AnsysMotorCADTrainingBPMU 200521 174342 (3)

Ansys Motor-CAD Training
BPM
May 2020
1
Topics
• Introduction
• Starting with Motor-CAD
• Electromagnetic Model
• Electromagnetic Analysis
• Efficiency Maps and Drive Cycle Analysis
• Thermal Model
• Thermal Analysis
• Mechanical Model
• Mechanical Analysis
• Advanced Modelling
• Conclusion
2
Starting with Motor-CAD
Electrical Machines Design Software
3
Starting with Motor-CAD Tip: blue background on active tab
indicates E-Magnetic context
Motor-CAD Installation & Model Type
• Open Motor-CAD
• A default brushless PM geometry
appears.
• Check Model is set to E-Magnetic
• Select File -> Save As to save file

as EV_1_Geometry.mot
4
Starting with Motor-CAD
Motor-CAD Default Unit
• Motor-CAD allows users to select different units

• We will be working mostly in SI units
• Set units as shown below in Defaults -> Units
5
Electromagnetic Model
Motor-CAD E-Magnetic
6
Motor-CAD E-Mag Interface
• Geometry: radial, axial, 3D…

• Winding: pattern, conductors…
• Input Data: materials, settings for FEA
calculations, build factors, loss methods
• Calculation: operating point for FEA
• E-Magnetics: FEA regions, 2D FEA
results and visualisation, measurements
customization
• Output Data: FEA and analytical results
• Graphs: transient results
• Sensitivity: sensitivity analysis
• Scripting: custom scripts in Visual Basic
7
Parameter Value Unit
Radial Geometry: Stator Slot Type Parallel Tooth -
• Go to Geometry -> Radial, set the stator Stator Ducts None -

parameters as follows Slot Number 48 -
Stator Lam Dia 198 mm
Stator Bore 132 mm
Tooth Width 4.5 mm
Slot Depth 21 mm
Slot Corner Radius 2 mm
Tooth Tip Depth 1 mm
Slot Opening 3 mm
Tooth Tip Angle 27 degrees
Sleeve Thickness 0 mm
8
Radial Geometry: Stator
• After changing a value, press

Enter or click ‘Redraw’ to update
drawing
• Modified dimensions will be
shown with green highlighting
9
Rotor Type Interior V (simple)
Pole Number 8
Notch Depth 0 mm
Magnet Layer 1
Radial Geometry: Rotor L1 Magnet Thickness 6 mm
L1 Magnet V Width 17 mm
• Set the rotor L1 Magnet Shift 0 mm
parameters L1 Bridge Bar Width 16 mm

L1 Bridge Thickness 1 mm
L1 Pole V Angle 150 degrees
L1 Outer Extension 2 mm
L1 Inner Extension 2 mm
L1 Magnet Post 0.5 mm
L1 Magnets Segment 1 mm
L1 Magnet Clearance 0.2 mm
L1 Layer Offset Angel 0 degrees
Airgap 1 mm
Banding Thickness 0 mm
Shaft Dia 80 mm
10
Axial Geometry
• Go to Geometry -> Axial, set the

following parameters:
Motor Length 260 mm
Stator Lam Length 160 mm
Magnet Length 150 mm
Magnet Segments 18
Rotor Lam Length 150 mm
• Save file using File -> Save or

press Ctrl+S
11
3D Geometry view
• Go to Geometry -> 3D to visualize

a 3D view of the motor
• Transparency levels of
components can be set by right
mouse click
• Components or groups of
components can be hidden by
deselecting the associated boxes
in the list
12
Winding Pattern
• Go to Winding -> Pattern, set:

Parameter Value
Winding Type Automatic
Path Type Central
Winding Layers 1
Phases 3
Turns 6
Throw 5
Parallel Paths 2
• Check All Phases tab, make sure

all slots are filled with the same
number of turns
13
Winding Phasors
• Check Phasors tab, that the

winding magnetic axes are at 120
electrical degrees apart.
• The arrows for each phase reflect
the 6 slot MMFs that are forming
per phase phasors in this design
with a total space MMF = 92.7At
14
Magneto-Motive Force (MMF) Harmonics
• Check Harmonics tab, this shows

the mechanical space harmonics
amplitude for one phase MMF.
• Note the correlation between
mechanical and electrical
harmonics
• Mechanical = Electrical * Poles/2
4st Mechanical
→ =
1st Electrical * 8/2
15
Winding Factors
• Check Factors tab. This shows

the winding factors for one phase
• Only odd order harmonics, as the
machine is considered balanced
and symmetrical
• In this case the first factors are
the following:
‒ 1st = 0.966 (fundamental)
‒ 5th = 0.259
‒ 7th = 0.259
‒ 11th = 13th = 0.966
16
Tip 1: the Conductor/Slot Drawn parameter
will be highlighted in red if the required
number of conductors cannot fit into the slot
Electromagnetic Model Tip 2: remember to press Enter or click
‘Redraw’ to update drawing
Winding Conductors Definition
• Go to Winding –> Definition, set:

Coil Style Stranded
Divider Type Overlapping
Winding Definition Wire Size
Wedge Model Wedge
Wire Type Metric Table
Wire Gauge [0.885, 0.800] mm
Liner Thickness 0.25 mm
Copper Depth 100 %
Conductor Separation 0.02 mm
Strands in Hand 18
17
Electromagnetic Model Tip: materials used in the model
are highlighted in yellow
Materials Assignment
• Go to Input Data -> Materials tab

