Simcenter 3D Acoustics Simulation Based Noise Reduction of Electric Machines Hermann Höfer 13. Nov. 2018

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1 Simcenter 3D Acoustics Simulation Based Noise Reduction of Electric Machines Hermann Höfer 13. Nov Realize innovation.

2 Possible modelling time line for electric machine design Powertrain Pre-sizing Machine sizing Machine analytical design Machine control validation Machine detailed design Vibro-acoustic analysis due to electro-magnetic forces Motor thermal integration Motor Vibroacoustic analysis Dynamic model for drivability Electric machine design time line Page 2

3 Market Trends Electrification is growing substantially Source: international energy agency Over 100 electric motors in a standard car Page 3

4 Electric Motors Lower absolute noise YET higher ANNOYANCE ICE EM Page 4

5 Simcenter 3D 3D CAE for the digital twin Best-in-class simulation modeling Multi-discipline integration Openness and scalability Leading in system simulation Leverage industry expertise Page 5

6 Simcenter 3D Acoustics Engineering View: source system transfer - receiver Source System Receiver Mechanical (from MBS, from Test) FEM Vibro-Acoustics Simcenter Nastran Vibrations/Forces/Stress Acoustics Electromagnetics (from EM sim) Directivity Sensors BEM Vibro-Acoustics Simcenter Acoustics BEM Acoustic (from Aco sim, or formula) Contributions Functions Page 6

7 Simcenter 3D Acoustics Technology View FEM AML FEMAO ATV Random Vibro-Acoustics Fast Multipole BEM H-Matrix BEM Page 7

8 Simcenter 3D Acoustics Key Capabilities NX Nastran based FEM solution for Vibro-Acoustics Noise radiation Sound Power One Model bdf Simcenter Nastran OP2 PCH One Pre/Post One Solver Structural Eigen modes Vibration/Stress Page 8

9 Comp. time Model size Simcenter Acoustics AML (Automatically Matched Layer) AML auto-creates a Perfectly Matched Layer PML layer at solver level, which fully absorbs outwards traveling waves Yields accurate results in regular (red) FEM domain first Then, post-processing yields results outside the FEM domain PML layer is allowed to be put very close to radiator Lean and FAST FEM models ρc AML 500 k DOFs 80 k DOFs incl PML X s/freq X / 20 s/freq Page 9

10 SC Acoustics FEMAO Auto-adapting (f) fluid element order Leaner models in pre-processing Faster at lower frequencies More efficient at higher frequencies 2 to 10 x faster compared to standard FEM FEM mesh FEMAO mesh Full vehicle exterior acoustics Panel loading due to tire / tailpipe noise Standard FEM 1 single model for all frequencies Standard FEM several models for different frequency ranges FEMAO 1 single model for all frequencies Less DOF required for FEMAO Optimal DOF size over all frequencies log(f) Submarine sonar scattering Page 10

11 Simcenter Acoustics ATV (Acoustic Transfer Vector) Set ATV enables fast multi-rpm acoustic analysis ATVs are INDEPENDENT from load conditions (rpm, order ) For exterior radiation, ATVs are SMOOTH functions (f), which can be interpolated Page 11

12 ATV example Radiation of a gearbox 1 node, smp=4 SOL111 Response SOL111 ATV Response freqs Hz Hz Time 22 min 3 min 120,00 SPL at MIC ,00 80,00 60,00 40,00 Windows 7 laptop 32 GB RAM 4 cores, 8 threads 2.8 Ghz 20,00 0,00 0,00 200,00 400,00 600,00 800, , , , , ,00 no atv atv Page 12

13 Simcenter 3D Acoustics Application View Machinery noise radiation engine, E-motor, compressor, pump.. Full Vehicle Radiation/ Scattering Pass-by Noise, pedestrian safety, submarine scattering Duct (Vibro)Acoustics Intake/ exhaust/ muffler Transmission Loss, orifice noise and shell noise Enclosure / Panel Design Panel Transmission Loss, Insertion Loss Cabin Acoustics Cars, tractors, excavators Random Vibro-Acoustics Spacecraft Mission De-risking Page 13

14 Simcenter 3D Acoustics Key Capabilities Scaling up 3D simulation with NX Open, fully record complex processes for efficient re-use and customization. Scalability to run many designs very efficiently Going from TO Page MM.DD

15 Noise spectrum from an Electric Motor Resonances: Structural and Acoustic Switching frequencies rpm db Pa Mechanical, cooling and Electro-magnetic Orders Hz Page 15

16 Noise Sources of Electric Machines Flow induced: e.g. cooling fan Mechanical: Misalignments, bearing defects, eccentricity result in bearing forces on the stator Electro-magnetic: EM mechanisms induce harmonic forces on the stator Page 16

