Electrical machine developmentactivities and future challenges inproduct design

CRECOS seminar 2010, Aalto UniversityKari TammiResearch Professor – Eco-Efficient MachinesVTT Technical Research Centre of Finland

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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

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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

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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

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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

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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

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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