• Assign the following materials:
Component Material
Stator Lam M250-35A
Stator Winding Copper
Rotor Lam M250-35A
Magnet N30UH
• Check the total weight to make
sure the geometry and materials
have been set up correctly
• Save file
18
Electromagnetic Model Tip: materials used in the model
Materials Database
• Need to assign materials for rotor,

stator, winding and magnets.
• Go to Input Data -> Material
database.
• Motor-CAD provides a default
database with full details of many
commonly used materials.
• The user can add data for any
other materials not included by
default.
19
Summary
• Geometry
‒ Radial
‒ Axial
‒ 3D view
• Winding
‒ Pattern
‒ Conductor distribution
‒ Harmonics & Factors
• Materials
‒ Material properties
20
Electromagnetic Analysis
Motor-CAD E-Mag
21
FEA Simulation in Motor-CAD
• Save as EV_2_Electromagnetic.mot
• Go to Calculation tab, set the following:
Shaft Speed 3000 RPM
Line Current Definition Peak
Peak Current 480 A
DC Bus Voltage 400 V
Phase Advance 45 Elec deg
Drive Mode Sine
Winding Connection Star Connection
Magnetisation Parallel
Winding / Magnet Temperature 65 / 65 °C
22
FEA Results
• Click Solve E-Magnetic Model

button. The simulation should
complete within 1 minute.
• Go to E-Magnetics -> FEA tab. This
tab provides the user with the FEA
geometry, mesh and FEA results
during the simulation or played after
• Results are saved in a separate file at
each calculation, including the single
operating points (always simulated)
• Results can be viewed using the
dropdown list on the left hand page,
highlighted here
23
FEA Results Result Comment
Cogging Cogging Torque calculation
• Available results depend on the On Load Torque On load transient torque (Torque calculation)
calculation run (performance test,
Loss calculation from on load transient
solver type…) On Load Loss
torque (Torque calculation)
• In this example we have the Single point no load (Q Axis current
following results files to choose Static OC
calculation – always performed)
from:
Open Circuit Open circuit transient
Transient (Back EMF calculation)
Open Circuit Loss calculation from open circuit transient
Loss (Back EMF calculation)
Single point on load
Static Load
(On Load calculation – always performed)
24
FEA Simulations in Motor-CAD
Results
• Select OnLoadTorque_result_1.mes from

the dropdown on the left hand of the page
• The Shading options allow the user to

choose which quantity is displayed
• Select Flux Density
• Each time step of the simulation can be

selected from the dropdown
• The Play All button is used to get an

animation of the flux over time
• Plots can be customized with the Options

25
FEA Results
• Select OnLoadLoss_result_1.mes
from the dropdown to visualize the
losses in the machine
• Note that no time step controls are
available since losses are
calculated over the full electrical
cycle
• The Shading option can be used to
view different types of losses
• Select Eddy Loss (solid) to see
the distribution of eddy current
losses in magnets
26
Numerical Results: Drive page
• Go to Output Data tab to view

detailed information on the
machine performance
• Drive page gives:
‒ Voltage
‒ Current
‒ Phase advance
‒ Inductances
‒ …
27
Numerical Results: E-Magnetics page
• E-Magnetics page gives:

‒ Shaft torque
‒ Electromagnetic torque
‒ Efficiency
‒ Input power
‒ Output power
‒ …
28
Numerical Results: Losses page
• Loss page gives:

‒ Winding losses
‒ Magnet losses
‒ Stator / Rotor iron losses
‒ Mechanical losses
‒ …
29
Graph Results: Waveforms
• Go to Graphs -> Graphs, then select Currents and Back EMF
Currents Back EMFs
30
• Select Torque and Cogging Torque to visualize the electromagnetic and cogging torques
Cogging torque
Electromagnetic torque
31
• Select Flux Linkage on Load to

view the flux linkages waveforms
32
Graph Results: Harmonic Content
• Select Graphs -> Harmonics for

harmonic analysis of waveforms
• Note the characteristic 6th and 12th
harmonics in the torque waveform
33
Results: Graph Viewer
• Graph viewer available under Help -> Graph Viewer

• Other quantities calculated by Motor-CAD can be plotted
• Customise graphs and export data using Graph Editor
34
Summary
• FEA Calculation setup
‒ Drive
‒ Temperatures
‒ Performance tests
• FEA Results
‒ Field plots
‒ Output data
‒ Graph
35
Motor-CAD Lab
Efficiency Maps, Torque-Speed Curves,
Drive Cycles Analysis & Thermal Envelope
36
Motor-CAD Lab
Motor-CAD Lab Interface
• Model Build: configure the detail and

accuracy of the EM & loss models to build
• Calculation: voltage and operation
definition, turns and temperature scaling. No
need to build the model again if changed
• Electromagnetic: calculation of torque
speed curves and 2D maps for efficiency,
losses, working conditions
• Thermal: calculation of torque speed curves
and 2D maps for thermal limit
• Duty Cycle: calculation from torque, speed
vs time definition
• Operating Point: calculation for specific
torque, current, temperature and speed
• Calibration: open & short circuit tests
37
Motor-CAD Lab
Peak Torque-Speed Characteristic Tip: a green background indicated Lab context
• Save as EV_3_Lab_TorqueSpeed.mot
• Switch to Lab using Model -> Lab or press Ctrl+B
• Under Model Build -> Model Options, set:
Parameter Value
Model Type Saturation Model (Single Step)
Model Resolution Coarse
Loss Model Neglect
Maximum Speed 10000rpm
Max Stator Current (Peak) 480A
• Make sure the Saturation Model checkbox

is enabled and click Build Model
• The simulation should complete with 10-20s
38
Motor-CAD Lab
Peak Torque-Speed Characteristic
• Go to Calculation tab, set:

Parameter Value
DC Bus Voltage 400V
Maximum Modulation Index 1
Operating Mode Motor
Control Strategy Maximum Torque/Amp
Mechanical Loss Neglect
• Notes
‒ Iron Loss Build factors are disabled
since losses are neglected
‒ The Scaling options are left to their
default values
39
Motor-CAD Lab Tip: previously calculated results can also be loaded
at a later point with the Load Results Viewer
Peak Torque-Speed Characteristic
• Go to Electromagnetic tab and set:

Parameter Value
Calculation Type Max. Torque/Speed Curve
Speed: Maximum 10000rpm
Speed: Step 500rpm
Speed: Min. 0rpm
Current: Max. (Peak) 480A
• Click Calculate Electromagnetic

Performance
• The calculation should complete in a
few seconds
40
Motor-CAD Lab
Peak Torque-Speed Characteristics
• Results are automatically shown in a new window

• Different values can be plotted by changing the X Axis or Y Axis dropdown
Peak Torque vs Speed Peak Power vs Speed
41
Motor-CAD Lab
Efficiency Maps
• Save as EV_4_Lab_EfficiencyMap.mot and return to the Lab module (Ctrl+B)

