Flux Magazine2004Oct

Key words: ATILA, CIVA, Magnetisation, FLUX, Motor-CAD, NDE, Skewed Motors, Training,...

CEDRAT

N° 46 - October 2004 - CEDRAT - CEDRAT TECHNOLOGIES - MAGSOFT Corp.

Magnetize

elevators rotors.

Eliminate the stress of working with magnetized magnets... (pages 13)

>> Software:

FLUX 9.1: New release...

CIVA: CEDRAT and CEA, partners for NDE...

New application for skewed motor...

Motor-CAD activeX links....

ATILA 5.2.4: New release...

NDE: Non Destructive Evaluation with FLUX....

>> FLUX application:

KOP's: Analysis of subsea umbilical systems...

>> Magnetic measurements:

Magnetize elevators rotors...

>> Training: New training: FLUX 3D and

Non Destructive Evaluation...

New CEDRAT 2005 training catalogue...

>> Agenda:

2004 European FLUX Users Club at Meylan...

CEDRAT in Germany...

Dates to remember...

Motor-CADactiveX links.Motor-CAD and SPEED can be fully automated and run from any ActiveX enabled software... (pages 10-11)

15, Ch. de Malacher - Zirst 38246 MEYLAN Cedex FRANCETel. : +33 (0)4.76.90.50.45 - Fax : +33 (0)4.56.38.08.30

Email: [email protected] - Web: www.cedrat.comEditing manager : B. Ribard, Managing Director of CEDRAT

and CEDRAT TECHNOLOGIES

CEDRAT & CEA partners for NDE. Widely used in various domains, Non Destructive Evaluation (NDE) has been one of the main topic of interest for CEDRAT this last year... (pages 2-4)

FLUX 9.1: New features. As promised last year during the Users Club in Paris, this year’s version of FLUX will bring you a new and complete preprocessor. PREFLUX now includes geometry, mesh and physics... (pages 8-9)

ATILA Version 5.2.4.The new PreFlux preprocessor for ATILA 5.2.4... (page 7)

Skewed motors. New application will be available in FLUX 9.1... (pages 5-6)

EDITORIAL.The Commercial Team - CEDRAT.

This autumn’s harvest.

As you all know, winter is the favourite season for inhabitants of Grenoble (and Meylan).

We are getting ready to spend the best winter ever.

On the one hand, ATILA 5.2.4 has now been released with a new preprocessor for

more fl exibility.

On the other hand, FLUX keeps fulfi lling its users’ need: for cable design, as the testimony

from Kvaerner Oilfi elds Products (Norway) shows; for motor design, as described in the

article regarding modelling of skewed machines; for Non Destructive Evaluation (NDE),

which has been one of our main fi eld of interest: developments in FLUX that lead to a

dedicated training to NDE modelling and commercial agreements with CEA List for the

distribution of CIVA, the most complete software solution for NDE simulation.

At last, but not the least, FLUX 9.1 is now in its fi nal stage of Quality Assurance process.

Discover a preview of this version, before the offi cial presentation, during the Users Club

in Grenoble.

- 2 -


SOFTWARE>>

Non Destructive Evaluation with FLUX. Anouar KALAI, Fabrice FOUCHER, Sébastien CADEAU-BELLIARD - Cedrat ; Thierry SOLLIER ( CEA_LIST).

(continued on page 3)

Previous simulations of Non Destructive Evaluation (NDE) processes have already been

peformed at CEDRAT using FLUX (see article «Non Destructive Testing with FLUX», FLUX Magazine n° 45). The results obtained to the TEAM workshop (Problem 8) prove the validity of the tools and methods that have been developed at CEDRAT to better account for all phenomena occurring when simulating NDE processes.After the modelling of a differential probe over a plate with a rectangular fl aw, several other confi gurations have been studied to confi rm FLUX’s ability to simulate such processes. Measurements have been provided by the CEA LIST, partner of CEDRAT in the project «MUTSIC». This project is supported by the French government through the RNTL

(Réseau National des Technologies Logicielles = National Network for Software Technologies) consists in the realisation of a multitechnique software (Analytical and Finite Elements Methods) dedicated to NDT applications (US, Xray, Eddy current) including FLUX capabilities with a dedicated GUI.

First study

Among the new studies, one of them was realised with an absolute probe and a conducting plate.The probe is made of two coils. The fi rst coil moves across the rectangular fl aw of the plate (resistivity: 1.03 10-6 Ohm.m) and the second refers to a Wheatstone’s bridge that compensates the ambient temperature variations. Coils are supplied by a sinusoidal signal with a 500 kHz frequency.

To model such a device with FLUX (3D), we only need to represent the fi rst coil moving across the plate. The main value of interest in NDE is the variation of the real and imaginary parts of the coil impedance, while this coil moves over the plate. This value is computed by FLUX and compared to measurements completed at CEA-List.

Figure 1: Magnetic field distribution when the coil is right ahead of the crack.

Figure 2: Real part of impedance variation.

Figure 3: Imaginary part of impedance variation.

CEDRAT and Non Destructive

Evaluation. Sébastien CADEAU-BELLIARD - Cedrat.

Non Destructive Evaluation is widely used to examine materials during the manufacturing or in process. Many domains are concerned by such an evaluation: aerospace, aeronautics, civil engineering, nuclear industry, ship-building industry, petrochemistry…

In this context, simulation of NDE plays an increasing role for conceiving methods and devices, demonstrating their performances at a low cost, teaching, training and providing help to operators. As simulation permits to master the parameters involved during an examination, it is a crucial factor to increase inspection reliability.

In order to provide adapted solutions to technicians and engineers concerned by this matter, CEDRAT acted in two complementary directions:• Development of tools and methods in FLUX, allowing a better computation of all the phenomena of Eddy currents NDE,• Partnership with CEA (Commissariat à l’Energie Atomique) for the distribution of CIVA, simulation solution of NDE devices and systems (Eddy currents and ultrasounds).

Moreover, the knowledge gathered by CEDRAT these last years about phenomena in non destructive evaluation are now materialised by a training dedicated to those phenomena and their simulation. After a great success when presented to experienced professionals, it is now proposed to any interested potential customer.

Figure 4: Eddy currents distribution in the plate.

- 3 -


SOFTWARE>>

Non Destructive Evaluation with FLUX. (continue)

Anouar KALAI, Fabrice FOUCHER, Sébastien CADEAU-BELLIARD - Cedrat ; Thierry SOLLIER ( CEA_LIST).

