. For a specific case of 4-Pole Induction Motor various slot-bar combinations are investigated using JMAG for electromagnetic and NVH effects.

The presentation deals with the electromagnetic NVH of electrical machines for electric vehicle application. It aims at presenting the current AVL-workflow for the JMAG-based calculation of NVH related issues in electrical machines and at discussing strategies to improve the NVH behavior. An in-house developed interior permanent magnet synchronous machine will be used as example for the simulations.
The presentation will be structured as follows:
- General introduction of the topic
- Calculation of the radial and tangential airgap flux densities using JMAG
- Evaluation of the corresponding time and space harmonics by applying 2D FFT
- Discussion of NVH critical parameter and strategies for reducing noise

At present, most of the finite element software in the market can only output basic electromagnetic parameters. These electromagnetic parameters cannot fully characterize the electromagnetic performance of the motor. A post-processing software based on JMAG-Designer named FAW-AutoPost_Motor is developed by FAW and IDAJ-China. The software mainly has following functions. Firstly, the JMAG computing jobs can be started in batch through the pre-processing interface. Secondly, using the algorithm embedded in the software, the basic electromagnetic parameters calculated by JMAG-Designer software can be converted into advanced electromagnetic parameters such as D/Q-axis inductance, phase voltage, power, loss and efficiency of the motor. Finally, post-processing data filters can be customized. According to the motor speed, phase voltage and other indicators, the motor performance parameters under the actual working conditions of the vehicle are screened out, such as motor n-T curve, efficiency map, etc. The application of the software reduces the workload of the post-processing software from 2 - 3 working days to less than 1 hour, it will significantly improve work efficiency. Meanwhile, automated post-processing with programs can completely eliminate potential errors and mistake caused by engineers when manually processing data.

Pneumatic solenoid valves are used in a wide range of industries, medical care, automobiles, etc. In the apparatus to be used, small size and power saving are advanced, and more power saving and miniaturization of pneumatic solenoid valves are required. Using the optimization function of JMAG - Designer this time, the magnetic circuit which maximizes suction power is sought while maintaining the solenoid size, leading to development of power - saving solenoid valve. In the simulation, the optimum calculation was carried out by selecting the eight levels contributing to the magnetic path area from the movable iron core, the fixed iron core, the yoke and the like under a fixed product size. Then, in order to further optimize, we report magnetometric force to the level and report the result of optimization calculation which calculated while executing tradeoff between magnetomotive force and magnetic path area.

In the levitation melting furnace, the molten metal flows under the lorentz force due to the interaction between the magnetic field and the induced current.
We will introduce the flow phenomenon of molten metal using a JMAG-STAR-CCM+ two-way coupled analysis.

The implementation of a magnetic bearing within a high-speed, high-capacity SPM motor (450kW, 17,000rpm) and the subsequent elimination of the step up gear from the centrifugal compressor have achieved increased efficiency, size reduction, and oil-free design of large HVAC chillers.
This report describes Jmag analysis case examples on the higher radial suspension force technology of magnetic bearing. It is key technology to achieving higher speeds and compressor size reduction.

In designing induction heating coils that perform heating locally, the choice of frequency, electrical power, and heating time, etc., and the amount of clearance between the work piece and coil becomes important. Although induction hardening occurs within a heating time of a matter of seconds, an increase in work piece temperature also means an expansion of shapes which change the work piece and coil interval clearance.
This lecture reports on electromagnetic field-thermal stress coupled analysis performed on cylindrical shaped parts, in addition to verifications carried out with real experiments.

An accurate iron loss estimation method has been required for designing high-efficiency rotating machines for the vehicle.
One of the issue of the iron loss estimation is considering time harmonic and space harmonic. As a method of modeling physical phenomena such as minor hysteresis loop caused by harmonics and skin effect of eddy current in laminated iron core, after the two-dimensional magnetic field analysis, as postprocessing, a hysteresis model and one-dimensional magnetic field analysis is available.
In this presentation, we report on the accuracy when the iron loss estimation model using hysteresys model to the single sheet and the motor, and the problems clarified in the application.

