INNOVATIVE SOLUTIONS FOR HIGH-POWER-DENSITY E-MOTORS FOR AEROSPACE PROPULSION

© Copyright 2023 ANSYS, Inc.
Innovative Solutions for High-Power-Density
E-Motors for Aerospace Propulsion
Shi-Uk Chung, PhD
Senior Application Engineer, Electronics Business
ANSYS Inc.

1 © 2023 ANSYS, Inc.
Agenda
I. Introduction
• History at a Glance
• Ansys Capabilities and Solutions
II. Ansys Solution for Electric Motor Development
• Electrification Challenges
• Path to High-Power Density Motors
• Ansys Solution for Electric Motor Development
III.Summary

History at a Glance
Look back to look forward
Powered flight
1903
Me 262
(First jet fighter)
1942
SR-71
(Mach 3.3)
1964
Bell X-1
(Mach 1)
1946
First commercial jet
1949
Firs commercial
supersonic jet
1976
Solar powered
intercontinental flight
2012
First all-electric
passenger plane
2022
Structures
1970
Democratize Analysis
Decarbonize Aircraft
Material
2019
Fluid
2006
Electronics
2008
3D modeling
2014
Semiconductors
2017
Optics
2018
Optimization
2019
Motor-CAD
2022
Ansys Simulation Capabilities
1970
1900 1920 1940 1960 1980 2000 2020
• More electric aircraft
• Full electric aircraft
• Hybrid electric aircraft
• Top-of-the-line tools
• Training/ALH
• Technical support
Going green(electric)

Ansys Capabilities and Solutions
Comprehensive simulation platforms for all major physics
Platform
Software/Systems
Ansys SCADE Architect
Ansys SCADE Suite
Ansys SCADE Display
Ansys Medini Analyze
Ansys Twin Builder
Semiconductors
Ansys PathFinder
Ansys PowerArtist
Ansys RedHawk
Ansys RedHawk-SC
Ansys Totem
Ansys Variance FX
Structures
Ansys Mechanical
Ansys Autodyn
Ansys LS-DYNA
Ansys AQUA
Ansys ACT
Ansys nCode
Optics
Ansys SPEOS
Ansys VRXPERIENCE
Ansys Theia-RT
Ansys HIM
Ansys Genesis
Ansys Aesthetica
Electromagnetics
Ansys HFSS
Ansys Maxwell
Ansys SI-Wave
Ansys Icepak
Ansys Q3D Extractor
Ansys Motor-CAD
Design & Additive
Ansys Discovery AIM
Ansys Discovery Live
Ansys SpaceClaim
Ansys Exasim
Ansys Flex
Fluids
Ansys Fluent
Ansys CFX
Ansys Chemkin-Pro
Ansys TurboGrid
Ansys FENSAP-ICE
Ansys BladeModeler
Ansys Polyflow
• Electric motor multiphysics simulation tools

High voltage system2: 28V(As is) → Over 3kV(Megawatt class)
• Dielectric breakdown → Safety/Reliability
• EMI/EMC → Safety/Reliability
Electric motor1: 5kW/kg(Siemens) → 13kW/kg(NASA target)
• High-power density/High efficiency
• Fault tolerance → Safety/Reliability
• Thermal management
Energy storage2: 250Wh/kg(As is) → 500Wh/kg(for 150 seats)
• High energy density battery pack
Advanced materials
• Composite material
• High permeability/low loss electrical steel
Structure
• Lightweight/high strength
Aerodynamics
• Low drag design
Source:
1. Z. Rahman, ARPA-E, 2019
2. Aviation Week Network, 4/30/2021
Electrification Challenges

• Interactions between different physical domains lead to conflicting performance metrics
• Increasing need for multiphysics design and analysis to meet multicriteria requirements
Jet Engine
• 3050,000 parts
• Multiple moving components
Electric motor
• Less than 100 parts
• One moving component
VS.
• Electromagnetic: Torque, efficiency
• Electrical: High voltage/current
• Thermal: Cooling, peak/cont. ratings
• Mechanical: Robustness at high speed, NVH
Multiphysics problem
• High Efficiency (%)
• High torque/power density (kW/kg)
• Reducing cost ($/kW)
• Shorter development cycles
Multicriteria requirements
Automobile Combustion Engine
• 67,000 parts
• Multiple moving components
Multiphysics problem & Multicriteria requirements