Figure 5: Real part of impedance variation.

Figure 6: Imaginary part of impedance variation.

For several years, CEDRAT has been interested in non destructive evaluation and has developed in FLUX, its highlight product, tools and methods to better account for all the phenomena of eddy currents non destructive testing.For example, new formulations (i.e. new way to express the Maxwell’s equations allowing a standard computer to get precise results in a reasonable computation time) have been developed to better account for Eddy currents. Moreover, the features to account for any translation motion enabled to increase accuracy of the results. Finally, in order to use all the capabilities of those new tools, CEDRAT set up numerous methods and examples.Next session that will take place from 3rd to 5th November 2004 aims to pass on this knowledge to any user.

The programme is available at [email protected] or by phone at +33 (0)476 90 50 45.

Plesae register now at: [email protected] or www.cedrat.com, the number of seats is limited, to offer a more personnalised training.

New training: FLUX (3D) and Non Destructive

Evaluation. Sébastien CADEAU-BELLIARD - Cedrat.

Eddy currents distribution under the probe.

The impedance variation is then calculated as the difference of the impedance in two cases: with or without fl aw (to prevent “mesh noise”, both cases have the same mesh).The previous study (TEAM workshop, Problem 8) allowed highlighting the most signifi cant parameters of fi nite element model to obtain good results of the coil’s impedance variation.Those are:

• Restriction to the maximum of the mesh noise inherent in the fl ux computation.

Although an unmeshed coil is used, the coil geometry is represented in order to obtain an adapted mesh of the air around to the coil. A constant mesh with regards to the motion will improve the accuracy. The fl ux computation is realised with the “FLUX _INDUCTOR” method.

• Description of the plate mesh

Thanks to geometrical representation of the volumes of the plate over which the probe passes, the mesh is refi ned in the plate where Eddy currents will raise without generating too many nodes in the rest of the plate.

• Choice of the best formulation

The best results are obtained mixing:

- The new reduced formulation versus T

0 : H= T

0- grad φ with

T0=H

0 - grad δφ

- The TΩ formulation with edge interpolation: H= T- gradφ

For both longitudinal and transversal motions, FLUX results obtained for the variation of the real and imaginary parts of impedance fi t very well to measurements as presented in fi gures 2 and 3.

More accurate results

Another study with the same probe and the same plate has been made. This time the rectangular fl aw was across the total thickness of the plate.For this kind of fl aws, the new formulation Tφ with edge interpolation has been used in the plate (H=T+ T

0-gradφ).

This simulation also has been realised for longitudinal motion and transversal motion and FLUX gives even better results compared to measurements.Other simulations realised with FLUX using the same modelling

technique permitted to obtain very good results, for example when modelling probes using coils with a ferrite core or modelling plates with a triangular fl aw.

Capitalised knowledge

This work was part of a long-term action of CEDRAT towards NDE simulation with FLUX. It has improved again our knowledge of the processes and their simulation. From this very study, 6 cases have been exerted to be used during Assurance Quality process for FLUX. They will be part of the numerous cases (more than 55 now) that are regularly run at every patch and version to check FLUX validity.

NEW TRAINING!!


A complete and comprehensive line of

solutions for NDE

CEDRAT is already present in the NDE domain thanks to FLUX, fi nite element solution for the simulation of electromagnetic, electromechanical and thermal devices and systems. Moreover, its expertise being unquestionable in the distribution of software solutions for electrical engineering, its technical support and the accompaniment of actors in the electric domain, a partnership was naturally built up between CEDRAT and CEA to distribute CIVA. Both organisations will closely work together to provide performing software solutions for NDE.

Completing its line of solutions for NDE, this partnership put CEDRAT ahead to provide software solutions for the simulation of NDE devices and systems.

More information about CIVA at www-civa.cea.fr.

Contacts: [email protected] and www.cedrat.com

CEDRAT and CEA (Commissariat à l’Energie Atomique) are proud to

announce their partnership for the distribution of CIVA, simulation solution of non destructive evaluation devices and systems, developed by CEA List (Laboratoire d’Intégration des Systèmes et des Technologies).

CEA List

CEA List develops numerical systems aimed to be integrated in innovating products and processes. Its competencies domains include embedded systems (autonomous), interactive systems (human-machine interaction, virtual reality, robotics), instrumentation and metrology as well as materials (assembly and non destructive evaluation of mechanical systems, development).In the heart of industrial activity and environment, domains such as sensors and signal processing are part of the keys technologies of information and communication society. This domain on the edge of technological innovations answer to social and economical stakes giving access to more and more performing measurements facilities with high performances with regards to quality and industrial productivity.This activity has lead CEA List to develop CIVA as well as innovating devices for NDE.

Non destructive evaluation with CIVA

CIVA simulation software capitalises results of research in non-destructive evaluation (NDE) carried out at CEA and its partners. Today, CIVA deals with ultrasonic testing and eddy current techniques. CIVA offers within the same framework several simulation modules suitable to research and industrial needs.

The imaging system associated with the signal and image processing tools enables the interpretation and expertise of simulation and experimental results

Since its fi rst steps, the development of CIVA followed a two fold strategy: the choice of semi-analytical methods and the development of models integrated into software modules usable by operators who are not simulation specialists. In early nineties, the fi rst version of the CIVA software program was released, bringing together in the same environment, imaging, processing and simulation tools, thus enabling a direct comparison to be made between experimental and theoretical data. Since then, modelling NDE has been constantly gaining in importance, and its applications have become increasingly diverse. Over the years, and with successive versions, the results of modelling research works have been integrated into CIVA in the aim of fulfi lling requirements of various users which belong also to various industrial sector and especially aircraft industry. The domain of validity of ultrasonic models and the capabilities of the software have been extended. At the same time, Eddy current semi-analytical models have been developed and implemented in the same software environment; A X-ray simulation module will be present in 2005.

- 4 -SOFTWARE>>

CEDRAT and CEA, Partners

for Non Destructive Evaluation. Sébastien CADEAU-BELLIARD - Cedrat.

- 5 -


SOFTWARE>>


New Application for Skewed Motor. Patrick LOMBARD, Cedrat - Lakdar SADI-HADDAD (LMBE).