• Select Model Build -> Model Options tab and set the following:
Parameter Value
Model Type Saturation Model (Full Cycle) Model Type
Model Resolution Fine Model
Resolution
Loss Model FEA Map Loss Model
• The Message Display window indicates that the proximity losses

(AC losses) are not included in the model. These losses will be
considered later in the Advanced E-Magnetic Modelling section
42
Tip: cells highlighted in red in the Model
Status table indicate that the saved model
Motor-CAD Lab build does not match the selected options
and the model must be rebuilt
Efficiency Maps
• Keep the maximum speed and

current the same as before
• Make sure the Saturation Model
and Loss model checkboxes are
enabled
• Click Build Model
• The simulation should complete
within around 5 minutes
43
Motor-CAD Lab
Efficiency Maps
• Go to Electromagnetic tab
• Click Calculate Electromagnetic Performance and compare with the previous result
Torque vs Speed (Single Step Model) Torque vs Speed (Full Cycle)
44
Motor-CAD Lab
Efficiency Maps
• Close the Motor-CAD Lab Viewer

and return to Calculation tab

Iron Loss Stator Build Factor 1.5
Iron Loss Rotor Build Factor 1.5
Calculation Type User Defined
Friction Loss 50W W
Friction Loss Exponent 1
Windage Loss 0W W
Windage Loss Exponent 2
Reference Speed 10000rpm rpm
45
Motor-CAD Lab
Efficiency Maps
• Go to Electromagnetic tab and set:

Parameter Value
Calculation Type Efficiency Map
Speed: Maximum 10000rpm
Speed: Step 500rpm
Speed: Minimum 500rpm
Current: Maximum (Peak) 480A
Current: No. of Increments 30
Current: Minimum (Peak) 1
Smooth Map Enabled
• Click Calculate Electromagnetic
Performance to run the calculation
46
Motor-CAD Lab
Efficiency Maps
Torque-Speed Map with Efficiency Isolines
• The efficiency map is automatically
shown when simulation finishes
• Different values can be plotted by
changing the Y Axis or Z Axis
dropdown
• The appearance of the plot can be
customized by the user in the Options
Tab (e.g. min/max values, number of
isolines…)
• Data can be viewed & copied to
clipboard from Data tab
• Can export figure or numerical data
with the Export Figure/Data menu
47
Motor-CAD Lab
Thermal Envelope
• The Thermal tab can be used to calculate the continuous thermal performance of the
machine for steady-state and transient conditions
• The resulting thermal envelope will show the maximum capability of the machine based
on the specified maximum temperatures
• Since the thermal model has not been configured yet, this part will be studied later in the
tutorial
48
Motor-CAD Lab Tip: the user can specify a custom drive cycle from
an external data file – covered later in the tutorial
Duty Cycle Analysis
• Go to Duty Cycle tab

• Set Automotive Drive Cycle and US06
• Set the Vehicle Model parameters as
follows:
Parameter Value
Mass 1521
Rolling Resistance 0.007
Frontal Area 2.29
Drag Coefficient 0.28
Final Drive Ratio 7.938
49
Motor-CAD Lab Tip: the user can specify a custom drive cycle from
an external data file – covered later in the tutorial
Duty Cycle Analysis
• Click Calculate Duty Cycle

Performance to run the calculation
• The simulation should complete within
about 2 minutes
50
Motor-CAD Lab
Duty Cycle Analysis
• The viewer will automatically show the torque profile over the selected cycle
• In the Analysis tab various useful parameters calculated over the cycle are shown
Torque Profile over Cycle Analysis
51
Motor-CAD Lab
Duty Cycle Analysis
• The Duty Cycle operating points

can also be included on the
efficiency map
• Since the cycle contains both
motoring and generating points,
the map must be calculated for
both modes
• Go to Calculation tab and set
Operating Mode to
Motor/Generator
52
Motor-CAD Lab
Duty Cycle Analysis
Efficiency map in both modes with operating points
• Return to Electromagnetic tab and
click Calculate Electromagnetic
Performance again
• Once the results are shown, select
the Show Drive Cycle option to
display the operating points
• The duty cycle loss values can be
exported to the Thermal module in
order to calculate the thermal
performance over a cycle. This will
be studied later after having
configured the thermal model.
53
Motor-CAD Lab
Single Operating Point
• Go to Operating Point tab

• Set the following conditions:
Definition Torque
Speed 6000 rpm
Torque 160 Nm
E-Magnetic Operation Point:
Model Coupling E-Magnetic
Thermal Model No Coupling
• Click Calculate Operating Point
54
Motor-CAD Lab
• Return to E-Magnetic module

(Ctrl+M)
• Go to Calculation tab and note
that the operating conditions
previously calculated in Lab are
set
• Select only the Torque option in
the Performance Tests section
55
Motor-CAD Lab
• When solving is complete go to

Output Data -> E-Magnetics tab
• Can visualise results for an
extensive set of parameters
• Note that torque and efficiency
values found from the transient
FEA model are very close to the
analytical values
56
Motor-CAD Lab
• Other detailed results can be viewed under the Graphs tab

Electromagnetic Torque vs Position Flux Linkages vs Position
57
Summary
• FEA Model Build
• Peak Torque-Speed Characteristics
• Efficiency Maps
• Duty Cycle Analysis
• Single Operating Point
58
Thermal Model
Motor-CAD Therm
59
Thermal Model Tip: a red background indicates a thermal context
Motor-CAD Therm Interface
• Geometry: radial, axial, 3D…

• Winding: pattern, conductors…
• Input Data: materials, cooling methods,
build factors, loss definition and thermal
model customization
• Calculation: simulation definition
• Temperatures: temperature results, lumped
parameter thermal circuit, 2D thermal FEA
(advanced user)
• Output Data: numerical results
• Transient Graphs: transient results if solved
• Sensitivity analysis
• Scripting in Visual Basic Scripting
60
Thermal Model
Lumped Parameter Circuit Model
• Very fast analytical model