High-Energy Density Battery
Electrochemistry
Battery cell
0
Y t
driving_cycle
0.00 200.00 400.00 600.00 800.00 1000.00 1200.00 1400.00
Time [s]
0.00
5.00
10.00
15.00
20.00
25.00
30.00
driving_cycle.VAL
Curve Info
driving_cycle.VAL
TR
v_ref
mech_tv
c_s
c_b
sta
rt
sto
p
d
rive
id
le
driver_hev
c_in_s
c_in_b
start
stop
drive
c_out_m_s
c_out_m_b
idle
c_controller_ev
0.00 500.00 1000.00 1400.00
Time [s]
0.00
0.25
0.50
0.75
1.00
c_controller_ev.bat_soc
Curve Info
c_controller_ev.bat_soc
TR
Electrode_negative
Electrode_positive
Pack
Battery
+
V
Battery_voltage
CONST
wind_velocity
C
ON
ST
grading_angle
vw
a
lp
h
a
mech_tv
stop
idle
chassis_hev1
alpha
stop
mech_rv mech_tv
idle
wheel_hev
control
stop
mech_rv
idle
brake_hev
free
a
b
l_
d
o
l_
q
o
la
mb
d
a
_
p
mo
o
me
g
a
_
e
o
p
_
o
p
h
i_
e
o
power_o
r_
so
rpm
c
mech_rv
pmsm_hev
c_brake
c_velo
l_d
l_q
la
mb
d
a
_
p
m
o
me
g
a
_
e
p
p
h
i_
e
power_m
r_s
rpm
idle
start
stop
a
b
c
free
plus_b
minus_b
pmsm_controller_hev
GAIN
A
Battery_current
BMS
contactor
BMS_Code
S1
BMS
High-Efficient Energy Conversion
Power Electronics
High voltage
High frequency
Electric Motors
High efficiency
High power density
High power AC
(High voltage/current/frequency)
High power DC
(High voltage/current)
Safety/Reliability
• EMI/EMC → Critical component malfunction
• Dielectric breakdown → Catastrophic failure
High voltage & High frequency

Efficiency • Lcopper: Copper loss( Current2)
• Liron : Rotor/stator iron loss( flux density2, frequency2)
• Lsolid : Solid loss( flux density2, frequency2)
• Lmech : Mechanical loss( Speed)
𝜂 =
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛
=
𝑃𝑖𝑛−𝐿𝑡𝑜𝑡𝑎𝑙
𝑃𝑖𝑛
, 𝐿𝑡𝑜𝑡𝑎𝑙
Path to High-Power Density Motors
Multiphysics simulation
Power • B1 : Fundamental airgap flux density
• D 2L : Rotor volume
• A : Electrical loading(Heat generation source)
• 𝝎: Speed( Voltage, frequency)
Power = Torque x Speed
𝑇𝜔 =
𝜋
2 2
𝑘𝑤1𝐵1𝐷2𝐿𝐴 𝜔
→ EM design(Motor-CAD/Maxwell), Material(Granta), Optimization(OptiSlang)
→ EM/Structural design(Motor-CAD/Maxwell/Mechanical), Material(Granta), Optimization(OptiSlang)
→ Thermal design(Motor-CAD/Fluent), Optimization(OptiSlang)
→ Thermal design(Motor-CAD/Fluent), EMI/EMC/Dielectric(EMA3D)
Heat generation:
Power/efficiency decrease

Durability & NVH Simulation
Electromagnetic Analysis
Thermal Management
Operational Performance Mapping
System Integration
Process
Integration
and Design
Optimisation
Concept Detailed Design & Verification
Ansys Solution for Electric Motor Development
End-to-end electric motor design toolchain: Concept to detailed design & Verification

1999
THERMAL module
2013
LAB module
2014
EMAG module
2015
Full Multiphysics
2018
MECH module
2022
NVH
The evolution of Motor-CAD Over 20 Years
Democratizes Electric Motor Design
Multiphysics concept design: Motor-CAD
• Dedicated class-leading tool for electric motor design
• Front-end multiphysics motor design tool
• Fast, template-based Emag performance predictions
• Thermal performance predictions and advanced cooling design
• Mechanical rotor stress analysis and NVH predictions
• Efficiency mapping and drive cycle performance analysis
MOTOR-CAD
NOW
• Multiphysics
• Wide operating range
• Rapid development
• System integration
THEN
• Single physics (Emag)
• Fixed operating conditions

10 © 2023 ANSYS, Inc.
• Optimization via meta-model in optiSLang:
- Powerful optimization algorithms and
automated workflow generation
- Perfect balance between accuracy and
computation time
- In-depth investigation of the design space
- Efficient Multiphysics, multi-objective design
optimization
Data-driven optimization using Motor-CAD and optiSLang
10,000 designs
Best designs
Multiphysics/Multi-objective optimization: Motor-CAD & optiSLang
optiSLang