17 Electro-magnetic noise How noise is created Forces from Electro- Magnetic Simulation / Analytical Reference forces Resulting in Vibrations of the housing Radiating off as unwanted noise Page 17

18 Infolytica MagNet / Speed Simcenter Acoustics for Machine Noise Radiation Process View on an Electric Motor model JMAG / Maxwell Simcenter Mapping/Processing Simcenter 3D Simcenter Structural + FLuid Meshing, assembly, BC E-Mag Forces *bdf SC3D DSP/Gluing *unv *op2 Modes, Vibrations, Acoustic Radiation Analyze forces Page 18

19 Simcenter Simcenter Simcenter Simcenter Simcenter 3D Noise Radiation Modes, Operational Vibrations Plot sound radiation maps CAD or FEM structural model Meshing for Acoustics, microphone points Sound Power Page 19

20 Simcenter 3D Solutions A part of a broader vision 1D - 3D co-simulation : 1D control, Structural, Acoustics System of systems simulation and design 3D tests hybrid modelling : Model updating (improve trust in CAE) Real time hybrid testing Out of the box integration with Teamcenter: Synchronize simulation and design Easily manage simulation data out-of-the-box with Teamcenter Simulation Knowledge capture and process automation Page 20

21 Further System-level approach 1D 3D integrated solution Motor Concept Optimization Controls Concept Magnetic simulation JMAG Vibro-Acoustic Model Simcenter Look-up tables of Flux & Torque vs. Voltage & current JMAG Functional Motor Model Imagine.Lab Thermal SRM Model Imagine.Lab Vehicle Energy Model Imagine.Lab Optimization of switched reluctance electrical motor and controls design for NVH & thermal performance Page 21

22 Demo: Vibro-Acoustics with Simcenter 3D Electro-Magnetic Forces Page 23

23 Demo: Vibro-Acoustics with Simcenter 3D Geometry Preparation Structural Meshing Assembly FEM Acoustic Meshing Magnetic Loads Simulation Setup Post- Processing Page 24

24 Demo: Vibro-Acoustics with Simcenter 3D Geometry Preparation x Structural Meshing x Leverage Siemens CAD strength for efficient and associative CAEgeometry abstraction Simple, economic and robust meshing of complex geometry Page 25

25 Demo: Vibro-Acoustics with Simcenter 3D Assembly FEM Easy reuse of existing subcomponent models Hybrid models (combine FEM s, FRF s, Superelement s, ATV s, ) Efficient team-collaboration Page 26 2x

26 Demo: Vibro-Acoustics with Simcenter 3D Acoustic Meshing Fast acoustic meshing due to dedicated tool s Surface Wrapping Convex Mesher Microphone Meshes Infinite Plane v=0 Page 27

27 Demo: Vibro-Acoustics with Simcenter 3D Magnetic Loads Load Recipe Simulation Setup Seamless workflow to reuse magnetic forces from EMAGanalysis Easy setup of combined simulation for Dynamics & Acoustics Page 28

28 Demo: Vibro-Acoustics with Simcenter 3D Post- Processing Structural Vibration 1400Hz Comprehensive toolset to quickly extract and view relevant performance data Acoustic Pressure P 1400Hz Page 29

29 Demo: Vibro-Acoustics with Simcenter 3D Geometry Preparation Structural Meshing Assembly FEM Acoustic Meshing Leverage Siemens CAD strength for efficient and associative CAEgeometry abstraction Simple, economic and robust meshing of complex geometry Easy reuse of existing sub-component models Hybrid models (combine FEM s, FRF s, Superelement s, ATV s, ) Efficient team-collaboration Fast acoustic meshing due to dedicated tool s Surface Wrapping, Convex Mesher, Microphone Meshes, Magnetic Loads Simulation Setup Seamless workflow to reuse magnetic forces from EMAG- analysis Easy setup of combined simulation for Dynamics & Acoustics Post- Processing Comprehensive toolset to quickly extract and view relevant performance data Page 30

30 Punch Powertrain New generation of switched reluctance motors with superior NVH performance Reduced total development time by at least 50 percent Developed new generation of motors with better NVH performance Implemented a new simulation-based process with knowledge transfer Leverage simulation to guarantee the product meets expectations Use Acoustic Simulation to understand complex sound fields Customize software for specific applications When we consider the fact that it took only half a year to put this process in place, we can definitely say that the total development time has been reduced by at least a factor of 2 Diederik Brems; Mechanical Engineer; Punch Powertrain Page 31

31 Punch Powertrain Page 32

32 Possible modelling time line for electric machine design Powertrain Pre-sizing Machine sizing Machine analytical design Machine control validation Machine detailed design Vibro-acoustic analysis due to electro-magnetic forces Motor thermal integration Motor Vibroacoustic analysis Dynamic model for drivability Electric machine design time line Page 33