‒ 3D lumped parameter thermal
network
‒ Uses equivalent thermal
resistances and capacitances
• Every component has a specific
colour throughout the thermal
module
61
Thermal Model Tip 1: red background indicates Thermal context
Tip 2: (recall): press Enter or click Redraw to update
Geometry
• Switch to Thermal:
• Save as EV_5_Thermal.mot
• Set the following parameters
under Geometry -> Radial:
62
Thermal Model
Radial Parameter Value Units
Axial Geometry Shaft Dia [F] 20 mm
Shaft Dia [R] 20 mm
• Under Geometry -> Axial, set the following →
Wdg Add [Outer F] 3 mm
Wdg Add [Outer R] 3 mm
Axial Parameter Value Units

Endcap Length [F] 30 mm
Endcap Length [R] 30 mm
Endcap Thickness [F] 10 mm
Endcap Thickness [R] 10 mm
WJ Channel Width 30 mm
WJ Channel Spacing 35 mm
63
Thermal Model
Winding
• Go to Winding -> Positions tab

• Motor-CAD automatically places the
conductors in the slot based on common
manufacturing methods but the user is
free to customize it (advanced user)
• Cuboids are used to represent the
thermal behaviour within the lumped
parameter network. They can be drawn
by selecting Cuboids in the Winding
View
• The number of cuboids can be
customized under Input Data ->
Settings -> Winding
64
Thermal Model
Cooling: Housing Water Jacket
• Go to Input Data -> Cooling tab

• The Housing Water Jacket option is
enabled by default
• Other cooling types can be enabled
and general options for the motor
environment are configured
• Under Miscellaneous Data, change
the Ambient Temperature as
follows:
Parameter Value Units
Ambient Temperature 65 °C
65
Thermal Model
• Before defining the water jacket

the flow rate must be defined in
liters per minutes instead of m3/s
(SI)
• Go to Defaults -> Unit in the main
menu
• In the Units dialog box, navigate
to Thermal Tab and set Volume
Flow Rate unit to l/min
• Click OK
66
Thermal Model
• Go to Input Data -> Housing

Water Jacket -> Flow Options
• Set the following parameters:
Constant
Flow Definition
Flow Rate
Fluid Volume
6.5 l/min
Flow Rate
67
Thermal Model Parameter
Inlet Temperature
Value
65
Units
°C
Fluid Properties EGW 50/50
Include Duct Wall Roughness Enabled
• Go to Fluid Flow tab, and set → → → Duct wall roughness 0.0025
Active Cooling Only Enabled
Non Spiral Ducts Unbaled
Endcap Cooling No Endcap Cooling
Flow Direction Front -> Rear
Calculate or Input Number Flow Channels Calculate
Parallel Flow Paths 1
Duct Wall Thickness 0 mm
• The fluid flow table shows the area, flow rate and pressure values for the housing water jacket along
with other thermal parameters
68
Thermal Model
• Go to Geometry tab to view the final configuration

Axial View 3D View
69
Thermal Model
Interface Gaps
• Go to Input Data -> Interfaces

• Interface gaps depend on materials
and manufacturing, used to calculate
thermal resistances
• Typical values of airgaps between
components are provided by Motor-
CAD based on significant experience
and real-world testing
• For the Stator Lam – Housing
component select Lamination-Metal
– Good Surface Contact (0.01)
70
Thermal Model
End Space and Advanced Options
• Different endcap options are available

under Input Data -> End Space. Leave
the default values as no extra cooling is
needed
• Internal convection is calculated from
empirical correlations based on
experience and testing
• Parameters related to heat dissipation
are shown in the table and can be
modified
• Advanced options are also available
under Radiation and Natural
Convection tabs
71
Thermal Model
Materials
• Go to Input Data -> Materials

• The list of materials is longer than
E-Mag as there are more
components in the thermal model
• Leave the default materials for the
Housing, Impregnation Slot Liner
etc.
72
Parameter Value
Definition Torque
Thermal Model Speed

Torque
1000rpm
200Nm
E-Magnetic Model Coupling O.P → E-Magnetic
Losses
Thermal Model No Coupling
• Go to Losses -> Loss Model

• Motor-CAD provides different models to
scale losses with speed and temperature
• Losses can be either input by the user or
calculated from E-Magnetic or Lab
module
• Switch to Lab and set up the Operating
Point
• Check Motor-CAD E-Mag Model
checkbox is enabled and click Calculate
Operating Point
73
Thermal Model
Losses
• Switch to E-Magnetic module and go

to Calculation tab
• Check the operating conditions have
been imported correctly from Lab
• Make sure only the Torque
performance test is enabled
• Set the E-Magnetics-Thermal
coupling option to E-Magnetics
Losses -> Thermal
• The calculated values will be directly
transferred to Thermal module
74
Thermal Model
Losses
• Once solving complete got to Output

Data -> Losses to check loss values
75
Thermal Model
Motor-CAD Therm Interface
• Return to the thermal model

(Ctrl+T)
• Go to Input Data -> Losses ->
Loss Model and check the
imported loss values
• Set the following parameters
given in the table on the right
Parameter Value
• Note that there are no mechanical Speed Dependent Losses Disabled
losses as they have not been Single value of Speed [REF] Disabled
calculated in E-Mag
Copper Loss Variation with Temperature Enabled
Winding Temperature at which Stator Copper Losses Input 65°C
76
Summary
• Geometry
• Winding Model
• Cooling
‒ Housing Water Jacket
‒ Interface Gaps
‒ Advanced Settings
• Materials
• Losses
77
Thermal Analysis
Motor-CAD Therm
78
Thermal Analysis
Steady State Simulation
• Go to Calculation tab
• Make sure Calculation Type is set
to Steady State
• Click Solve Thermal Model or
press Ctrl+R
• Once solving complete, Motor-CAD
automatically shows the results
79
Thermal Analysis
Steady State Analysis
• Go to Temperatures -> Radial and Temperatures -> Axial to view the final temperatures
Radial View Axial View
80
Thermal Analysis Schematic View
• Can view an overview of the

lumped parameter thermal network
in Temperatures -> Schematic ->
Overview
• Every component has a specific
colour used throughout the module
81
Thermal Analysis Detailed View
• Go to Temperatures -> Schematic ->

