Multi-physics coupled motor end cover structure analysis method

Abstract

A multiphysics-coupled method for analyzing the structure of motor end caps relates to the field of finite element analysis (FEM) for motor end caps. This method effectively improves simulation accuracy and design reliability, and shortens product development cycles, thereby optimizing the design to enhance the overall reliability and service life of the motor system. The multiphysics-coupled method organically combines electromagnetic field analysis, thermal stability analysis, and static structural analysis into a complete and efficient multiphysics simulation process for comprehensive evaluation of the end cap. The maximum radial force of the rotor obtained from the electromagnetic field analysis is used as the load input for the static structural analysis, while the temperature field from the thermal stability analysis is directly imported into the static structural analysis to achieve effective coupling and transfer of multiple data. Through the final static structural analysis, the total deformation, equivalent stress, and safety factor of the end cap are obtained, providing crucial information for the reliability and durability design of the end cap.

Description

Technical Field

[0001] This invention relates to the field of finite element analysis technology for motor end caps, and more particularly to a method for analyzing the structure of motor end caps using multi-physics coupling. Background Technology

[0002] The motor end cover is a key supporting component in the motor structure. Its main functions include: support and protection, namely supporting the motor bearings and ensuring the rotor centering accuracy; sealing, namely protecting the internal electromagnetic components from external environmental damage; and bearing complex loads, namely bearing the rotor's own weight, the radial / axial force of the bearings, and the thermal field generated by bearing friction when the motor is running at high speed.

[0003] In traditional finite element analysis of motor end caps, the geometric model and the connection relationships between components are often oversimplified, and only a single physical field load is applied. However, this simplified analysis method ignores the complex coupling effects of multiple physical fields (such as structure, heat, and fluid) in actual working conditions, resulting in significant deviations between the calculation results and the actual situation, and ultimately affecting the reliability of key calculation results such as stress and deformation.

[0004] In other words, in the field of motor design, finite element analysis of end caps has become a standard procedure, but it generally has the following limitations: (1) Modeling: In order to reduce the number of meshes and reduce computation time, analysts usually delete some small fillets, small chamfers, and threaded holes. However, these places are usually the key areas where stress concentration occurs. Oversimplification will lead to more "idealized" results. (2) Connection conditions: The end cap and the housing are connected by bolts. The surface-to-surface behavior is non-linear (separable, slip-slip). Generally, for simplification, the analyst will bind the end cap to the housing, which leads to inaccuracies in deformation and stress transfer. (3) Single load: Only static load and electromagnetic force in one direction are considered. The complex multi-physics coupling during motor operation, thermal load generated by bearings and preload during assembly are not comprehensively simulated, resulting in serious discrepancies between the analysis results and actual working conditions. (4) Complex analysis process: The motor needs to be analyzed in a comprehensive manner, including structural, thermal, and electromagnetic physical fields. Due to the different selection of analysis software, the interaction between the various physical fields cannot be transmitted, which has certain limitations. Summary of the Invention

[0005] The purpose of this invention is to provide a multi-physics coupled method for analyzing the structure of motor end caps, which can effectively improve simulation accuracy and design reliability, shorten the product development cycle, achieve lightweighting and cost savings while ensuring safety, and identify potential failure risks in advance, thereby optimizing the design to improve the overall reliability and service life of the motor system.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A multiphysics coupled method for analyzing the structure of motor end caps organically combines electromagnetic field analysis, thermal stability analysis, and static structural analysis, forming a complete and efficient multiphysics simulation process for comprehensive evaluation of the end caps. The maximum radial force of the rotor obtained from the electromagnetic field analysis is used as the load input for the static structure analysis, while the temperature field from the thermal stability analysis is directly imported into the static structure analysis to achieve effective coupling and transmission of multiple data. The final static structural analysis is used to obtain the total deformation, equivalent stress, and safety factor of the end cap, providing a key basis for the reliability and durability design of the end cap.

[0007] In practical applications, the electromagnetic field analysis includes the following steps: Model import: Export the external model as a DXF or DWG file and import it into Maxwell software, or create the cross-sectional area of ​​the motor stator, rotor, permanent magnet, winding, and air gap in Maxwell software. Specify materials and assign appropriate materials to each component; Set the excitation and boundary conditions according to the parameter input table; Furthermore, in post-processing, the total magnetic force of the entire rotor is calculated, and the total magnetic force has two components, X and Y, and the maximum value of the component is found as the input for the subsequent static structural analysis.