A new application will be available in Version 9 of FLUX. This application

allows taking into account skewed machine. Two different models have been developed: 2D N-slices model and extruded model. For each model, you can solve the machine for different working point, using the different magnetic application: static, magneto-harmonic and transient. The rotor or the stator can be skewed. In the fi rst part, the methods are presented. In the second part, the results of simulations of an induction motor are presented.

Numerical methods

The main idea is to consider the case as 2D problem extruded with the length L of the motor in the axial OZ direction.The air regions including the end windings are not described by fi nite elements at the ends of the motor, where a tangential magnetic fi eld condition is imposed. The end windings of the rotor and the stator are taken into account by an electrical circuit coupling. In practice, the user of the 2D software describes the case at the z = 0 end of the motor as another 2D problem. Two models have been tested to take into account the skewed slots: the 2D N-slices model and the extruded model.

A. N-slice model

In the N-slice model, the base 2D surface mesh, which is perpendicular to the shaft, is propagated n times. The motor is considered to be composed of n slices. Thus each slice has a thickness of L/n and is represented by a disk with a surface mesh. The rotor mesh of two adjacent disks has been turned by an angle of α/n, where α corresponds to the total angle of the skew. The winding and bar currents are assumed to be continuous from one disk to another. The standard 2D Az one component magnetic vector potential formulation is used for this model.

B. Extruded model

In this approach, the base 2D surface mesh has been extruded to produce a 3D mesh. The 2D rotor mesh is extruded through a

helical geometric transformation, and the 2D stator mesh through an OZ translation.

The bars of the rotor are solid conductors, coupled to the rotor circuit, and are described by a t-t

0- φ formulation. The stator

and rotor steel sheet regions are described by the total magnetic scalar potential formulation, and the air gap and the other air regions by the t

0-φ reduced scalar

potential formulation .The two skewed models described above have been implemented in FLUX software developed by CEDRAT and LEG (Laboratoire d’Electrotechnique de Grenoble).

Results

A 5.5 kW induction motor has been modeled using the method described above. The motor has 2 pole pairs, 48 stator slots, and 28 rotor slots with a skewing of 0.8 of the stator slot pitch. Only one-fourth of the mesh of the motor and one-fourth of the circuit have been described due to a periodicity. In this section only the N-slice model is presented, because of the time savings that it offers compared to the extruded model.The results obtained with the N-slice model have been compared on the one hand with experimental measurement and on the other hand with results obtained from a purely 2D model, i.e., one consider-ing that the rotor slots are straight. (This model is referred to above as the straight slot 2D model, using FLUX, 2D application, version 8.)

A. Results for rated load

Our first interest concerns the results of the induction motor operating at constant speed. Let us consider the rated load test of the machine, which corresponds to a slip of 1.93%, i.e., a rotation speed of 1471.05 rpm. Results are focused on :• Comparison of rms current and average torque,• Torque ripple analysis.

A comparison of the results ob-tained by the N-slice model with measurements is provided in table I. It shows very good agree-ment at rated load condition. Indeed, the differences between

measurements and calculations are relatively small: approximately 0.88% with regard to the current and 0.33% for the torque.

Current (A) Torque (N.m)

N-slice 11.24 39.03Measurement 11.34 39.16

Difference 0.88% 0.33%

To show the effect of the skewing of rotor bars, in fi gure 3 the instantaneous evolution of the electromagnetic torque for the two cases of machine at the rated speed is given.The fi gure shows that the torque ripple in the skewed slots case model 1.3 N.m) is approximately fi ve times less than that of the straight slots model (6 N.m).The Fourier decomposition of the two signals shows that the straight slots case is more prone to parasitic effects, which results in a wider harmonic spectrum compared to the skewed slots case.

Figure 1: 2D N-slices model.

Figure 2: Extruded model.

Figure 3: Electromagnetic torque versus time for straight (pink) and skewed slots cases of the

machine (blue).

Table I. Comparison between experimental results and skewed slot calculation.

- 6 -


SOFTWARE>>

To confi rm the results obtained with these simulations, we carried out startup tests on the real machine (with skewed rotor slots).

Even if there is pulsation in both cases, we observed that they show very different mechanical characteristics. The starting torque ripple is much higher for the 2D straight slots model. In fact, the maximum torque ripple that occurs between t=0.6 s and t=0.8 s is equal to 66.63 N.m for the 2D straight slots model and 11.56 N.m for the N-slice skewed slots model.

It is clear that the curves presented in fi gure 7 are much closer to those obtained for the skewed slots model.In addition to the minimization of the torque ripple, the skewing of the rotor bars makes possible to mini-mize the harmonic distortions of the electric quantities. It is interesting to check the current versus time at no load. Theoretically, for the ma-chine considered, the skewing of the rotor has as a consequence the diminution of the order harmonics (kN/p±1)k integer, where N represents the number of stator or rotor slots. An attenuation of the harmonics order 13 and 15, then 23 and 25... is expected.In table II we provide the harmonic decomposition of the signals that are calculated when the machine is at stationary operation.

It is clear that the harmonic contents of the signals extracted from the straight slot model are richer than those of the skewed slots model. For the fi rst model the maximum amplitude is reached at the 13th order of the stator frequency. The amplitudes at the 15th, 23rd and 25th harmonic orders are signifi cant as well. The amplitudes for the skewed slots model are notably lower: for example, the

B. Results for a start up test

In this section our interest is in the results obtained for a start-up operating mode that requires the electromechanical coupling

The inertia of the rotor is J=0.4935 kg.m2, the resistant torque is Mr=3.5839 N.m and the friction coeffi cient is set to f=3.906.10-4 N.m.s.deg-1. Let us note that these coeffi cients also take into account the presence of the dumb-bell shaft and the load.

Figures 5 and 6 show the variation of the torque and the angular speed from start-up until the synchronous speed (1500 rpm) is reached for the straight slots model and the skewed slots model, respectively.

amplitude of the 13th harmonic order changes from 1.04 % of the fundamental amplitude for the straight slots case to 0.21 % for the skewed slots model.

Conclusion

In this paper, we have presented two methods, a 2D n-slice model and a t-t

0-φ 3D skewed model. They

take into account the coupling with the electric circuit, the nonlinear B(H) properties, the rotating motion and the inertia momentum conservation law. An induction motor has been simulated with these models. Two different cases have been analyzed: rated load and start-up. The current and torque of the rated load case with the N-slice model are in good agreement with measurements (less than 5% of differences). In the start-up case, the decreasing of the torque ripple and harmonic in the current has been observed between a straight model and a skewed model.