Detail -> Circuit to visualise the complete
model
• Use the Plot Options to simplify the view:
Parameter Value
Resistance No Display
Power Source No Display
Node Label
Grid No Display
• Can see the cuboids used for the thermal

model of the stator winding
82
Thermal Analysis
• The Output Data tab also

provides detailed results:
‒ Temperatures
‒ Heat transfer coefficients
‒ Thermal resistances
‒ Thermal capacitances
‒…
83
Thermal Analysis
Simple Transient Simulation
• Go to Calculation and Select Transient

• In Transient:
Parameter Value
Transient Calculation Type Simple Transient
Point Storage Reduction 1
Transient Period 7200s
Number Points 20
Change in Temp. ambient 0°C
Initial Transient Temps. Whole machine at specified temp.
Machine Temps. 60°C
• Go to Calculation tab, set Calculation Type

to Transient and solve the model
84
Thermal Analysis
• During solving the Transient Progress

bar shows the progress of the simulation:
• Once solving complete Motor-CAD

automatically change to Transient
Graphs -> Graphs -> Temperature page
• Note that temperatures converge towards
steady-state values and components
colours are respected
85
Thermal Analysis
• Go to Graphs -> Power tab to

visualize the power dissipated in the
motor over the transient period
• Stator copper losses increase with time
due to the use of the Copper Losses
Vary With Temperature model
• Power in other components remains
constant over time
• Setup tab allows the user to customize
graphs
• Data can be viewed & exported under
Data tab
86
Thermal Analysis
• The Temperatures -> Schematic /Radial/Axial and Output Data tabs show the final values at the
end of the transient calculation
Radial View Schematic View
87
Thermal Analysis
Duty Cycle Analysis
• We can simulate more complex duty

cycles
• Go to Input Data -> Duty Cycle ->
Settings and set the following:
Parameter Value
Transient Calculation Type Duty-Cycle Analysis
Point Storage Reduction 1
Change in Temp. ambient 0
Number of Cycles 1
Initial Transient Temp. Ambient Temp.
88
Thermal Analysis
Duty Cycle Analysis
• Go to Calculation -> Duty Cycle

• The thermal duty cycle is typically
defined according to speed and
losses versus time
• In EM design it is more usual to
define the duty cycle with a torque
speed profile
• Lab module is used here to
calculate the power losses from
torque/speed vs time profiles
89
Thermal Analysis
Duty Cycle Analysis
• Switch to Lab module (Ctrl+B)

• Go to Duty Cycle tab
• Check that parameters previously set
up (slide 59) are correct
• Click Calculate Duty Cycle
Performance
• Click Export Duty to Thermal Model
• Once solving complete, a message
window confirms losses have been
exported with success
• Return to the thermal model (Ctrl+T)
90
Thermal Analysis
Duty Cycle Analysis
• Go to Calculation -> Duty Cycle

• Check losses and speed versus
time have been updated
• Check that Calculation Type is
set to Transient
• Solve the thermal model
91
Thermal Analysis
Duty Cycle Analysis
• In this case stator winding and

magnet temperatures are of great
interest
• Go to Transient Graphs -> Setup
-> Temperature Graph Setup
and customize the transient graph
to show only Ambient, Magnet,
Winding (Average) and Winding
(Hotspot) nodes
• Deselect the Draw Points option
92
Thermal Analysis
Duty Cycle Analysis
Graph customization Magnet/Ambient/Winding temps vs Time (1 cycle)
93
Thermal Analysis
Duty Cycle Analysis
• It is possible to change the

number of simulated cycles
• Go to Calculation-> Transient ->
Duty Cycle and set Number of
Cycles to 5
• Run the simulation again under
Calculation time
94
Thermal Analysis Transient Temperatures vs Time
Duty Cycle Analysis
• When saving the file, the following

message appears:
• For duty cycles with more than 500

periods Motor-CAD save the data in
an external file to prevent the size of
the .mot file from growing too large
• Select a location for the file
95
Thermal Analysis
Continuous Thermal Performance Parameter Value Units
Thermal Map Type Envelope
• Switch to Lab (Ctrl+B), go to Thermal tab, Thermal Calculation Steady State

set: Thermal Limit Stator Winding + Magnet
Maximum Winding Node Average
Initial Current Estimate (Peak) 240 A
Speed: Maximum 10000 rpm
Speed: Step 500 rpm
Speed: Minimum 200 rpm
Maximum Temp.: Stator Winding 160 °C
Maximum Temp.: Magnet 140 °C
Limit on Max. Current Disabled

• Click Calculate Thermal Envelope
96
Thermal Analysis
Continuous Thermal Performance
Shaft Torque vs Speed
• The calculation can take some

time as Lab module iterates with
Thermal module
• A good estimate of the initial
current is advised (typically ½ of
the model build current)
• Note that the motor cannot
operate continuously at peak
performances within the thermal
limits (see slide 51)
97
Thermal Analysis
Continuous Thermal Performance
• Select Stator Winding Temp Average and then Magnet Temp on the Y Axis
• Note the motor is constrained at low speed (resp. at high speed) by the winding temp. (resp. the
magnet temp.) Winding Temp. vs Speed Magnet Temp. vs Speed
98
Summary
• Steady State Simulation
• Simple Transient Simulation
• Duty Cycle Analysis
• Continuous Thermal Performance
99
Mechanical Model
Motor-CAD Mech
100
Mechanical Model
Units
• Go to Defaults -> Units

• Select Mechanical
• Set Stress unit to Mpa
• Save the file as
EV_6_Mechanical.mot
101
Mechanical Model
Assumptions
• Simulation:
‒ 2D FEA
‒ Plane stress condition
• Materials:
‒ Homogeneous
‒ Isotropic
• Loads:
‒ Rotation only 𝜹
‒ No temperature effect
‒ No manufacturing effect Hook’s law →
• Contacts:
‒ Bonded
102
Mechanical Model
Tip: a yellow background indicates a thermal context
Motor-CAD Mech Interface
• Geometry
• Input Data
‒ Material
‒ Settings for FEA calculations
• Calculation:
‒ Operating point for FEA
• Mechanical:
‒ 2D FEA results and visualization
• Output Data
‒ FEA numerical results
• Sensitivity & Scripting
103
Mechanical Analysis
Motor-CAD Mech
104
Mechanical Analysis
Calculation settings
• In Drive, set Shaft Speed to
12000rpm, corresponding to 20%
overspeed
• In Mechanical Component
Options, set:
‒ Include Magnets
‒ Adhesion factor = 0.2
105
Mechanical Analysis
FEA results
• Go to Mechanical -> FEA tab

