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EV simulation tools
The design of electrical machines for use in EVs and HEVs is dependent on cost
fluctuations of materials due to market pressures and overcoming multiphysics problems

Electric machines that use Figure 1: An efficiency map of an

interior permanent magnets embedded permanent magnet motor
rely on rare earth metals that can
vary drastically in price over a the need to determine the effects
relatively short period of time. This of losses and distributed forces on
unpredictability forces design the thermal, as well as noise and
engineers to look at alternative vibration of the electric machine, is
machine designs such as three- critical. Electric machine design is a
phase induction motors, which, multiphysics problem at its core. For
unfortunately, can also become example, electrical energy is applied
susceptible to fluctuation in the to the machine via power electronic
price of copper. devices (i.e. inverters), which
As such, engineers who design introduce temporal harmonics to
electric machines need simulation the system. This electrical energy is
tools that can quickly, yet very converted to magnetic energy, which
accurately, be employed to drive in turn sets the rotor in motion,
product development. The method introducing spatial harmonics. This
of choice by engineers who design conversion is not 100% efficient
electric machines is the finite and the losses that are incurred
element method (FEM). Historically, are realized as an increase in
the FEM has been used as a final temperature in the electrical
check – the last step of the design machine that needs to be reduced.
process before releasing the design Finally, the magnetic forces that
to manufacturing. Successful cause the rotor to turn are the
companies have discovered that source of the stresses and strains
this is no longer acceptable and across the machine that introduce
have moved simulation to early in noise and vibration. All physical
the design cycle. The main reason properties – electrical, magnetic,
for this is that technology has thermal, stress, acoustic – need to
improved to the point where it is be addressed by the design team.
considerably faster, while not Ansys has developed a simulation
compromising accuracy. With the environment that enables seamless
advent of high-performance integration of these various physics
computing and advances in the problems to be achieved
FEM, solution times have become concurrently. By employing Ansys
so fast that problems solved with Workbench technology, a design
the FEM can now be used with Figure 2: A multiphysics simulation of an embedded permanent magnet motor engineering team can access the
optimization algorithms that enable best-in-class single physics solvers,
design engineers to attain higher through the use of customized more importantly, it is critical for the and integrate the solutions of these
machine efficiencies with less toolkits available in the Ansys design engineer to know how to solvers (Figure 2).
material and lower costs. Maxwell program. The user simply improve the design. Can the same
The entire solution domain in enters a few input parameters and efficiency map be obtained with a
which an electrical machine operates then clicks on ‘Calculate Efficiency motor design that uses less material
is most commonly characterized by Map’, and the software automatically and is easier to manufacture, in
at Ansys
its efficiency map (Figure 1). In order calculates all the necessary order to reduce costs? Using Scott Stanton
1 32 00 ext: 130
to predict the efficiency map design points and generates the simulation early in the design phase, T. +1 412 26
@ ansys.com
through simulation, a relatively large efficiency map. the engineering team can perform E. scott.stanton
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W.
number of datapoints need to be Determining how a particular any type of optimization desired.
calculated. The extraction of these design will perform is a necessary Once the design engineer is able
datapoints has been automated step in the design process, but to determine the optimum topology,
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Electric & Hybrid Vehicle Technology International // July 2013 // 191