With the N-slice model the results are closer to measurement, validating the implementation of this new model in FLUX software.The next step will be the modeling of motors with complete 3D models, i.e. with end regions described by fi nite element regions.

Acknowledgement

The authors acknowledge Ludovic DOFFE of the LMBE laboratory of Amiens (France) for providing data and measurements.

New Application for Skewed Motor. (continue) Patrick LOMBARD, Cedrat - L. SADI-HADDAD (LMBE).

Figure 7: Variation of the torque and speed from start-up to the synchronous speed (Experi-

mental results).

Figure 4: Torque spectrums in percent of the fundamental for the straight and skewed slots

models.

Figure 5: Variation of the torque and speed from start-up to the synchronous speed for the

straight slots model.

Figure 6: Variation of the torque and speed from start-up to the synchronous speed for the

skewed slots model.

Table II Comparison of amplitude harmonics with respect to the percentage of the fundamental.

Harmonic order

13 15 23 25

Straight 1.04% 0.24% 0.52% 0.49%Skewed 0.19% 0.03% 0.17% 0.23%Measure 0.21% 0.08% 0.12% 0.13%

N-Slice model

available in FLUX 9.1!!

- 7 -


SOFTWARE>>

The New Preprocessor PreFlux

for ATILA 5.2.4. Nicolas LHERMET - Cedrat Technologies.

Version 5.2.4 of ATILA is now ready. Several improvements have been made : increase of the speed for modal analysis, best account for cylindrical polarisation and 2D axisymmetric acoustic radiation. But the main novelty is the integration of FLUX’s preprocessor in ATILA.

The new graphical interface will pro-vide large time savings due to its high level of interactivity (e.g. icons for the most used commands). All the commands are also available in the tool bar on the top left of the window. Developed using new pow-erful tools, this preprocessor has all the main facilities of a standard CAD tool.

Time savings come also from the display tools. Handling the 3D de-vice is now easy with the mouse: left click, right click or scroll are now the assets of the users for easily displaying the complex 3D shapes and devices.

Entity selection is now far easier: the grayed display of the non se-lected entities and the possibility to select in either window (up to 4) help largely the user.

The data tree gives now an easy access to all the properties, and the python command language helps the experienced users to automate the design. Finally, the output win-dow provides useful information about the modelling. Finally, error messages appear in pop up win-dows that cannot be missed.

Improvement of the mesh genera-

Figure 1: Mesh of an electronic board including a piezo patch.

Figure 2: Soldering high power ultrasonic transducer.

Figure 3: Geometry of an ultrasonic motor.

Figure 4: Mechanical piece imported through STEP

format.

Figure 5: Mesh generation of this piece with PreFlux.

Finally, all ATILA tutorials have been updated to this version. Two more 3D tutorials have been made to help the user by the disciver of the new preprocessor.

ATILA Version 5.2.4

New release!!

MOTOR-CAD V.2

New release!!

Motor-CAD V.2

CEDRAT and Motor Design Ltd are proud to announce that Motor-CAD Version 2 is available for distribution. This new release features improved simulation and interface technologies. Several new machine types have been added as well.

CEDRAT’s electric machine customers are now equipped with a suite of award-winning numerical tools to deliver innovation.

Motor-CAD 2 now includes these machine types:• Brushless permanent magnet motors• Induction motors• Switched reluctance motors• Brush permanent magnet motors• Synchronous generators• Claw pole generators

Discover more during the Users Club in Meylan!

- 8 -


SOFTWARE>>

FLUX 9.1: This year’s harvest.

Sébastien CADEAU-BELLIARD, Cedrat.

Figure2: “Edit array”: edit sev

As promised last year during the Users Club in Paris, this year’s version of FLUX will

bring you a new and complete preprocessor. PREFLUX now includes all the tools needed to defi ne one case: geometry, mesh and physical properties in its user-friendly Windows style interface.Let us have a preview of this version, that will be offi cially presented during the Users Meeting in Grenoble, October 14th and 15th.

Make your everyday life easier

This has been our leitmotiv when developing FLUX 9.1: helping you to spend more time… coffee breaking!And we integrated many tools to speed the design up: improvement of the graphical user interface and enhanced display of the devices, “edit array” to check several entities in only one table (parameter, regions, points…), instead of checking them one by one, “close all” button to close all the dialog boxes in one shot…The list is too long to be complete…All those little things that make your life easier are now in this version.

Geometry import: more than an evolution, the

revolution

The work started few years ago now reaches a new step: the import and mesh of ANY type of complex shape (STEP and IGES formats) is now possible in 2D and 3D with FLUX. The only limit to import is now… your imagination.

FLUX now also includes automatic tools for correction of geometry. Should there be undefi ned intersections between lines, the user can now correct them automatically. Should two points be not exactly similar (lack of accuracy when drawing it in your CAD tool), FLUX gives you now the possibility to merge them…

More examples will be shown during the users meeting…

Figure1: Complex sample geometry imported in FLUX (initially STEP format).

Figure 3: Complex sampl

Shipment starts in

January 2005 !!

FLUX 9.1

during the club.

Flux 9.1 will be presented at 9.30 pm on october 14th, PLM Center, Meylan.

All the support team will be there from october 14th to 15th to answer all your questions regarding FLUX 9.1 ... and others.


SOFTWARE>>- 9 -

ape meshed in FLUX.

Figure 4: Physical properties definition within FLUX.

Figure 5: Electrical circuit coupling and display

News models

Finally, as usual, CEDRAT does also care of the various applications you may have and implements every year new models.This year, the users, and especially the motor designers, are able to model skewed machines (rotor and/or stator). The infl uence of the skew on the outputs (torque for example) can then be studied…One article of this FLUX MAGAZINE presents precisely the computations that can be done with FLUX…

Looking forward to seeing you…

I already wrote too much… We will unleach all the news of FLUX 9.1 during next Users Meeting in Grenoble… and in next issue of FLUX MAGAZINE.

Physical properties

One of the main improvements of this version is the integration of the physical properties defi nition within the Windows style interface the users discovered last year. PREFLUX now includes all the tools for 2D and 3D preprocessing. Materials, regions, electrical circuit, boundary condition… any physical property may be now defi ned in this user-friendly interface.Now the electrical circuit may be displayed in this new interface for a fastest and easiest handling: several users of FLUX 3D have asked it, we are now proud to propose it!