• This tab provides the user with the
FEA geometry, mesh and FEA
results
• The Shading option allow the user
to choose which quantity is
displayed
• Select SVM, to observe the Von-
Mises stress distribution at 20%
overspeed
• Check Mesh to visualize the mesh
106
Mechanical Analysis
Numerical results
• Go to Output Data
• This tab provides detailed
information about the laminations,
including:
‒ Maximum stress value
‒ Averaged stress value
‒ Safety ratio with respect to the
material yield strength
• Analytical results give the stress
values for an equivalent
homogeneous hollow cylinder
107
Advanced E-Magnetic
Modelling
Motor-CAD E-Mag, Therm & Lab
108
Advanced E-Magnetic Tip: materials used in the model
Materials Database
• Need to assign materials for rotor,

stator, winding and magnets.
• Go to Input Data -> Material
database.
• Motor-CAD provides a default
database with full details of many
commonly used materials.
• The user can add data for any other
materials not included by default.
EV_7_Advanced.mot and switch to
E-Magnetic module (Ctrl+M)
109
Advanced E-Magnetic
New Steel Material
• The electrical steel 30DH, used

for rotor and stator, is not included
in the default database and must
be created
• Click Add Solid and set the
following:
• Click Add
110
Tip 1: notes can be added to the selected
material if needed
Advanced E-Magnetic Tip 2: the Material Filter can be used to
make it easier to locate the correct material
Steel Material Properties
• Go to Physical tab, set:

Thermal Conductivity 30 W/m/C
Specific Heat 460 J/kg/C
Density 7650 kg/m3
• Go to Electrical tab, check the new

material 30DH is selected in the list
on the left, and set the following:
Resistivity 5.9E-7 Ohm
Coefficient of resistivity 1.3 /C
111
Advanced E-Magnetic
Steel Material: Magnetic Characteristics
• Go to Steel BH tab
• Copy the B and H values from the
provided 30DH_Steel.xslx file
• Paste the data to the table either
with the Insert Data Points
button or by selecting the first cell
and using Ctrl+V
• The graph on the right hand side
is updated to reflect the new data
112
Tip 1: extrapolated data points are
shown in blue in the table to
distinguish from experimental data
Advanced E-Magnetic Tip 2: a blue dotted line indicates
the limits of the experimental data
Steel Material: Magnetic Characteristics
• Motor-CAD can estimate BH points

beyond available experimental data
• Select Enable Extrapolation option
• Set the following parameters:
Max H Value 1000000 A/m
Extrapolation Points 10
• Click Extrapolate
• Check the new points are added to
the graph
113
Advanced E-Magnetic
Steel Material: Specific Losses
• Need to define iron loss properties

of the steel
• Select Steel Losses -> Losses
• Copy the loss data from the
30DH_Steel.xslx file and Paste
to the table
• Click Update Graph
• Check all the curves are added to
the graph
114
Advanced E-Magnetic
• Click Find Coefficients

• Motor-CAD uses an iterative
curve fitting method to find the
coefficients. This can take a few
minutes
• Once the curve fitting is complete,
check the calculated loss models
fit the experimental data
• Click Update Database Values
button to store the calculated
coefficients
115
Tip: the user can select either the
Steinmetz or Modified Bertotti model to
Advanced E-Magnetic calculate the iron losses in electrical steel
under Input Data -> Settings -> Losses
• Go to Steel Properties tab, make

sure the calculated coefficients
have been correctly added
• Keep the default value for the
Minor Loop Hysteresis
Coefficient (Kc) to 0.65 – this is
an empirical value
• Set the Lamination thickness
property to 0.3 mm
• The process of adding the steel to
the materials database is now
complete
116
Advanced E-Magnetic
Materials Assignment
• Go to Input Data -> Materials tab

• Assign the following materials:
Component Material
Stator Lam 30DH
Stator Winding Copper (Pure)
Rotor Lam 30DH
Magnet N30UH

• Save file
117
Advanced E-Magnetic
Custom DXF Geometry
• The parameterized geometry in Motor-CAD gives a very fast estimation of the

electromagnetic performance with generally sufficient accuracy
• Sometimes the precise machine geometry cannot be reproduced using parameter
model, need to simulate exact geometry (e.g. including flux barrier) for accurate
prediction of torque ripple
• Import DXF geometry to use in FEA simulations
• The EV motor geometry has some minor differences compared to the Motor-CAD
parameter model. Save the file and switch to E-Magnetic module (Ctrl+M)
118
Advanced E-Magnetic
Custom DXF Geometry
• Select File -> Geometry Import from the main

menu or press Ctrl+I
• In the DXF Import dialog box, use the file open
button and select EV_rotor_model.dxf
• Click Display and close the dialog box
119
Advanced E-Magnetic
Custom DXF Geometry
• It is important that the Motor-CAD

parameter model matches the
DXF geometry as closely as
possible
• Check geometry against DXF in
Geometry -> Radial view and
adjust parameters as necessary
• Airgap thickness and location is
most important since this is
defined by Motor-CAD geometry
for the FEA simulations
120
Advanced E-Magnetic
Custom DXF Geometry
• Go to E-Magnetics -> FEA Editor

tab to activate the DXF geometry
• Set the following:
Parameter Value
Use Custom Regions E-Mag Enabled
DXF Import Options E-Mag Enabled
Use E-Magnetic DXF Import as Single Rotor Pole
Display DXF Errors Enabled
• Regions Warnings indicate that

we have duplicate regions defined
121
Advanced E-Magnetic
Custom DXF Geometry
• Click on the first warning text to

highlight the problematic region in
the table and the drawing
• The rotor air region at the end of
the magnet has to be corrected
• Zoom in by drawing a rectangle
with the left mouse button over
the area of interest
• The drawing can be panned by
holding down the right mouse
button and dragging the view
122
Advanced E-Magnetic
Custom DXF Geometry
• Select the region with the left

mouse button and use drag and
drop to place it in the correct
location
123
Advanced E-Magnetic
Custom DXF Geometry
• Double Click to reset the zoom