Due to the development of CAE technical and computer technology in recent years, many analyses and reports have been using three-dimensional models of transformers. However, analyses have been difficult to perform within a practical amount of calculation time, and have been simplified to partial models.
This paper describes an example in which the three-dimensional magnetic field analysis of a large-scale transformer is performed at a real scale level via parallel calculation processing using an actual PC held in our company. The utility of the process of parallelization is evaluated also.

With more and more attentions paid to environmental problems, we are pushing forward the development of the Multi-injection injector, and thus it has become very important to predict the solenoid valve motions before trial manufacturing.
In this study, we incorporated the injector drive control program into solenoid valve motion simulator, and propose the control circuit model for multi injection solenoid valve motion prediction.

Vibration of traction motor is defined by electromagnetic force which is acting as vibration source and vibration transmission structure of the motor.
In automotive applications, the motor generates electromagnetic force including high frequency by a battery driven inverter.
Therefore, we introduce simulation methods to calculate the electromagnetic force by applying motor behavior model. This motor behavior model connects system analysis results including the inverter and battery model.

The Development of PMSM is proceeding at a rapid phase because of the expanding range of their application. Continuous development in energy products and technological ecosystems has been influential for this rapid growth.
Existing high-performance machine architecture can be enhanced marginally in performance by better thermal management. However, for next generation electric machines co-development with cooling ecosystem and vehicle powertrain is essential to deliver optimum and overall system performance.
This paper presents an integrated framework to enable the radical design changes which are essential to achieve higher performance and low-cost to ensure longer team targets are met. This framework evaluates each optimized electromagnetic design for its thermal boundaries at each iteration considering the system limitations. And cost estimation model is also an integral part of the optimization framework, which enables us to have better understanding of the impact that each design has on the cost. This empowers us with essential datasets to support innovations that are essential to meet the performance and cost targets.

In conventional carburizing heat treatment, gas carburizing is mainstream for indirect heating using Resistance Heating, which is a process that can take a long period of time spanning several tens of hours. At Koyo Thermo Systems, we have developed a “ultra rapid carburizing treatment” using the direct heating method of induction heating. This is a dramatically accelerated process of carburizing treatment.
With this “ultra rapid carburizing treatment”, a high speed rise in temperature and carburization within a small amount of time is now a possibility. However, the speed of this temperature increase, as well as heat patterns, both have a large effect on thermal processing quality. Therefore, improvements in accuracy and stabilizing quality are planned through simultaneous evaluation using analysis and verification using real machines.
In this study, as for the above, we conducted an analysis using current control, so introduce the case.

Shunt reactors have gaps in the core in order to obtain a desired reactance. Eddy currents are generated in the windings of shunt reactor due to fringing of the magnetic flux. It is difficult to simulate the phenomena with accuracy by 3-D magnetic field analysis of conventional methods because of the multiscale problem.
This presentation shows an example of solving the above problem using “Zooming Analysis”. It is expected that the accurate distribution of currents and losses in the windings can be obtained by using “Zooming Analysis” in the multiscale problem.

JMAG-RT is an effective tool for the design of both motors and motor control.
Additionally, the amount of space that a motor as an electrical component can occupy within a vehicle layout is narrow and limited, so in order to account for this, it is not necessarily uncommon that a motor would be flat with a thin, disc-like shape.
To increase accuracy in analyses for flat geometry, however, 3D analysis becomes necessary, and the time required for creating RT models greatly increases.
This paper will introduce case study content that deals with the above issues using HPC.

Highly efficient permanent magnet synchronous motors are widely used for electric appliances and electric vehicles. In order to further improve the efficiency of the permanent magnet synchronous motor, it is necessary to simulate the motor characteristics under the actual operating condition. In this study, we introduce numerical results of PWM drive using JMAG-Designer Ver.17.1 with control circuit modeling functions. We describe the influence of eddy current loss on analysis results by using control circuit modeling functions. In addition, we also report the results of loss comparison of sinusoidal drive and PWM drive at typical operating points.