11 © 2023 ANSYS, Inc.
Detailed electromagnetic analysis: Maxwell 2D/3D
10.00 15.00
Time [ms]
-1.00
-0.80
-0.60
-0.40
-0.20
0.00
0.20
0.40
0.60
0.80
1.00
NodeVoltage(IVa)
[kV]
-150.00
-100.00
-50.00
0.00
50.00
100.00
150.00
-BranchCurrent(VIA)
[A]
Ansoft LLC 4_Partial_Motor_TR_PWM
Phase Voltage / Current
Circuit model/PWM voltage excitation
Universal motor Claw pole motor
Axial gap motor
3D PM eddy loss
2D/3D electromagnetics
• General 2D/3D electromagnetic FEA tool
- Arbitrary geometries and flux path
- End-effects and axial segmentation
- Various machine topologies in Maxwell(RMxprt)
- Multiple types of motion
• Detailed loss modeling
- Eddy current
- Circulating current
• Circuit modeling
- Circuit (e.g., power electronic switching)
- Fault conditions (e.g., sudden short-circuit)
Maxwell

12 © 2023 ANSYS, Inc.
Detailed mechanical analysis: Mechanical(Rotor sleeve design & NVH)
• Rotor Sleeve design
- It is crucial to retain magnets at high speeds to
ensure the durability and safety of the rotor.
- Ansys offers a composite material PrePost (ACP)
solution, which can account for rotor stress
analysis at high speed.
• NVH analysis
- NVH plays a crucial role in ensuring passenger
comfort, crew health, safety, and maintenance in
aircraft.
- Ansys provides a seamless multiphysics
simulation workflow to account for electric
motor NVH analysis.
Electric motor NVH analysis
Rotor sleeve design(composite material)
Mechanical

13 © 2023 ANSYS, Inc.
Detailed thermal analysis: Discovery & Fluent
• Temperature determines the continuous and
peak performance of a motor.
• Rising temperature in the motor results in
increased losses and decreased both torque and
efficiency.
• Ansys provides multi-fidelity thermal design
solutions:
- Motor-CAD: Concept design by LPTN
- Discovery: Macro design by CHT analysis
- Fluent: High-fidelity design by full FEA
Fluent advanced CFD
Discovery GPU
accelerated CHT
Motor-CAD design trade-off
Fluent

14 © 2023 ANSYS, Inc.
System design via ROM(Reduced Order Model): Twin Builder
System model in Ansys Twin Builder
Electric machine ROM
Electric machine FEA model
• A large complex system comprises various
components including electric motors.
• System simulation and optimization using FEA
models is computationally inefficient.
• Ansys Twin Builder enables system simulation
using ROMs(Reduced Order Model):
- Fast design iterations
- Improved accuracy
- Reduced complexity
- System-level optimization
Twin Builder

15 © 2023 ANSYS, Inc.
EMI/EMC, Dielectric breakdown mitigation solution: EMA3D
Cable harness shielding in EMA3D
• EMI/EMC Issues:
- Systems with high power and voltage levels
increase the risk of EMI/EMC problems.
- EMI/EMC mitigation is critical since EMI/EMC
problems in electric aircraft cause interference
with the aircraft’s electronic systems and can
cause sensor/control malfunction.
• Dielectric breakdown can lead to catastrophic
motor/power electronics failure.
• What EMA3D can do:
- ANSYS EMA3D is a powerful tool that enables the
prediction and mitigation of EMI/EMC issues and
dielectric breakdown in electric aircraft.
Dielectric breakdown on PCB
EMA3D

16 © 2023 ANSYS, Inc.
Material properties: Granta
• ANSYS Granta provides a comprehensive solution for
managing materials information, improving the
accuracy and efficiency of simulations.
- Centralized material information stored in a single
organized system
- Consistency and accuracy in material properties
across all simulations
- Easy to share material data, improving
collaboration
• Over 4000 materials and properties including:
- Mechanical, electrical, thermal, optical, chemical,
environmental, and processing properties
ESDU
Medical Eco
Additive
MFG
Polymers
Metals Composites Aero
EMAG
GRANTA
Cobalt iron
• Higher permeability/saturation
• 20~25% higher power density
Magnet BH curve vs. Temp
Structures
Electromagnetics Fluids
Granta

17 © 2023 ANSYS, Inc.
Summary
• The design process for electric motors requires a true multiphysics solution across
various disciplines.
• Ansys Motor-CAD is the front-end multiphysics electric motor design tool that allows
full design space exploration.
• Ansys end-to-end electric motor design toolchain enables comprehensive analysis
from an early design stage, leading to better electric motor designs.

Run on it.
Take a leap of certainty

INNOVATIVE SOLUTIONS FOR HIGH-POWER-DENSITY E-MOTORS FOR AEROSPACE PROPULSION

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