• Repeat the process for any further
warnings Check that there are no
remaining warnings
• Electromagnetic performance with
new geometry can now be
simulated & compared with
previous results (Electromagnetic
Analysis section)
124
Advanced E-Magnetic
Custom DXF Geometry
• Go to Calculation tab and set the

following parameters:
Shaft Speed 3000 rpm
Peak Current 480 A
Phase Advance 45 Elec deg
• Enable only Torque, Back EMF

and Cogging Torque calculations
in Performance Tests
125
Advanced E-Magnetic
Custom DXF Geometry
• When solving completed go to E-Magnetics -> FEA and check the different graphs
Flux Density on Load with DXF Geometry Back-EMF with DXF Geometry
126
Advanced E-Magnetic
Custom DXF Geometry
Cogging Torque with DXF Geometry Load Torque with DXF Geometry
127
Advanced E-Magnetic
Advanced Settings
• Input Data -> Settings tabs

provide many advanced settings
for the electromagnetic
calculations
• We can use some of these
settings to improve the accuracy
of the EV model
• Motor-CAD manual has detailed
information on all available
settings
128
Advanced E-Magnetic
Advanced Settings: Loss Build Factors
• Measured power loss in steel materials

is often greater than datasheet values
due to manufacturing processes
• Go Input Data -> Settings -> Losses
-> General Tab and set the following:
Parameter Value
Stator Build Factor 1.5
Rotor Build Factor 1.5
• Build factors are also available for

magnet and shaft losses but not
required here
129
Advanced E-Magnetic
Advanced Settings: Manufacturing Factors
• Found under Input Data ->

Settings -> E-Magnetics tab
• In case of complex geometry or
external factors, manufacturing
factors can be used to adjust
some parameters:
‒ Resistance
‒ Flux densities
‒ Flux linkages
• These factors are typically
calibrated with experimental data
130
Advanced E-Magnetic
Advanced Settings: Sine Drive Modulation
• Input Data -> Settings -> Drive

tab is used to configured the motor
control
• For the EV motor, the Circle
Tracking strategy is used for the
sine wave drive modulation
• This setting allows Motor-CAD to
calculate the correct voltage
available from the inverter
• An LC filter circuit can also be
defined at the input of the machine
131
Advanced E-Magnetic
Advanced Settings: Calculation
• Input Data -> Settings ->

Calculation tab is used to
customize settings used in FEA
calculations:
• Mesh (Mesh Control)
‒ Symmetry (Model Size)
‒ Solver (Magnetic Solver)
‒ Time steps (Points per cycle)
‒ …
• The full Transient solver is required
for accurate loss calculations
132
Advanced E-Magnetic
Advanced Settings: Graph Display
• Input Data -> Settings -> Graphs

tab is used to customise display of
results
• Standard torque calculations in
Motor-CAD for a sine-wave driven
BPM machine
‒ Maxwell Stress (MS)
‒ Virtual Work (VW)
‒ dq axis analytical torque (DQ)
• By default the VW method is
enabled
133
Advanced E-Magnetic
Advanced Settings: Proximity AC Losses
• Motor-CAD provides two methods to

calculate AC losses: Hybrid FEA and Full
FEA
• Go to Input Data -> Settings -> Losses
-> Proximity tab and set the parameters
given on the table on the right
Parameter Value
• The Skew Distribution option allows Proximity Loss Model Hybrid FEA
different sizes for the cuboids
Include Bundle Effect Enabled
• The Bundle Aspect Ratio is the height- Bundle Aspect Ratio 1.5
width ratio of the conductor bundle
Cuboid Size Skewed distribution
Number of Cuboids 6
134
Advanced E-Magnetic
• Go to Winding -> Definition tab

• Set the Winding View to Cuboids
to visualize the cuboids
• Cuboids towards the slot opening
are smaller than those at the
bottom to capture higher proximity
losses and improve accuracy of
calculation
135
Advanced E-Magnetic
• We solve a high speed operating

point to see the effect of AC losses
• Select improved method
• In Calculation tab, set the following:
Shaft Speed 6000 rpm
Peak Current 200 A
Phase Advance 65 elec deg
• Ensure Torque calculation is selected

and Solve the model
136
Advanced E-Magnetic
• Go to Geometry tab to view the final configuration

Total AC Copper Losses Scroll Down for Full Details
137
Advanced E-Magnetic
• Transfer losses to thermal model

to see effect on temperatures
EMagnetics - Thermal Coupling
to E-Magnetics Losses ->
Thermal
• No need to solve the model again
138
Advanced E-Magnetic
• Switch to Thermal model and check loss values under Losses -> Loss Models
• Can check distribution over cuboids under Input Data -> Settings -> Losses -> AC Winding
(set from E-Mag results)
139
Advanced E-Magnetic
• In Calculation tab, set Calculation

Type to Steady State and Solve the
thermal model
• Visualise slot temperature in

Temperatures -> Radial tab
• Higher temperatures towards slot
opening
140
Advanced E-Magnetic
• Go to Temperatures ->
Schematic -> Detail -> Circuit
• Can see distribution of losses and
more detailed cuboidal model
• Use Plot Options to display only
Power Source Value
141
Advanced E-Magnetic
• Note: previously saved external

duty cycle file no longer valid
since it does not contain the
proximity loss data
• Go to Calculation -> Duty Cycle,
use Clear Data button to clear the
external duty cycle data
142
Advanced E-Magnetic
Lab Model
• Change in machine geometry and

addition of AC losses means we
need to rebuild the Lab model
• Switch to Lab context, go to
Model Build -> Model Options
• Check options, ensure both
Saturation Model and Loss
Model options are enabled and
click Build Model
143
Calculation Type Efficiency Map -
Advanced E-Magnetic Power Limit Enabled -