FLUX 9.1

parameters in one table.

- 10 -


SOFTWARE>>

The SPEED and Motor-CAD packages form a perfect combination for designing

electric motors and generators. The thermal capabilities of Motor-CAD ideally complement the electromagnetic capabilities of the SPEED software. To obtain a true optimum design it is essential to take account of both the electromagnetic and thermal design aspects. In fact there should be strong interaction between the two disciplines as it is impossible to accurately analyse one without the other, i.e. the losses are critically dependent upon the temperature and vice versa. The combination of SPEED and Motor-CAD is now even easier to use as it is now possible to automatically transfer data between the two packages. The data transfer is carried out using ActiveX links – this is a standard technique used in Windows® to pass data between packages.

Additionally both Motor-CAD and SPEED can be fully automated and run from any ActiveX enabled software such as Excel, Matlab, C++, Python, etc. This allows the user to combine either of the packages into their own design environment, automatically passing any relevant data between the users code and Motor-CAD and/or SPEED. Also the user can easily write automated optimisation and sensitivity analysis routines.

Motor-CAD

Motor-CAD is the worlds only software package dedicated to the thermal analysis of electric motors and generators. It is developed by Motor Design Ltd in the UK. The head of Motor Design Ltd is Dr David Staton who worked in the SPEED Laboratory from 1989 to 1995. Since leaving the SPEED Laboratory he has developed a major interest in thermal analysis of electrical machines and saw that there was a need for a software product to make thermal analysis easier to carry out – hence the development of Motor-CAD.Motor-CAD operation is very similar to the SPEED software in that its analytically based algorithms allow near instantaneous calculation

SPEED or the user own software. He must then select materials and make decisions of what cooling types are to be used. A comprehensive set of cooling models are available, i.e. totally enclosed natural ventilation (TENV), totally enclosed fan cooling (TEFC), drip proof, through ventilation, water jacket, wet rotor and wet stator and spray cooling methods.

For steady-state thermal analysis the schematic diagram is an ideal graphical tool for displaying the temperatures of all components (nodes) within the network and to examine the power fl ow between nodes (fi gure 3). The resistances in the network are colour coded to the components in the cross-section editors. If the user is interested in transient analysis then the required duty cycle load is defi ned using the graphical editor shown in fi gure 4.

speeds and make possible “what-if” scenario calculations in real time. Also, like the SPEED software, its sophisticated user interface is designed such that input parameters can be effortlessly changed and their effects on the design easily viewed using dedicated output diagrams, graphs and design sheets.

In Motor-CAD the user inputs the geometry using dedicated cross-section editors as shown in fi gures 1 & 2. For thermal analysis the 3-dimensional nature of the machine must be defi ned. Much of the geometry and the winding details can be imported directly from the SPEED software or the users own analytical design program. The user then just needs to set a few additional geometric parameters that describe the housing and details such as gaps around the end-winding, etc. The losses in the machine must then be defi ned. Again these can be imported from

Motor-CAD ActiveX Links. Dave STATON, Motor Design Ltd.

Figure 2: Motor-CAD Axial Cross-Section Editor.

Figure 1: Motor-CAD Radial Cross-Section Editor.

Figure 3: Motor-CAD Steady-State Schematic.


Figure 4: Motor-CAD Duty-Cycle Editor.

MOTOR-CAD V.2

New release!!

- 11 -


SOFTWARE>>

Figure 7: Radial Fin Spacing Optimisation routine in Excel (calls

Motor-CAD).

The thermal transient is then calculated and plotted as shown fi gure 5. fi gure 5 also shows the excellent agreement with test that can be achieved – in this case measured temperature data for the winding, housing and front fl ange have been imported into Motor-CAD and plotted on the same graph.

In the past thermal analysis has tended not to be given as much emphasis as the electromagnetic design. One reason for this is that most motor designers have an electrical background rather than mechanical and so are not as familiar with heat transfer theory as with electromagnetic theory. Motor-CAD is a product that tries to make thermal analysis available to everyone, even if their knowledge of heat transfer is limited. To achieve this, a thermal equivalent circuit approach has been adopted in which all the thermal resistances and capacitances within the network are calculated automatically. The user need only supply readily available parameters that defi ne the geometry, winding, materials and losses – much of this data can be imported directly from SPEED or the users own analytical design package. More complex details of the thermal design can also be examined, e.g. non-perfect impregnation and interfaces between components such as the stator lamination and housing. For such complexities, parameters are provided in the software that that give physical meaning to the phenomena. For instance non-perfect impregnation is modelled as an impregnation goodness factor (e.g. a value of 0.8 means there is 20% air in the impregnation) and will typically have a higher value if vacuum impregnation is used rather than trickle or dip impregnation techniques. Interface thermal resistances between components are modelled as equivalent airgaps. To assist users set up such parameters, data from practical measurements on real machines are included in the online help. Using Motor-CAD it is possible to quickly perform sensitivity analysis and identify all the parameters

that have a signifi cant impact on the design such that effort can be concentrated on the most relevant design variables when putting the motor into manufacture. Such sensitivity analysis can be fully automated and run from such packages as Excel or Matlab.

Motor-CAD links to SPEED

Losses and geometry data can be passed from SPEED to Motor-CAD and temperatures and geometry back. The data transfer is carried out using ActiveX links. The dialog box that controls the data that is to be imported from SPEED and exported from Motor-CAD is shown in fi gure 6. The user can select the amount of data that is to be imported and exported using the check boxes provided. An option is provided in the dialog to iterate to a converged solution. When activated an automatic iterative loop is performed where the SPEED losses are imported and the Motor-CAD temperatures exported until convergence is obtained (losses dependent upon temperature and vice versa).

Motor-CAD links to other software

Sensitivity analysis and optimi-sation routines that call Motor-CAD and/or SPEED as black-box calculators can be written in any ActiveX enabled programming lan-guage such as Excel-VBA, Matlab, C++, Python, etc. This makes it possible for the user to develop very powerful packages of their own that automate repetitive cal-culations. The user can use calls to Motor-CAD such as LoadFromFile,

SetVariable, GetVariable, DoStea-dyStateAnalysis, DoTransientAna-lysis, etc. A similar set of calls can be made to the SPEED software. An example of a simple sensitivity analysis routine that calls Motor-CAD to optimise the fi n spacing in a particular design is shown in fi gure 7.

