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Simulation of Distributed Windings Using the Insert Technique

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Simulation of Distributed Windings Using the Insert Technique i SIMULATION OF DISTRIBUTED WINDINGS USING THE INSERT TECHNIQUE Bachelor’s Degree Project in Mechanical Engineering G2E, 30 credits Spring term 2019 Hue Hoang Matilda Widerström Supervisor: Ulf Stigh & Tobias Andersson Industrial supervisors: Goran Ljustina & Niklas Helsing Examiner: Lennart Ljungberg i Abstract During the insert process when the windings of an electric motor are pushed into the stator slots, some detrimental phenomena can occur that affect the efficiency and life of the motor. To detect these phenomena and optimize the process, a simulation would be useful. An investigation of the possibility to perform a simulation, using an appropriate numerical method for the insert process of distributed windings in a permanent magnet synchronous motor, was performed. During the project, a literature study was carried out to investigate existing methods and key-parameters for the simulation of the process. Explicit finite element method has been shown to be a suitable numerical method for simulating another winding process. An explicit finite element analysis was performed with a simplified model of the stator, the wires, the transmission tool and the needles by using the software Abaqus/CAE. In order to reduce the computational time, beam elements were used to model the wires and the other parts as rigid bodies. The model accounted for example contact and provided numerical results. The result was a suitable model. However, it needs to be developed further. i Certification This thesis has been submitted by Hue Hoang and Matilda Widerström to the University of Skövde as a requirement for the degree of Bachelor of Science in Mechanical Engineering. The undersigned certifies that all the material in this thesis that is not my own has been properly acknowledged using accepted referencing practices and, further, that the thesis includes no material for which I have previously received academic credit. Hue Hoang Matilda Widerström Skövde 2019-06-07 Skövde 2019-06-07 Institutionen för Ingenjörsvetenskap/ Institutionen för Ingenjörsvetenskap/ School of Engineering Science School of Engineering Science ii Acknowledgements At first, we would like to sincerely thank our supervisors at Volvo Car Skövde, Goran Ljustina and Niklas Helsing for giving us the opportunity to perform our bachelor’s degree project and for all the help and support they provided us with. Next, we would like to thank our supervisors Ulf Stigh and Tobias Andersson at the university of Skövde for the great interest in the project, their expertise and for all the helpful supervisions. We would also like to thank Daniel Svensson at the university of Skövde for sharing tips regarding the simulation, Micael Danielsson at Volvo Car Skövde for the enlightenments regarding the insert process, and the employees working in the lab at Volvo Car Skövde for showing us the insert process. Lastly, we want to thank our examiner Lennart Ljungberg. iii Table of Contents Abstract .................................................................................................................................................... i Certification ..............................................................................................................................................ii Acknowledgements ................................................................................................................................. iii List of Figures ........................................................................................................................................... vi Glossary .................................................................................................................................................. vii 1. Introduction ......................................................................................................................................... 1 1.1 Problem Statement ................................................................................................................... 1 1.1.1 Aim and Goal ...................................................................................................................... 1 1.1.2 Limitations .......................................................................................................................... 2 1.1.3 Sustainable Development .................................................................................................. 2 1.2 Overview .................................................................................................................................... 3 2. Background .......................................................................................................................................... 4 2.1 Finite Element Method .............................................................................................................. 4 2.1.1 Finite Element Method Software ....................................................................................... 4 2.2 Multibody Dynamics .................................................................................................................. 4 2.2.1 Multibody Dynamics Software ........................................................................................... 5 2.3 Articles found during the literature study ................................................................................. 5 2.4 Volvo Car ................................................................................................................................... 6 2.5 Electric Motor ............................................................................................................................ 6 2.5.1 Permanent Magnet Synchronous Motor ........................................................................... 7 2.6 Stator ......................................................................................................................................... 8 2.7 Windings .................................................................................................................................... 9 2.7.1 Distributed Windings ........................................................................................................ 10 2.8 Insert Technique ...................................................................................................................... 10 3. Method .............................................................................................................................................. 13 3.1 Important Parameters ............................................................................................................. 13 3.2 Simulation ................................................................................................................................ 13 3.2.1 Model Approach ............................................................................................................... 13 3.2.2 Model Properties .............................................................................................................. 14 3.2.3 Loads and Restraints ........................................................................................................ 15 3.2.4 Step Definitions ................................................................................................................ 15 iv 3.2.5 Interaction Properties ...................................................................................................... 16 3.2.6 Mesh ................................................................................................................................. 16 4. Results ............................................................................................................................................... 17 5. Discussion .......................................................................................................................................... 21 5.1 Technology, Society and the Environment .............................................................................. 23 6. Conclusions ........................................................................................................................................ 24 7. Future Work ...................................................................................................................................... 25 References ............................................................................................................................................. 27 Appendices ............................................................................................................................................ 31 Appendix 1 Work Breakdown and Time Plan ........................................................................................ 31 Appendix 2 FEM software ..................................................................................................................... 35 Appendix 3 MBD software .................................................................................................................... 38 Appendix 4 Concentrated windings ...................................................................................................... 40 Appendix 5 Important parameters ........................................................................................................ 41 Appendix 6 Clamping factor .................................................................................................................
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