EV is misunderstood that there are few noise and vibration issues. However, EV has peculiar issue. In the case of In-Wheel Motor, since the space of the motor unit is limited, new issue not existing in the conventional EV may occur depending on specifications. This time, I will present about factor analysis and countermeasures on the case of IWM-EV motor noise incorporating a motor in the rear wheels.

Miniaturization and weight reduction are always required in the development of motors. As a solution, we report the results of a feasibility study in which CFRP (Carbon Fiber Reinforced Plastic) with lightweight and high strength properties is applied to the motor support structure.
In accordance with the requirements of the motor, we optimized the structure and lamination method making full use of the characteristics of CFRP and confirmed that there is a possibility of contributing to weight reduction.
We hope to be a hint for future motor development.

JMAG is used for the design of an LIM-type eddy-current rail brakes
(LIM-ECB) that is possible to operate without an external power source, supplying excitation power by self power generation as a linear induction machine. This system is driven by a constant voltage and operates in a state in which loss of system and generated power are balanced by frequency control. It is because of this that an understanding of accurate power generation performance is crucial.
Reproducing entire lengths is also important because of the necessity to account for the existence of armature end parts that cause degradations in performance. A thin skin mesh is additionally required in order to calculate rail eddy currents at a high accuracy. The object of analysis is therefore a model that increases in scale due to the above factors, which means that parallel processing needs to be faster.
This paper will introduce analysis case studies through high parallel processing.

We will introduce the background of introducing JMAG and the process from Introduction

AC copper losses can be a severe loss component in high speed AC machines, if not dealt with in a correct manner. Simple stranding does not solve the problem, as well as extreme stranding. Additionally, with the movement of designs towards solid conductors, AC copper losses are significant factor in machine design.

In recent years, minimally invasive surgery has been spreading rapidly within surgical fields. While this means many benefits for the patient, however, there is a considerably larger amount of burden on medical team in the case of abdominal laparotomy.
With the objective of reducing this burden, research has been made into the development of a force-controlled medical robot arm for endoscopic surgical. This goal is achieved by making it so that medical tram can make direct operation during surgery, operating the arm both safely and easily thanks to its force-control, which also allows them to maintain their field of vision of the whole procedure.
Because of the necessity of these direct operation, what is expected of the arm is actuators that move smoothly with little vibration. As so to realize a motor with low cogging, low torque, and a lack of vibrations, investigations are carried out with both JMAG and analyses linked with vibration and control.

In the talk, I will show the JMAG simulation of the WPT coil system and consider the electrical effects of the aluminum coil.

Our company has been developed a Wireless Power Transfer system for EVs. The shape of the WPT coil has a great influence to the WPT system on the efficiency and the amount of received power at the misalignment. By optimizing the shape, the capacity of control at the whole WPT system is reduced. In this report, we report the result of optimization of WPT coil calculated by JMAG.

In recent years, electrification of automotives has been a trend. There are attempts to replace PM motors with induction motors. PM motor analysis methods are well established with Jmag software. However, in the induction motor analysis, the calculation time tends to be long as the transient response is slow, determined by the slip frequency. The high efficiency induction motor tends to have small slip, thus, it is long. For example, one operation point needs a few minutes for PM motors, but a few days are needed in induction motors. Short cut analysis methods have been adapted, but it is better to understand what kind errors are likely. In addition, simplified description of induction motor model including magnetic saturation and frequency dependence of the secondary resistance are presented.

The selection of a machine type and design is highly dependent on the application. Unlike automotive applications where the cost, efficiency, and manufacturing complexity are major concerns, aerospace applications demand high power and volumetric densities along with safety and reliability. This study aims at identifying the requirements and challenges in designing an appropriate motor for more electric aircraft applications. Different types of synchronous machines are analyzed and their performance metrics compared against the requirements.

Currently, radial motors using laminated steel sheets are the mainstream for motors, but the needs for automotive applications about miniaturization and higher output are increasing. For these trends, we have demonstrated that axial gap motors with soft magnetic powder cores are effective for thinning and high power output for radial motors of the same size. In this presentation we will introduce the latest situation of the development of soft magnetic powder core contributing to high performance of various motors including the above-mentioned motors and examples of application to motors.