[0008] The thermal stability analysis includes the following steps: Model import: Export the end cap model as a step or x_t format and import it into the Workbench software; Specify materials and assign appropriate materials to each component; Thermal boundary conditions are set, with the bearing friction heat in the end cap being the main heat source. The heating power of the bearing is calculated using empirical formulas and applied to the inner surface of the bearing chamber. At the same time, internal convection and external convection are applied to the inside and outside of the end cap. And then, post-processing is performed to calculate the temperature contour map of the end cap.

[0009] Specifically, the static analysis includes the following steps: Thermo-structure coupling involves dragging the static structural model from the Workbench software into the thermo-coupling solution. Specify materials and assign appropriate materials to each component; Set boundary conditions and loads, install cylindrical supports at bolt connection through holes, apply preload to bolt holes connecting end caps and housing, apply the calculated maximum radial force to bearing housing, and directly import the temperature field based on coupling. In addition, post-processing is performed to check the total deformation and equivalent stress of the end cap after solving, and to calculate the safety factor.

[0010] Compared with existing technologies, the multi-physics field coupled motor end cover structure analysis method described in this invention has the following advantages: The multiphysics-coupled motor end cover structure analysis method provided by this invention organically combines electromagnetic field analysis, thermal stability analysis, and static structural analysis to form a complete and efficient multiphysics simulation process for comprehensive evaluation of the end cover. The maximum radial force of the rotor obtained from the electromagnetic field analysis is used as the load input for the static structural analysis, while the temperature field from the thermal stability analysis is directly imported into the static structural analysis to achieve effective coupling and transmission of multiple data. Through the final static structural analysis, the total deformation, equivalent stress, and safety factor of the end cover are obtained, providing key basis for the reliability and durability design of the end cover. Therefore, it can effectively improve simulation accuracy and design reliability, effectively shorten the product development cycle, achieve lightweighting and cost savings while ensuring a safety factor, and identify potential failure risks in advance, thereby optimizing the design to improve the overall reliability and service life of the motor system. Attached Figure Description

[0011] Figure 1 A flowchart illustrating the multi-physics field coupled motor end cover structure analysis method provided in this embodiment of the invention; Figure 2 This is a schematic diagram of the end cover model in the multi-physics field coupled motor end cover structure analysis method provided in the embodiments of the present invention.

[0012] Figure label: 1- Model of the casing; 2- Bolts on the mating surface; 3- Model of the end cover. Detailed Implementation

[0013] For ease of understanding, the method for analyzing the multi-physics field coupled motor end cover structure provided by the embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0014] This invention provides a method for analyzing the structure of a motor end cover using multi-physics coupling, such as... Figure 1 and Figure 2As shown, electromagnetic field analysis, thermal stability analysis, and static structure analysis are organically combined to form a complete and efficient multiphysics simulation process for comprehensive evaluation of the end cap. The maximum radial force of the rotor obtained from the electromagnetic field analysis is used as the load input for the static structure analysis, while the temperature field from the thermal stability analysis is directly imported into the static structure analysis to achieve effective coupling and transmission of multiple data. The final static structural analysis is used to obtain the total deformation, equivalent stress, and safety factor of the end cap, providing a key basis for the reliability and durability design of the end cap.

[0015] Compared with existing technologies, the multi-physics field coupled motor end cover structure analysis method described in this embodiment of the invention has the following advantages: The multiphysics-coupled motor end cover structure analysis method provided in this invention organically combines electromagnetic field analysis, thermal stability analysis, and static structural analysis to form a complete and efficient multiphysics simulation process for comprehensive evaluation of the end cover. The maximum radial force of the rotor obtained from the electromagnetic field analysis is used as the load input for the static structural analysis, while the temperature field from the thermal stability analysis is directly imported into the static structural analysis to achieve effective coupling and transmission of multiple data. Through the final static structural analysis, the total deformation, equivalent stress, and safety factor of the end cover are obtained, providing crucial basis for the reliability and durability design of the end cover. Therefore, it can effectively improve simulation accuracy and design reliability, effectively shorten the product development cycle, achieve lightweighting and cost savings while ensuring a safety factor, and identify potential failure risks in advance, thereby optimizing the design to improve the overall reliability and service life of the motor system.

[0016] In practical applications, the above electromagnetic field analysis may include the following steps: Model import: Export the external model as a DXF or DWG file and import it into Maxwell software, or create the cross-sectional area of ​​the motor stator, rotor, permanent magnet, winding, and air gap in Maxwell software. Specify materials and assign appropriate materials to each component; Set the excitation and boundary conditions according to the parameter input table; Furthermore, in post-processing, the total magnetic force of the entire rotor is calculated, and the total magnetic force has two components, X and Y, and the maximum value of the component is found as the input for the subsequent static structural analysis.