To fi nd out more about Motor-CAD visit the website at www.motor-

design.com.

Motor-CAD ActiveX Links. (continued)

Dave STATON, Motor Design Ltd. MOTOR-CAD V.2

New release!!

- 12 -SOFTWARE>>

KOP: Analysis of Subsea Umbilical Systems for

Oil and Gas Industry. Truls NORMANN, KOP.

Kvaerner Oilfi eld Products' (KOP) uses the FLUX software for electrical and

magneto-dynamic analysis of subsea umbilical systems for the global oil and gas industry. The umbilicals work like lifelines to the subsea production systems, providing electrical power communications, as well as hydraulic power and chemicals for optimal oil production.

The picture below shows the IPU™ (Integrated Production Umbilical) which typically consists of the fol-lowing items:

• Flowline (in centre, for oil/gas. External PVC elements and other items for fl owline insulation),

• Tyco’s STS heat tracing system (patented electrical pipeline heat-ing system based on skin effect phenomenon),

• Fibre optic lines (for tempera-ture monitoring and high-speed communications),

• Signal quad cables (for back-up communications and low voltage power supply to subsea control modules),

• Steel tubes (for hydraulic supply to subsea systems),

• High voltage power cables (for subsea pump and compressor sys-tems, typically in the range up to 5 MW and up to 36 kV).

In order to optimise overall IPU performance from an electrical point of view (both high voltage and low voltage) KOP typically carry out the following analysis, Using Cedrat FLUX software:

• Induced voltages in signal ca-bles,

• Induced currents in steel tubes and fl owlines,

• Cable parameter estimation (based on magnetic coupling to surroundings),

• Combined electro-thermal ana-lysis,

• Overall power system optimisa-tion and system earthing,

• Power losses in various items,

• Harmonic analysis (critical frequencies from variable speed drives (used for subsea pump and

Typical subsea production system (parts of KOP’s Dalia project for Total, West Africa).

Typical subsea X-mas tree (wellhead) systems with power distribution to subsea or downhole electrical submersible pumps.

KOP’s IPU™ insulated flowline with 3-phase high voltage cables (on top) and other utilities like STS (Skin effect heat

tracing) electrical flowline heating system.

Magnetic field around IPU power cables and inside STS heating tubes (120degrees angle between phases for power cables and heaters).


compressor motors) and communications frequen-cies),

• Visualisation of mag-netic fi elds, current den-sities (in STS heating system), etc.

KOP fi nds the FLUX software an excellent tool for all these applications, and foresees that this software package and knowledge about the subsea electrical and high voltage technology are among key factors for success in the future, especially based on the increased focus on marginal oil and gas fi elds, with long step-outs, deep waters and need for subsea pipeline heating and subsea boosting (compressors and pumps).

In addition, there is a global offshore market trend for full subsea development projects with no oil platforms, like i.e. the ongoing Ormen Lange gas fi eld project at the West-Coast of Norway, where step-out distance from shore is around 120 km, and where the technology development program means that a 60 MW subsea compressor station is competing with a traditional fl oating platform solution. Subsea power distribution systems (including umbilicals and power cables) are key technology in order to reach that target, and this depends on advanced multi-discipline fi nite element software.


MAGNETISATION>>

- 14 -


SOFTWARE>>

The new 2005 training catalogue of CEDRAT and CEDRAT TECHNOLOGIES is now available on our web site at:http://www.cedrat.com/training/training.htm.

Discover our new trainings "FLUX 3D and the NDT" ; "Study of Induction machines" ; Linear magnetic actuators" ; Rotating electric machines...

As all others trainings...

A full list of training programmes can be obtained from Joëlle Six at CEDRAT - Email: [email protected].

New 2005 CEDRAT Group

Trainings Catalogue. Patrick LOMBARD - Cedrat.

>> >> SOFTWARE SOLUTIONSSOFTWARE SOLUTIONS FOR ENGINEERS FOR ENGINEERS Join one of our meetings in GermanyJoin one of our meetings in Germany

> CEDRAT in Germany.

This autumn you cannot miss CEDRAT in Gremany. We will be present for three "Software for Engineers Days" in German universities in November.

>16th November at Stuttgart >17th November at München >18th November at Dresden

Ask for your free invitation and all the details of the conferences at [email protected]

CEDRAT

As it will take place at the Centre Paul Louis Merlin at Meylan, the 2004 FLUX Users’ Club will represent an opportunity to present the software, its new features and current developments, as well as debate together on your FLUX experience.We invite you all on Thursday and Friday, 14th and 15th October 2004 at Grenoble-Meylan. The registration forms has been sent to you by e-mail. If you have not received it yet, please contact Joëlle Lescene: [email protected]

2004 FLUX Users' Club...

Let's all meet in Meylan ! Sébastien Cadeau-Belliard - CEDRAT.

AG

END

A- 15 -


Dates to re member

A full list of training programs can be obtained from Joëlle Lescene ([email protected]) at CEDRAT, or from our web site http:www.cedrat.com. The dates are already fi xed up until the end of year 2005, allowing you to prepare your training course calendar. Email: [email protected].

Training coursesOctober 26-28 2004FLUX (2D) & rotating machines

May 31, June 1-3 2005FLUX (3D) & rotating machines

November 3-5 2004FLUX (3D) & N.D.T.

June 21-23 2005Magnetic linear actuators

November 16-18 2004March 30-31, April 1st 2005FLUX (2D) introductory course

October 2005Thermal analysis

December 14-16 2004June 8-10 2005PSCAD introductory course

November 8-10 2005Study of induction machines

February 15- 17 2005Active materials & actuators

November 23-25 2005Rotating electric machines

March 2-4 2005September 20-22 2005Magnetism for electrical engineering

November 23-25 2005FLUX (3D) introductory course

April 5-7 2005September 26 - 28 2005ATILA introductory course

November 30 , Dec. 1st 2005FLUX (3D) advanced course

May 18-19 2005FLUX (2D) advanced course

October 03-07 2004 (Magsoft)IAS, Seattle, Washington, USA.

October 10-13 2004 (Magsoft)IEEE/PES Power Systems, New York, USA.

October 14-15 2004 (Cedrat)European Flux Users Club 2004, Grenoble, France.

October 18-20 2004 (Magsoft)Convergence, Detroit, Michigan, USA.

October 19-21 2004 (Cedrat Technologies)MesurExpo 2004, Paris, France.