Electric machine design specific software called Motor-CAD has been developed by Motor Design Ltd in order to support motor designer, which covers thermal analysis. Motor-CAD has the utility in generating thermal network automatically and estimating thermal resistance between parts where MDL has acquired knowhow in the field of consulting related to motor.
This session will be focused on thermal analysis of motors using Motor-CAD. Motor-CAD can be used for time efficient evaluation and comparison of several motor designs at the early design phase.

In progress of electrification of vehicle, cooling method for driving moto r is getting important design topic, recently, oil cooling is more considerable theme. However, at the stand point of CFD, oil cooling needs a lot of computational resource because it is solved by multiphase flow analysis and unsteady simulation.
This session introduces Simcenter STAR-CCM+ multiphase model property and utilization of multiphase transition and multi time scale CHT for oil cooling.

Recently due to the market expansion of EV, more efficient motor gearbox design process is desirable. For identifying noise issues early in the design stage, it is necessary not to proceed with designing gearbox and motor separately but to also consider interactions each other.
This session will be focused on the right first time design procedure with whole system vibration response considering housing case with each excitation from motor and gearbox.

Prof. Miller will describe the history of motor and generator windings from the earliest days (1860) to the present, explaining how AC evolved from DC and setting out the foundations of the theory of windings in slots, which was already well established by 1918. Today the same principles are involved, but there is still relatively little guidance on the synthesis of winding configurations and so he will present two examples, both with fractional slots/pole, one suitable for a medium-sized induction motor and one for a brushless PM motor. In contrast, the analysis of machine windings has a vast literature, and Prof. Miller will show some of the classic techniques including the generalized approach to harmonic analysis, leading to some particular methods such as the Gorges diagram for harmonic leakage, and the importance of some not-so-obvious winding parameters. These techniques involve not only theory and calculation, but also test and measurement. Brief reference will also be made to the theory of reference-frame transformations, including the dq-axis transformation, symmetrical components, and space-vectors, and also to some key calculations that can be enhanced with finite-element analysis.

There is an active amount of research and development dedicated to the electrified vehicles, such as HEV and EV.
Drive motors for vehicles require a high degree of efficiency in a wide range of operations; this includes low to mid-speeds in urban environments as well as higher speeds on highways, which is why there is a need to both evaluate and improve efficiency for all possible drive regions. It is already known that motor losses can increase from the influence of control systems and inverters, and insofar as motor structure, it has been pointed out that eddy current loss increases at high rotation speeds in recently adopted rectangular wire coils. For that reason, methods of linking various technologies with control circuit simulations and using detailed 3D motor calculations are indispensable when it comes to predicting vehicle drive motor loss and efficiency.
This report outlines an investigation where waveforms of actual drive conditions are derived using linked analysis with 1D plant models and 3DFEA models. Those current waveforms are then input into a detailed 3D model, and efficiency is evaluated.
Predicting this efficiency is carried out simultaneously with a real machine and compared with simulations.

Last year, the first full scale hyperloop test track, DevLoop, was successfully built and tested in Apex, Nevada. By the end of 2017, a peak speed of 240mph (387kph) has been reached on a track length of only 500 meters.
One of the many challenges was to design a linear motor that could take the pod to such a speed in a short distance and later to design a fail-safe braking system, that brings the pod to a complete stop on less than 200 meters of track.
This presentation will give insight into the hyperloop system and the design and analysis of the DevLoop linear motor and the eddy current braking system.

