End Winding Characterization

CAD Package for Electromagnetic and Thermal
Analysis using Finite Elements
FLUX 10
3D Application
End winding characterization
Copyright - October 2009

FLUX is a registered trademark.
FLUX software : COPYRIGHT CEDRAT/INPG/CNRS/EDF

FLUX technical papers : COPYRIGHT CEDRAT
This technical paper was edited on 7 October 2009
Ref.: KF 3 05 - L - 10 - EN - 02/08
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Foreword
About the The aim of this technical paper is the computation of end windings
technical paper inductance. It contains the general steps and all data needed to describe the
model of asynchronous machine.
Required Before preceding this technical paper, the user must have under control all
knowledge functionalities of the Flux software. The user can gain the required knowledge
in the Generic tutorial, which explains in detail all actions to build the
geometry and mesh of the study domain.
Path The files corresponding to the different cases studied in this technical paper
are available in the folder: \DocExamples\Examples3D\EndWinding\
Command files The files provided for this technical paper are:
and Flux files command files,
come in handy to build the Flux projects
Flux files
already built project files
The use of files is explained in the table below.
the user can
To describe execute the
follow recover the Flux file*
command file
the 2D geometry
2 2DGeoMesh.py 2D_GEO_MESH.FLU
and mesh
the 3D geometry
and mesh 3 3DGeoMeshPhys.py 3D_GEO_MESH_PHYS.FLU
the physics
case 1 4 3DCase1A_1B.py 3D_CASE1A.FLU, 3D_CASE1B.FLU
the user can

To describe execute the
follow recover the Flux file*
command file
coil 1 coil_1.py
coil 2 coil_2.py
3.3.7 3D_GEO_MESH_PHYS.FLU

coil 12 coil_12.py
* Flux files are ready to be meshed and then solved.

FLUX10 TABLE OF CONTENTS
TABLE OF CONTENTS
1. General information .................................................................................................................1
1.1. Overview of the sample problem ..................................................................................................3
1.1.1. Foreword.........................................................................................................................4
1.1.2. Description of the device ................................................................................................6
1.1.3. Studied cases ...............................................................................................................10
1.2. Strategies of the geometry description, mesh generation and physical description...................11
1.2.1. Main phases for geometry description and mesh generation of the motor ..................12
1.2.2. Main phases for physical description of the motor .......................................................14
1.3. Computation of end windings inductance: principle & method ...................................................15
1.3.1. Inductance computation principle .................................................................................16
1.3.2. Operating mode with Flux 3D application.....................................................................19
1.3.3. Self inductance or cyclic inductance computation?......................................................21
1.3.4. Symmetry and periodicity .............................................................................................22
2. Motor 2D geometry and mesh ...............................................................................................23
2.1. Geometry and mesh of the 2D stator slot ...................................................................................25
2.1.1. Create geometric parameters and coordinate systems................................................26
2.1.2. Create points and basic lines .......................................................................................28
2.1.3. Create transformations .................................................................................................29
2.1.4. Create lines by propagation..........................................................................................30
2.1.5. Build faces ....................................................................................................................30
2.1.6. Create and assign mesh points ....................................................................................31
2.2. Geometry and mesh of the 2D rotor slot.....................................................................................33
2.2.1. Create geometric parameters and coordinate systems................................................34
2.2.2. Create points and basic lines .......................................................................................36
2.2.4. Create lines by propagation..........................................................................................38
2.2.5. Build faces ....................................................................................................................38
2.3. Geometry of the motor 2D model................................................................................................41
2.3.1. Import into a new project ..............................................................................................42
2.3.2. Create coordinate systems ...........................................................................................42
2.3.3. Create symmetries........................................................................................................43
2.3.5. Create lines and faces by propagation .........................................................................44
2.3.6. Add an infinite box ........................................................................................................46
2.3.7. Create points and lines .................................................................................................47
2.3.8. Build faces ....................................................................................................................49
2.4. Mesh of the motor 2D model.......................................................................................................51
2.4.2. Generate the mesh .......................................................................................................54
2.4.3. Create the basic 2D motor object .................................................................................55
3. Motor 3D geometry, mesh and physical description..............................................................57
3.1. Geometry of the motor 3D model................................................................................................59
3.1.1. Import into a new project ..............................................................................................60
3.1.2. Create coordinate systems ...........................................................................................60
3.1.3. Create symmetries / periodicities .................................................................................61
3.1.5. Create volumes by extrusion ........................................................................................62
3.1.6. Add an infinite box ........................................................................................................63
3.1.7. Create lines...................................................................................................................64
3.1.8. Build faces and volumes...............................................................................................64
3.2. Mesh of the motor 3D model.......................................................................................................65
3.2.1. Assign mesh points.......................................................................................................66
3.2.2. Create and assign mesh lines ......................................................................................67
3.2.3. Create and assign the mesh generator ........................................................................68
3.2.4. Generate the mesh .......................................................................................................69
END WINDING CHARACTERIZATION PAGE A