October 28-30 2004 (Cedrat Technologies)ARWtr04, Advanced Research Workshop on Modern Transformers , Vigo, Spain.

November 3-5 2004 (Magsoft)SMMA Fall Conference 2004, St. Louis, MO, USA.

November 16-18 2004 (Magsoft)PowerSystems World, Chicago, Illinois, USA.

November 22-25 2004 (Motor Design)EWEC 2004, London, United Kingdom.

November 23-25 2004 (Maccon)SPS DRIVES 2004, Nuremberg, Germany.

December 06-10 2004 (Cedrat)ELEC 2004, Paris Nord Villepinte, France.

CEDRAT, CEDRAT TECHNOLOGIES and partners will take part in the above exibitions.

CEDRAT Partner of EWEC

2004 European Wind

Energy Conference

22-25 November, London UK

http://www.ewea.org/

06b_events/events_

2004EWEC.htm

New PSCAD version 4.1 presented on CEDRAT booth

(Hall 2, K77)

For any information Contact Mr. Lionel GRAND:

[email protected]

CEDRAT in PolandPresent at ICEM 04 in Lodz where more than 10% of the overall presented paper have been completed using our software solutions (FLUX, SPEED, MOTOR CAD, PSCAD), CEDRAT met also for the fi rst time its users in Katowice. 22 people met to discuss about FLUX, the applications they deal with and the news of Version 9. This fi rst FLUX KLUB was a great success and all participants were satisfi ed by the tools and support they get from CEDRAT and TERMAGSOFT.«This meeting was a great opportunity for us to strengthen the relationships between CEDRAT, TERMAGSOFT and all the FLUX Users in Poland», said Marc Vilcot, Sales Manager of CEDRAT.We thank here all the authors of the ICEM papers as well as the speakers at the FLUX KLUB.

ICEM 04

For all your projects in electrical engi-neering, the CEDRAT Group provides a fully integrated line of tools, products and services.

CEDRAT and its partners form a world-wide consortium with a reputation built on the success of FLUX software; APA piezo actuators; and R&D activity.

FLUX, quality-certified through EDF, has more than 1000 companies as clients, active in research and production of every type of electromagnetic device or process, from small appliances to large machinery, in automotive and aerospace industries, defence, energy transfer and conversion, telecommunications and information systems, household ap-pliance and medicine… FLUX supports high-precision design of electrical and electromechanical devices. FLUX is part of a complete range of software dedica-ted to Electrical Engineering. From power systems to electromecha-

nical devices drive and control, from active materials based structures to electromagnetic and thermal design of electrical machines, the CEDRAT Group provides a software solution adapted to your application.

CEDRAT’s extensive R&D activity is conducted by a multidisciplinary team of experts. CEDRAT’s laboratories are equipped with a complete library of engineering software and specialised measurement apparatus. CEDRAT focuses its expertise on industry needs for innovation and optimisation and is a member of EARTO (European Association of Research and Technology Organisations). CEDRAT’s innovations are part of your life today (fuel injection, watch motors, industrial cooktops, stress sensors) and will work to bring you a safe and comfortable future as well (vehicle suspension, flight control, electromagnetic bar codes). Amplified Piezoelectric Actuators


T C

EDR

AT

AB

OU

T C

EDR

AT

demonstrate CEDRAT’s outstanding in-novation in smart materials applications. CEDRAT’s smart materials-based line of products meets the most stringent specifications for aerospace and indus-try. Application fields include precise and rapid actuation, optics, instrumentation and control of vibrations.

CEDRAT provides a complete range of precision instruments for electroma-gnetic measurements and magneti-sation.

CEDRAT offers comprehensive training in magnetism, electrical and electric power engineering.

Strong synergy between its software, hardware, and research activities and a worldwide network of distributors make CEDRAT your partner for any electrical engineering project.

Cedrat, your partner in electrical engineering.

CAE: Distribution of CAE software for Electrical Engineering Piezo: Distribution of Piezo Products

- AMERIca:

Brazil: ELECTROMAGNETICS TECNOLOGIA.Rua Florida, 512, 09550-000 São Caetano do Sul - S P, Brazil. Phone: +55 11 3091 54 15 Fax: +55 11 3814 40 13 [email protected] CAE

Canada - USA - Mexico: ADAPTRONICS Inc.1223 Peoples Avenue - Troy, New York - 12180, USA. Phone: +1 518 276 24 84 Fax: +1 518 271 83 66 [email protected] http://www.adaptronics.comPiezo

Canada - USA: MAGSOFT Corp.20 Prospect St. - Suite 311- Ballston Spa, NY 12020Phone: +1 518 884 05 05 Fax: +1 518 884 86 88 info@magsoft-fl ux.com http://www.magsoft-fl ux.comCAE

- AsIa:

China: A&P INSTRUMENT Co., Ltd.Beijing branch Shanghai branchTel: +86 10 6207 4835 Tel: +86 21 33013686Fax: +86 10 6207 7434 Fax: +86 21 5393 [email protected] [email protected]://www.anpico.comPiezo

Hong-Kong: A&P INSTRUMENT Co., Ltd.Headquarter: Unit 1, 1/F, Kam Hon Industrial Building8 Wang Kwun Road, Kowloon Bay,Hong Kong.Phone: +852 2755 6578 Fax: +852 2755 [email protected] http://www.anpico.comPiezo

India: Maxsoft.448, 2nd Floor, Service Road (Ring Road)IV Block, HBR Layout,Bangalore - 560043 INDIA.Phone: +91-80-25430676 Fax: +91-80-25430686 [email protected] http://www.maxsoft-india.comCAE - Piezo

Indonesia & Singapore: Peacock Technology Pte Ltd.627A Alljunied Road, Biztech Centre, #04-01.Singapore 389842.Phone : +65 747 4460 Fax : +65 747 6460CAE

Japan: Keystone International Co. Ltd.Kurosawa Building, 3F13-27 Sakasai Kashiwa Chiba, 277-0042 Japan. Phone: +81 47 175 8810 Fax: +81 47 175 [email protected] http://www.keystone-intl.co.jpPiezo

Japan: Small Motors Laboratory.Heiwa Plaza # 305 8-12 Toyooka - Tsurumi-ku, Yokohama-shi, 230, Japan. Phone: +81 45 586 0800 Fax: +81 45 586 0792CAE