In order to prevent short circuits in magnetic flux and to efficiently convert magnetic force into a mechanical output (torque), permanent magnet motors are provided a flux barrier around the vicinity of the magnet. In order to suppress flux leakage to the adjacent pole, improvements can be made to motor properties by making the narrow portion known as the bridge as thin as possible. But in order to prevent rotor failure as a result of centrifugal stress during high rotation speeds, there are times when stress on the bridge portion must be of a certain value or less. As so to prevent any mechanical issues that may occur during these high rotation speeds, it is necessary to carry out a motor analysis that considers the tradeoff relationship of centrifugal stress and motor properties.
In the analysis of rotor centrifugal stress of a permanent magnet motor and motor properties, what generally occurs is an exploration of motor geometry that meets the needed requirements while also making minute adjustments to FB geometry. It cannot be said that this necessarily constitutes an exploration of a wider design space, however. Ideally, an optimized geometry could be obtained where holes to insert magnets while also including a flux barrier are generated automatically, and both requirements concerning centrifugal stress and motor properties are satisfied. This would result in a considerable reduction in investigation lead time, but at present this is difficult to achieve. If a geometry closest to that of the most optimal model possible can be obtained, then the amount of time dedicated to verifications can be reduced by investigating that model as early as possible, despite this not being entirely the best solution.
This reports on the use of the optimization engine equipped with PSL and JMAG to calculate permanent magnet motor properties and rotor centrifugal stress, and attempts to analyze a model that satisfies both requirements.

Nowadays, an impressive effort is done to precisely predict the occurring losses of a rotating electrical machine. With increasing availability of high performance computing (HPC) and the acute interest for precise loss calculations, the simple empirical approaches to estimate additional losses may have come to their limits. Especially in the field of losses in the end-winding region of high power density electrical machines, this tendency has been further aggravated by changing the winding technology from thin wire pull-in winding to massive conductor bar-wound winding.
This paper presents a method to combine basic machine learning approaches with highly complex 3D modeling and parallel solving using HPC systems for ac loss model identification. The identified models are discussed and their strength and accuracy are evaluated at several test designs. The approach is illustrated at a 100kW traction motor machine where the additional losses are depicted for several operating points within the drive map.

Last year's 2017 JMAG User Conference saw the presentation of "Application Studies of the JMAG Optimization Function in the Design of Wristwatch Motors". The JMAG optimization function used involves optimization calculations carried out via an extension of parametric analysis chosen as a standard JMAG feature with the study of the application of a genetic algorithm. The challenge this year was therefore the optimization of topology with a higher degree of geometric freedom compared to parametric optimization, with the added possibility of reducing designer preconceptions and prior mindsets towards design. This similarly reports on the application studies of JMAG topology optimization in the design of wristwatch motors.

High efficiency and low cost are some of the challenges on the way to fully electrified car drivetrains to reach a high driving range and low battery cost. The biggest influence to a low loss electric machine is a high copper slot filling factor therefore the concept of the so called ‘hairpin winding’ is very popular among European carmakers. Despite its promising properties there are a lot of difficulties to face for the motor design engineer. Some of them like skin and proximity effect can lead to extensive losses in the high speed region deteriorating the overall car performance.
Starting from the primary design by using different approaches JMAG can be used in certain ways to handle most problems during the way to a robust, cost effective, mass production electric machine. Some new approaches of inverse design method will be discussed as well as some topics to find and optimize solutions for a good winding design that can be produced easily in high volumes and still keep a good compromise between cost and performance.

Updates will be provided on JMAG's roadmap for technological development and product development, and on the current situation.
FEM engine development supporting JMAG's high accuracy and high speed simulation has progressed steadily and even large-scale problems exceeding 10 million elements can be solved in practice. In the future, we will advance further speed-up of small- and medium-sized problems in addition to large-scale problems.
Regarding material modeling, we are working on excess eddy current loss which is a big problem remaining. In addition, we are improving the linking for importing material measurements for play models which can model hysteresis with high accuracy.
Meanwhile, not only analysis target components but also system level simulations including simulation for control and associated devices is becoming necessary, and to respond to this we have started to substantially improve control coupling functions and structural analysis functions.
Future expectations for simulation tools are automation of design centered on optimization and furtherance of model-based development. Because of this we are greatly enhancing pre-post parametric functions and data processing capabilities, and have started developing flexible user interfaces that can be used anywhere in the design process.
The progress of development and future prospects with examples and demonstrations will be presented.