Electrical machine development activities and future challenges in product design CRECOS seminar 2010, Aalto University Kari Tammi Research Professor – Eco-Efficient Machines VTT Technical Research Centre of Finland
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VTT in very brief Centre for Smart Machines in brief ยง VTT: applied research centre ยง About 2800 employees ยง Owned by Finnish Ministry of Employment and the Economy ยง About 50 researchers working on: ยง Dynamic phenomena in machines & vehicles ยง Active control of noise & vibration ยง Machine durability ยง Industrial R&D ยง Academic research ยง Core competences: ยง Combining experimental & theoretical research ยง Knowledge of physical phenomena & our customersโ product
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Research challenges ยง Representing machines & vehicle sector research, focus on: ยง Energy efficiency ยง Life-cycle efficiency ยง Lightweight structures ยง Modelling & simulation
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Model and model data management based on semantic ontologies ยง Simantics platform developed by VTT ยง Open source platform ยง To be used as a hub to connect different modelling, simulation, and data management software ยง www.simantics.org ยง 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 lifecycle 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
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Why most electrical machines look similar? Radial flux, tubular design is dominant, why? ยง Manufacturing of 2D structures is attractive ยง Analysis in plane, even 3D computations are expesive ยง Tradition
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Exceptions exist Topology variations are higher in smaller machines ยง Disk drives ยง Stepping motors, etc Examples of larger machines ยง Hoisting machinery, benefits from the dimensions ยง High-speed trains
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How would the optimal structure look like? ยง ยง ยง ยง
No history Start from magnetomotive force Looser boundary conditions (material, manufacturing) Use modern design methodology
See what comes up
ยง Reality of wish list to Santa Claus?
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VTT creates business from technology
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