Korea: JAEWOO Technology Co. Ltd.Jangan Bldg 2F, 688-5, YukSam-Dong, KangNam-Ku 135-080, Seoul, Korea. Phone: +82 2 539 41 00 Fax: +82 2 539 4151 [email protected] http://www.jaewoo.comCAE

Korea: INNOTICS, IncHead Offi ce: #1016, Sam-Poong B/D, 310-68Eul-Gi-4Ga, Joong-Gu, 100-849, Seoul, Korea.Phone: +82-2-2276-1013 Fax: +82-2-2264-0469Email: [email protected]

Pakistan: TECHNOTRADE7-A Bank Square Market, Model Town, Lahore-PakistanPhone: +92 42 583 2403 Fax: +92 42 583 [email protected] http://www.tekno-trade.comCAE

World-wide representation:

- europa:

Austria - Switzerland: APPLIED MAGNETICS.Rue de la Gare 15A, CH - 1110 Morges, Switzerland. Phone: +41 21 803 58 68 Fax: +41 21 803 58 78 [email protected] CAE

Benelux: Micromega Dynamics SA.Parc Scientifi que du Sart Tilman, Rue des Chasseurs Ardennais, 4031 Angleur, Belgium. Phone: +32 4 365 23 63 Fax: +32 4 365 23 46 [email protected] http://micromega-dynamics.comPiezo

Croatia-Bosnia: Faculty of Engineering . Faculty of Engineering Rijeka - Dept. of Electrical Engineering. Vukovarska 58 - 51000 Rijeka - Croatia. Phone: +385 51 651435 Fax: +385 51 675818 [email protected]

Germany - Austria: SI Scientifi c Instruments GmbH.Romerstr. 67, D-82205 Gilching, Germany.Phone: +49 8105 77940 Fax: +49 8105 5577 [email protected] http://www.si-gmbh.de Piezo

Germany: Maccon GmbH.Kuehbachstrasse 9, D-81543, München, Germany. Phone: +49 89 65 12 20 0 Fax: +49 89 65 52 17 [email protected] http://www.maccon.de CAE

Italy: SPIN Applicazioni Magnetiche S.r.l. Via Leonardo da Vinci 17, 29010, Pianello (PC), Italy. Phone: +39 0 523 99 74 90 Fax: +39 0 523 73 33 64 [email protected]. http://www.spinmag.itCAE-Piezo

Switzerland: DIWAG AG.Grossfeld 39, FL-9492, ESCHEN, Liechtenstein. Phone: +423 232 8555 Fax: +48 22 826 98 15 [email protected]

Poland: PROJECT Uslugi Informatyczne.ul. Namyslowska 19 m.35, 03-455 W-Warszana, Poland. Phone: +48 22 818-42-21 Fax: +48 22 826 98 15 [email protected] Piezo

Poland: TermagSoft.al. 1-go Maja 19, 90-739 Lodz, Poland. Phone: +48 42 658 14 00 Fax: +48 42 658 14 00 [email protected] http://www.termagsoft.com.plCAE

Romania: Univ. POLITEHNICA de Bucarest.Faculté d'Electrotechnique, EPM_NM Laboratory, Splaiul Independentei 313 - 77206 Bucarest, Romania. Phone: +40 21 411 65 58 Fax: +40 21 411 65 58 fi [email protected] http://amotion.pub.ro/~epmCAE

Slovenia: Bober Inzeniring.Zasavska c. 20A, 4000 Kranj, SloveniaPhone: +386 4 2356710 Fax: +386 4 2356710 [email protected] http://www.boberinzeniring-bb.siCAE

Spain: INDIELEC.Pont Sec 5, Poligono Industrial Moncada II 46116 MONCADA (Valencia), Spain. Phone: +34 961 303 462 Fax: +34 961 309 167 [email protected] http://www.indielec.esCAE

UK: Motor Design Ltd.1 Eaton Court, Tetchill, Ellesmere, Shropshire, SY129DA, U.K.Phone: +44-(0)1691-623305 Fax: +1 419 831 92 55 [email protected] http://www.motor-design.comCAE

Taiwan: Scientifi c Formosa Inc.11th Fl, 354 Fu-Hsing North Rd - Taipei, Taiwan ROC. Phone: +886 2 2505 05 25 Fax: +886 2 2503 16 80 [email protected] http://www.sciformosa.com.twCAE

Taiwan: Superex Technology Corp.2F-5,203,Sec.2, Ho Ping East Road, 106 Taipei, Taiwan ROC.Phone: +886-2-2701-6281 Fax: +886-2-2705-6411Email : [email protected] Piezo

Partners: Canada: Manitoba HVDC Research Centre (Power System Simulator)[email protected] http://www.hvdc.ca

Finland: LUT (Motors).fl [email protected] http://www.ee.lut.fi

France: CEGELY (PHI3D Software)[email protected] http://www.cegely.ec-lyon.fr

France: ENSIEG - L.E.G. ( FLUX Software)[email protected] http://www.leg.ensieg.inpg.fr

France: Imagine (Fluid Power)[email protected] http://www.amesim.com

France: ISEN (ATILA Software)[email protected] http://www.isen.fr

France: Prismeca (InductionHeating)[email protected] http://www.prismeca.com

Germany: Mecatronix GmbH (Mechatronic systems)[email protected] http://www.mecatronix.de

Hungary: Budapest University of Technology and Economics (Superconductivity)[email protected] http://supertech.vgt.bme.hu

Italy: Laboratorio Elettrofi sico (Magnetizing Technics)[email protected] sico.com http://laboratorio.elettrofi sico.com

Italy: Inova Srl. (Induction Heating)[email protected] http://www.magnetic.it

Netherlands: Eindhoven University of Technology (Motors)[email protected] http://www.evt.ele.tue.nl/epe/

Sweden: R.I.T. (KTH) (Motors)[email protected] http://www.ekc.kth.se/eme/eme_eng.html

UK: ELEKTRO MAGNETIX Ltd. (Mechatronix Systems)[email protected] http://www.elektro.co.uk

UK: SPEED Laboratory (Speed Software)[email protected]

UK: University of Sheffi eld (Linear Actuators).r.e.clark@sheffi eld.ac.uk http://www.shef.ac.uk/eee/

USA: Rensselaer Polytechnic Institute (Software)[email protected] http://www.rpi.edu

Flux Magazine2004Oct

Documents

Transcript of Flux Magazine2004Oct