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How Alvier Mechatronics cuts development time of electric drive modules by 50%?
Automated simulation workflows are invaluable in the field of electromagnetic energy conversion, where precision and efficiency are paramount. These workflows offer numerous advantages tailored to this specific domain.
Efficiency is a key advantage. Electromagnetic energy conversion systems involve complex interactions between magnetic fields, electrical circuits, and mechanical components. Automating simulations in this context accelerates the design and optimization process. It enables rapid exploration of various design configurations and materials, ultimately leading to more efficient energy conversion systems. This is particularly critical in renewable energy applications, such as electric drivetrains, where improving efficiency directly impacts vehicle range. We capture these effects using the system optimization tool ePOP.
Accuracy is equally important in electromagnetic energy conversion. The intricate nature of these systems demands precise modeling. Automated simulations ensure that every aspect of the electromagnetic interaction is accurately captured, reducing the risk of errors associated with manual inputs. This precision is vital in applications like electric motors and generators, where even small discrepancies can result in energy losses or reduced performance. We automate using JMAGs Python interface.
Cost savings are substantial in this context as well. Developing and testing electromagnetic energy conversion systems can be resource-intensive. Automated simulation workflows cut down on the need for physical prototypes and testing, minimizing material and labor costs. They also facilitate the exploration of innovative materials and design concepts, identifying cost-effective solutions that may have been overlooked in traditional approaches. One example of such a workflow will be featured in the upcoming whitepaper: Optimization and Comparative Analysis of Electric Machine Topologies with Varying Magnetic Materials: Standard Steel Laminations vs. Soft Magnetic Composites, by Dr. Branko Ban.
In the realm of electromagnetic energy conversion, decision-making is often centered around trade-offs between various design parameters. Automated simulations enable engineers to quickly evaluate different scenarios, such as the impact of altering core materials, coil designs, or magnetic field configurations. This data-driven decision-making approach is crucial for optimizing systems in applications like electric drives, transformers and inductors, where efficiency and reliability are critical.
There are collaboration benefits from automated simulation workflows as well. In a field that often involves multidisciplinary teams of engineers, physicists, and materials scientists, these workflows enable real-time collaboration and knowledge sharing. Team members can collectively work on simulation projects, easily exchange ideas, and refine designs, ultimately leading to more robust and innovative electromagnetic energy conversion systems.
In summary, within the context of electromagnetic energy conversion, automated simulation workflows offer efficiency, accuracy, cost savings, data-driven decision-making, and improved collaboration. One example of how we achieve this is listed below:
- Adjusting FEM convergence criteria: +30-100% faster
- Using advanced FEM solver features: +50-100% faster
- Using domain decomposition on several CPUs: 10-150% faster
- Running several cases in parallel: 100-300 % faster
These benefits empower engineers and researchers to develop more effective and sustainable energy conversion technologies, which are essential for the transition to a cleaner and more energy-efficient future.
If you’d like to discuss any of these ideas further, please contact our experts, and we’ll set up a meeting with our technical experts to discuss how your problem could be analyzed faster, and with higher quality.
MASTER THESIS ELECTRICAL MACHINE OIL COOLING
YOUR TALENT. OUR OFFER.
About Thesis Work
Thermal management is a key aspect when designing electrical machines in general, and even more so in automotive traction systems. Most electrical vehicles on the road today tend to use water jacket cooling and/or spray oil cooling of some kind. The spray oil cooling typically provides superior performance but comes with the drawbacks of increased cost, weight, and complexity due to the added components (pump, heat exchanger, filter).
The objective for this thesis work will be to evaluate the cooling performance of some novel concepts and compare them to water jacket cooling on an automotive traction electrical machine. The evaluation should preferably contain both simulations and measurements on a prototype of the novel concepts based on an existing electrical machine. A key metric will be the continuous current density for each cooling concept.
You are a (or a plurality of) Master Student(s) in Engineering, you have at least basic knowledge of electrical machines, thermodynamics, fluid mechanics, measurement systems, and manufacturing methods. It will help to have some practical skills as the intention is to build and test.
Communication in English or Swedish is a requirement. The thesis shall be written in English.
Don’t hesitate to apply! We look forward to your application!
Kristoffer Nilsson, System Architect & Technical Lead, Alvier Mechatronics,
Good Environmental Choice toAlvier Mechatronics AB
ENVIRONMENTAL VERIFICAT 2023
Öresundskraft Marknad AB hereby verifies that the above company purchases electricity that meets the criteria for “Good Environmental Choice” as defined by the Swedish Society for Nature Conservation.
Electricity labelled Good Environmental Choice means among other things:
- The electrical energy included labelled Good Environmental Choice must originate from renewable energy sources, such as hydropower (built before 1996), wind power, solar energy, wave and tidal energy, combustion of biomass or biogas.
- Provision is made for funds for environmental improvement measures and reduced energy.
- Audits are performed every year (through an authorized, independent and SNF-approved auditor).
PASSION & CREATIVITY
Under the motto Passion & Creativity, the Alvier Mechatronics team had 3 really inspiring workshop days from 10 to 12 October. The focus was on team building in a growing, international and thus intercultural team. Based on the DISC method we worked on personal profiles, interaction and our feedback culture, learned cultural related differences in communication. An exciting team building experience was our visit to the Breakout room in Helsingborg.
An all around exciting and inspiring event where we worked on our strategy on the way to 2030 and our next goals for 2024.
Many thanks to everyone involved for their participation and dedication.
Ahoy and the necessary tailwind from passion & creativity for the future!
WHICH ARE YOUR KEY METRICS?
Did you know that ePOP can be used to quickly evaluate new technologies in various metrics such as for example cost, efficiency, sustainability, weight and performance?
The example here shows the difference in an EV drive unit between SiC MOSFET and SiC IGBT inverter technology in terms of energy consumption and total cost (drive unit + battery). As expected the SiC MOSFET gives a clear benefit in terms of drive cycle energy consumption, but interestingly it also gives a total cost benefit (due to battery downsizing enabled by the higher efficiency) even though there is an additional cost on the drive unit for this upgrade.
POWERING UP A GREEN FUTURE!
Alvier Mechatronics dedicated an afternoon to presentations on the sustainability of drive systems.
Partners were invited as experts for different aspects of sustainability in the development of eDrive solutions to give presentations on them.
- E-machine design for enhanced reyclability and minimised invieronmental impact
- The road towards sustainable motorsport
- Embedding sustainability into early stage R&D
WE HAVE MOVED!
Are you ready for HETCH?
Are you looking forward to a productive and inspiring exchange in one of the most beautiful co-working spaces in Sweden?
Come visit us at HETCH:
- 14 eDrive brains form Alvier Mechatronics work there on 260 sqm.
- We will have a prototype assembly area and one prototype validation area.
- The building is classified Environment building GOLD.
- We are committed to use renewable energy for electricity and climate control.
- The connection of the co-working space is excellent.
There are clear trends in motor design such as the sustainable use of resources and sustainability, the reduction of Costs/total costs of the system (TCO), efficiency, less installation space and weight, higher power density, intelligent mechanical and electronical solutions. Our engineering competence leads to the implementation of these trends in motor designs.