BLDC Simulation with Motor-CAD

Hello everyone, this is Daniel Esmaili and today I'm going to talk about "BLDC Simulation with Motor-CAD." I'm making this presentation on behalf of Ozen Engineering Corporation and the goal is to show you the capabilities of Motor-CAD and how you can adjust the settings for such a motor.

So today I'm going to talk about the introduction, then the initial input, and then Motor-CAD versus other ideas. There is an introduction. The introduction is that this is based on a thesis, but I'll also explain how you can take the data if you have a data sheet and you want to use Motor-CAD.

The setup and the Motor-CAD and then the results. So the introduction is that there is a thesis that studies the brushless DC motor for an electric bike and it used RMX, RMXpert. And that's the basis. So we'll talk about the introduction and then the final input, which is part of Maxwell.

We are going to use Motor-CAD today in order to run the same motor. The reason is that we want to show capabilities and you want to switch between these two software, as well as how to put some data if you have information from other sources such as data sheets.

Here, as you can see, I'm showing the slot type, and the information for the slot type is available on the slide. The information is available on the slide. The main things that we're going to cover today are slot type, rotor type, and winding settings.

In the RMX rm expert, as I highlighted here, we have different slot types that vary from one to six. One of the slot types chosen for this thesis is slot type four, and in each slot type, there are different parameters. When you go to the Motor-CAD interface, it's a little bit different.

Here is the Motor-CAD interface. As you can see, now we have a slot number, slot board, two feet, slot depth, and so on. The good thing about Motor-CAD is that it will change as you change parameters. For instance, let me change the radius, which is two right now.

So you can see that the diameter here changes as I change it. There are different parameters that you can change on the slots. The same applies to the rotor, where you can change different parameters such as diameter, air gap, magnet thickness, and so on.

The main ones are the pole and the slot number. It's good to keep in mind that this is for radial motors. If you have axial motors, you need to click on this step and fill in the information. You can also have a 3D view of your machine and rotate it to look at it from different angles.

So back to the radial numbers that we want to understand. For instance, stator depth would be the depth from this point all the way to this point. So basically, we're going to add HS2, HS1, and HS0 together to come up with the number, which is 35. For instance, 2T is HS0, which is three here.

What we're trying to tell you is that, if you have different parameters that don't have exact same wording, there is always a way to find the numbers and translate them. This is an example. It could be also from a data sheet.

So all you need to do is see what the slot type is, look at the parameters, and try to find the equivalent parameters in your machine. Now, for example, we have in here, we have the dynamic properties.

We have the initial depth of this parameter that we want for the temperature, and then we're going to multiply that in Motor-CAD. It's the same for the rotor as well. Here, we see the rotor.

So for the rotor, we have also on the left-hand side, the interface for the Motor-CAD, and on the right-hand side, the parameters that are needed for the RMX for Maxwell. And as you can see, it's shaft diameter, or rotor diameter. So we find that number and put it there.

Or the shaft hole diameter or inner diameter. I don't want to go that much into detail, but I'd like to keep this video short. The next one is winding. On the left-hand side, you see the interface for Motor-CAD, and on the right-hand side, you see the interface for the rm expert.

Again, you can get these data from data sheets as well. For the winding, it has two tabs: one is definition, and the other is pattern. I'll show it to you in a minute. But with these two different tabs, you can adjust different settings for the winding.

So I'm going to show you the different settings. If you have any questions, please let us know. You can email us at [support@ozenengineering.com](mailto:support@ozenengineering.com) if you have any projects we'll be more than happy to do it for you.

If you have questions or want to buy this software, please let us know. You're also more than welcome to visit our website and give us a call. Let me go back to the Motor-CAD interface. This is the winding that I was mentioning.

Here, you can do different types of winding, such as central, off-round, or lower. You can also change the phases. Here, you show different phases like if you want only phase one, you just click on this one. It shows you phase one. Same for the other one.

If you're not sure where you want to go, you can change it here. It's okay, but it's not a problem for me to do it for you guys. Let me show you here. You can do it for me, and I'll show you like this: phase three.

And if you want to look at the linear pattern, some people are more adjusted to looking at this way. You can have that interface. You can go with the phase for the mmf. You can look at the harmonics, etc. So let's go back to the radial pattern. This is the pattern as I told you.

You can put the turns, the number of parallel paths, winding layers, etc. You can also go for the definition. The definition is the wire inside the uh tooth. So you can, for instance, say strander. Or you can change the diameter for instance, from 1.98 to 2.5 and you can see how it changes.

There are different wire types that you can use, such as awg or metric. From your data sheet or from the model. But yeah, again, I don't want to go that much in detail. You can make a lot of changes here, and these are the outputs that you will see in the uh after solving the geometry.

You can also set your input data, such as the set of lamb or the armature and luther. For the magnet, you can choose the material. You can work with the far energy interaction. You can also use the material database. There are some advanced settings here that you don't need to worry about.

And then, if you look at this setting, it's for geometry, and it's for electromagnetic, for calculation, for the graphs. You can choose what type of graph you want here. This is something that you might need, or like, for instance, the frequency is based on causing electrical, etc. And losses.

So once you set that up, you go to the calculation, and here you can set up the speed, which I did it for 380 to match what we have in the data. In the thesis. And then we have the peak current, and you have the drive type. Some people might be interested to change the drive type.

Please note, there is a drive type here. So if I go to define, that drive type is gone now. So if you want to have a square wave for our motor, because it's a brushless DC motor, so we can change the drive type here. And then you can change the drive type here.

So if you want to have a square wave for our motor, we change it to calculated current, and then we have the square one. Once we do that, we can have the switch resistance or a 4-volt voltage for those switches and set them here.

Back to calculation, you can have torque, back EMF, cogent torque, etc. for your analysis. There are different settings here as well, but I'm going to skip that.

Talking about electromagnetism and thermocoupling here, please note that you can have the model at electromagnetic, thermal, lab, or mechanical. On this clip, you're just focusing on the electromagnetic, but this software can help you with the thermal or lab analysis as well.

So these are just some visuals, I mean, I ran it already. And made it ready. So once you run it, you'll see the result when it comes, for instance, to flux density. The part that you might be more interested in is some of the output.

For instance, for the electromagnetic, for the equivalent circuit, how much would be the D-axis inductance, Q-axis inductance, etc. Or how much would be the load. So you can see the losses, like on the certainty or magnet. You can look at the different output here for the winding.

There are some saliencies. And then another way to look at the output data is the graph. For instance, we have the back EMF here. We have the terminal voltage here. As you can see, it's like the step one for different phases, A, B, and C. Or you can look at the torque.

For instance, we can look at the flux linkage. Or we can look at the torque speed and it shows, you know, the different degrees, 10 degrees, 20 degrees, etc. So we will try to very quickly talk about this software, its capabilities. There are a lot more in this software.

But it was a high-level overview of the software. Again, you can use transfer from different software, for instance, Maxwell to Motor-CAD, or you can have your own data sheet and find the data in the data sheet and transfer it to Motor-CAD. It also has some model templates that you can choose from.

But again, if you have any questions, please let us know. And if there is any project that you have or anything that we can do for you, please feel free to contact us here at [support@ozenengineering.com](mailto:support@ozenengineering.com). Thank you for your time.