Max. Power 80000 W
Lab Model Speed: Maximum 10000 Rpm

Speed: Step 200 Rpm
• Compare calculated efficiency map with experimental Speed: Minimum 500 rpm
results Current: Maximum (Peak) 480 A
• In Calculation tab, set Operating Mode to Motor Current: No. of Increments 50 -
• In Electromagnetic tab, set the parameters in the table Current: Minimum (Peak) 1 A
on the right
144
Advanced E-Magnetic
Lab Model
• Calculate Emagnetic performance
145
Summary
• Add Material Database
• Custom DXF Geometry
• Calculation settings
‒ Loss Build Factors
‒ Manufacturing Factors
‒ Drive Settings
‒ Calculation Settings
‒ Graph Display Settings
• Proximity Losses
• Lab Model
146
Advanced Thermal
Modelling
Motor-CAD E-Mag, Therm & Lab
147
Advanced Thermal
Slot Conduction & Wdg Model Validation
• Cuboidal model for slot winding can be

calibrated with FEA simulations:
‒ Isolate active wdg from end-effects
‒ Power loss only in active winding
• Go to Input Data -> Losses -> Loss
Models
148
Advanced Thermal Tip: caption has changed to indicate
model is in 2D calibration mode
• Go to Calculation tab and set:

Parameter Value
Calculation Type Steady State
Model Size Full Model
Model Type 2D model for
FEA calibration
E-Magnetics – No coupling (default)
Thermal Coupling
• Solve the model
149
Advanced Thermal
• View circuit in Temperatures ->

Schematic -> Detail -> Circuit
• Motor-CAD neglects thermal
connections along the axial length
of the machine between windings,
stator and rotor
150
Advanced Thermal
• Go to Temperatures -> FEA tab,

set Area Select to Stator and
Solve Slot FEA
• Check differences between FEA
results and analytic model
• Adjust cuboid sizes if required
• Once model validation is
complete, restore full 3D model in
Calculation tab
151
Summary
• Slot Conduction & Winding Model Validation
• Custom Thermal Tests
152
Advanced Mechanical
Modelling
Motor-CAD Mech
153
Advanced Mechanical
Materials: Rotor Core
• Go to Material database tab

• Select 30DH material 1
• Go to Mechanical tab, set:
‒ Poisson’s ratio = 0.28
‒ Young’s Modulus [MPa] = 200000
‒ Yield Strength [MPa] = 450
154
Advanced Mechanical
Calculation settings
• Go to Calculation tab 1
• In Drive, set Shaft Speed to 3 2

12000rpm, corresponding to 20%
overspeed
• In Mechanical Component
Options, set:
‒ Include Magnets
‒ Adhesion factor = 1
155
Advanced Mechanical
Mesh Refinement
• Go to Input Data -> Settings ->
Calculation
• Set the following:
• Go to Mechanical tab
• Click Solve Mechanical Model
EV_8_Mechanical_Advanced.mot
156
Advanced Mechanical
Custom DXF Geometry
• Go to Mechanical -> FEA Editor

• In Geometry Options, select
Mechanical
• As before, move the problematic
markers inside the air region. The
following message appears:
• Click Yes
157
Advanced Mechanical
Custom DXF Geometry
• Move to FEA tab and Solve the

model again
158
Advanced Mechanical
Magnet Adhesion
• To account for the agent between

the magnets and the rotor core,
one trick consists in reducing the
magnet stiffness
Adhesion Factor to 0.3
• The Young’s modulus of the
magnets is then multiplied by this
factor
159
Advanced Mechanical
Magnet Adhesion
• Go to Mechanical tab and Solve
160
Conclusion
Q&A
161
This document contains proprietary information of Motor Design Ltd.
Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Motor Design Ltd. © Motor Design Ltd 2016 All Rights Reserved.

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• Select File -> Save As to save file

• Motor-CAD allows users to select different units

• Geometry: radial, axial, 3D…

• Go to Geometry -> Radial, set the stator Stator Ducts None -

• After changing a value, press

• Set the rotor L1 Magnet Shift 0 mm

parameters L1 Bridge Bar Width 16 mm

• Go to Geometry -> Axial, set the

• Save file using File -> Save or

• Go to Geometry -> 3D to visualize

• Go to Winding -> Pattern, set:

• Check All Phases tab, make sure

• Check Phasors tab, that the

• Check Harmonics tab, this shows

• Check Factors tab. This shows

• Go to Winding –> Definition, set:

• Go to Input Data -> Materials tab

• Need to assign materials for rotor,

• Click Solve E-Magnetic Model

• Select OnLoadTorque_result_1.mes from

• The Shading options allow the user to

• Select Flux Density

• Each time step of the simulation can be

• The Play All button is used to get an

• Plots can be customized with the Options

• Go to Output Data tab to view

• E-Magnetics page gives:

• Loss page gives:

• Go to Graphs -> Graphs, then select Currents and Back EMF

Currents Back EMFs

• Select Flux Linkage on Load to

• Select Graphs -> Harmonics for

• Graph viewer available under Help -> Graph Viewer

• Model Build: configure the detail and

• Make sure the Saturation Model checkbox

• Go to Calculation tab, set:

• Go to Electromagnetic tab and set:

• Click Calculate Electromagnetic

• Results are automatically shown in a new window

• Save as EV_4_Lab_EfficiencyMap.mot and return to the Lab module (Ctrl+B)

• The Message Display window indicates that the proximity losses

• Keep the maximum speed and

• Close the Motor-CAD Lab Viewer

Parameter Value Unit

• Go to Electromagnetic tab and set:

Duty Cycle Analysis

• Go to Duty Cycle tab

Duty Cycle Analysis

• Click Calculate Duty Cycle

• The Duty Cycle operating points

• Go to Operating Point tab

• Click Calculate Operating Point

• Return to E-Magnetic module

• When solving is complete go to

• Other detailed results can be viewed under the Graphs tab

Motor-CAD Therm Interface

• Geometry: radial, axial, 3D…

• Very fast analytical model