[0017] The aforementioned thermal stability analysis may include the following steps: Model import: Export the end cap model as a step or x_t format and import it into the Workbench software; Specify materials and assign appropriate materials to each component; Thermal boundary conditions are set, with the bearing friction heat in the end cap being the main heat source. The heating power of the bearing is calculated using empirical formulas and applied to the inner surface of the bearing chamber. At the same time, internal convection and external convection are applied to the inside and outside of the end cap. And then, post-processing is performed to calculate the temperature contour map of the end cap.

[0018] Specifically, the above static analysis may include the following steps: Thermo-structure coupling involves dragging the static structural model from the Workbench software into the thermo-coupling solution. Specify materials and assign appropriate materials to each component; Set boundary conditions and loads, install cylindrical supports at bolt connection through holes, apply preload to bolt holes connecting end caps and housing, apply the calculated maximum radial force to bearing housing, and directly import the temperature field based on coupling. In addition, post-processing is performed to check the total deformation and equivalent stress of the end cap after solving, and to calculate the safety factor.

[0019] In summary, the multi-physics coupled motor end cover structure analysis method provided by the embodiments of the present invention has the following advantages: I. Improving simulation accuracy and design reliability (electromagnetic, thermal, and structural fields are often treated independently, ignoring their mutual influence, leading to serious errors). This method couples electromagnetic force and temperature field to structural analysis, comprehensively considering the interaction of electromagnetic heating, thermal deformation, and mechanical stress, thereby more realistically simulating the behavior of the end cap under actual working conditions, and thus significantly improving simulation accuracy and design reliability. Second, by establishing a standardized multiphysics analysis process, automatic data transfer and integration between different software modules were realized, which effectively avoided manual data conversion and repetitive modeling, reduced the number of iterations, and thus effectively accelerated the entire process from electromagnetic design to structural verification, and effectively shortened the product development cycle. Third, based on the accurate results of multi-field coupling analysis, the stress concentration area and deformation of the end cap under high electromagnetic force and temperature load can be accurately identified, and the structural optimization and material selection can be guided, thereby achieving lightweighting and cost savings while ensuring the safety factor. IV. (As a key support and protection component of the motor, the performance of the end cap directly affects the overall operational stability of the machine.) This method can comprehensively evaluate its mechanical and thermal performance under complex working conditions, thereby identifying potential failure risks in advance and optimizing the design to effectively improve the overall reliability and service life of the motor system.

[0020] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for analyzing a multi-physical field coupled motor end cover structure, characterized in that, Electromagnetic field analysis, thermal stability analysis, and static structural analysis are organically combined to form a complete and efficient multiphysics simulation process for comprehensive evaluation of end caps. The maximum radial force of the rotor obtained from the electromagnetic field analysis is used as the load input for the static structure analysis, while the temperature field from the thermal stability analysis is directly imported into the static structure analysis to achieve effective coupling and transmission of multiple data. The final static structural analysis is used to obtain the total deformation, equivalent stress, and safety factor of the end cap, providing a key basis for the reliability and durability design of the end cap.

2. The method for analyzing the structure of a motor end cover using multiphysics coupling according to claim 1, characterized in that, The electromagnetic field analysis includes the following steps: Model import: Export the external model as a DXF or DWG file and import it into Maxwell software, or create the cross-sectional area of ​​the motor stator, rotor, permanent magnet, winding, and air gap in Maxwell software. Specify materials and assign appropriate materials to each component; Set the excitation and boundary conditions according to the parameter input table; Furthermore, in post-processing, the total magnetic force of the entire rotor is calculated, and the total magnetic force has two components, X and Y, and the maximum value of the component is found as the input for the subsequent static structural analysis.

3. The method for analyzing the structure of a motor end cover using multiphysics coupling according to claim 2, characterized in that, The thermal stability analysis includes the following steps: Model import: Export the end cap model as a step or x_t format and import it into the Workbench software; Specify materials and assign appropriate materials to each component; Thermal boundary conditions are set, with the bearing friction heat in the end cap being the main heat source. The heating power of the bearing is calculated using empirical formulas and applied to the inner surface of the bearing chamber. At the same time, internal convection and external convection are applied to the inside and outside of the end cap. And then, post-processing is performed to calculate the temperature contour map of the end cap.

4. The method for analyzing the structure of a motor end cover using multiphysics coupling according to claim 3, characterized in that, The static analysis includes the following steps: Thermo-structure coupling involves dragging the static structural model from the Workbench software into the thermo-coupling solution. Specify materials and assign appropriate materials to each component; Set boundary conditions and loads, install cylindrical supports at bolt connection through holes, apply preload to bolt holes connecting end caps and housing, apply the calculated maximum radial force to bearing housing, and directly import the temperature field based on coupling. In addition, post-processing is performed to check the total deformation and equivalent stress of the end cap after solving, and to calculate the safety factor.

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