Electrical machine developmentactivities and future challenges inproduct design
CRECOS seminar 2010, Aalto UniversityKari TammiResearch Professor – Eco-Efficient MachinesVTT Technical Research Centre of Finland
212/11/2010
VTT in very briefCentre for Smart Machines in brief
§ VTT: applied research centre§ About 2800 employees§ Owned by Finnish Ministry of Employment and the Economy
§ About 50 researchers working on:§ Dynamic phenomena in machines & vehicles§ Active control of noise & vibration§ Machine durability§ Industrial R&D§ Academic research
§ Core competences:§ Combining experimental & theoretical research§ Knowledge of physical phenomena & our customers’ product
312/11/2010
Research challenges
§ Representing machines & vehicle sector research, focus on:§ Energy efficiency§ Life-cycle efficiency§ Lightweight structures§ Modelling & simulation
412/11/2010
Model and model data management based on semantic ontologies
§ Simantics platform developed by VTT§ Open source platform§ To be used as a hub to connect different modelling, simulation, and
data management software
§ www.simantics.org§ Juha Kortelainen, Tommi Karhela
512/11/2010
Electrical machines research, background drivers
§ The world is electrifying, renewable and hybrid technologies are booming§ Cost-efficient solutions are viable§ Electrical machines and modern drive technologies are becoming prevalent in
machines and vehicles§ Lightweight design enables material savings and efficient logistics§ Requirements for low emission are tightening (heat, vibration, noise in this
context)§ Energy efficiency requires low losses and efficient cooling technologies§ Condition monitoring methods enable service business models and better life-
cycle control§ Virtual prototyping of complete product for efficient design processes§ Electrical drives become integrated components in machine/vehicle structures
612/11/2010
Challenges identified
§ The electrifying world needs high power density electrical machines, and drives integrated in products§ The challenges are:
§ Cost-efficient products§ Machine weight (Cu+Fe) and dimensions § Heat control§ Electro-mechanical excitations§ Bearings
§ The solutions are:§ Novel machine concepts created by multi-disciplinary project group § New material technologies (e.g. cooling, electric isolation) § Simulation-based multi-technical design approach§ Understanding of electro-mechanical interaction phenomena§ Understanding electrical drive as a part of machine/vehicle structure
712/11/2010
Focus & objectives
§ Compact, silent, care-free electrical machines, for example:§ Compact machines with high torque and high power density§ Future breakthrough machine concepts (created from scratch)§ Energy and environment efficient machines in terms of design,
manufacturing, operation, and maintenance§ Designed to be integrated in structure à truly lightweight construction§ Machines with reliable fault sensing and adaptive maintenance
intervals
812/11/2010
Why most electrical machines look similar?
Radial flux, tubular design is dominant, why?§ Manufacturing of 2D structures is
attractive § Analysis in plane, even 3D computations
are expesive§ Tradition
912/11/2010
Exceptions exist
Topology variations are higher in smaller machines§ Disk drives§ Stepping motors, etc
Examples of larger machines§ Hoisting machinery, benefits from the
dimensions§ High-speed trains
1012/11/2010
How would the optimal structure look like?
§ No history§ Start from magnetomotive force§ Looser boundary conditions (material, manufacturing)§ Use modern design methodology
See what comes up
§ Reality of wish list to Santa Claus?
1112/11/2010
VTT creates business from technology