TABLE OF CONTENTS FLUX10
3.3. Physical description of the motor 3D model................................................................................71

3.3.1. Define the physical application .....................................................................................72
3.3.2. Define physical aspects of symmetries / periodicities ..................................................72
3.3.3. Create materials............................................................................................................73
3.3.4. Create and assign volume regions ...............................................................................73
3.3.5. Create geometric parameters and coordinate systems for non-meshed coils .............77
3.3.6. Create electric components ..........................................................................................78
3.3.7. Create non-meshed coils..............................................................................................79
3.3.8. Define sensors ..............................................................................................................92
4. Case 1: reference computation ............................................................................................. 93
4.1. Case 1: physical properties (continued) and solving process.....................................................94
4.1.1. Complete 3D simulation: Modify the physical properties..............................................95
4.1.2. Define the solving scenario...........................................................................................95
4.1.3. Simulation in 2D conditions: Modify the physical properties.........................................96
4.2. Case 1: results post-processing..................................................................................................97
4.2.1. Inductance computation: main results ..........................................................................98
4.2.2. Inductance computation: additional results ..................................................................99
5. Case 2: single-phased computation .................................................................................... 101
5.1. Case 2: physical properties (continued) and solving process.................................................. 102
5.1.1. Complete 3D simulation: Modify the physical properties........................................... 103
5.1.2. Define the solving scenario........................................................................................ 104
5.1.3. Simulation in 2D conditions: Modify the physical properties...................................... 105
5.2. Case 2: results post-processing............................................................................................... 107
5.2.1. Inductance computation: main results ....................................................................... 108
5.2.2. Inductance computation: additional results ............................................................... 109
6. Case 3: effect of the magnetic saturation............................................................................ 111
6.1.2. Define the solving scenario........................................................................................ 114
6.2.1. Inductance computation: main results ....................................................................... 118
6.2.2. Inductance computation: additional results ............................................................... 119
6.2.3. Compute and display isovalues of the magnetic flux density on volume regions ..... 120
7. Case 4: influence of the rotor .............................................................................................. 123
7.1.2. Solving scenario......................................................................................................... 125
7.2.1. Inductance computation............................................................................................. 128
8. Inductance computed values for a Flux 2D study ............................................................... 129
8.1.1. Physical description ................................................................................................... 130
8.1.2. Electric circuit description .......................................................................................... 131
PAGE B END WINDING CHARACTERIZATION

FLUX 10 General information
1. General information
Introduction This chapter describes the device and introduces the theoretical aspects of the
end winding reactance in asynchronous machines and inductance computation
principle.
Contents This chapter contains the following topics:
Topic See Page

Overview of the sample problem 3
Strategies of the geometry description, mesh generation and 11
physical description
Computation of end windings inductance: principle & method 15
Bibliography Complementary information is available in the following documents:

Contribution la modlisation de la machine asynchrone cage par
logiciels dlments finis 2D et 3D - thesis of Abdelhalim TAIEB
BRAHIMI 1992 - INPG (Contribution to the modeling of the
asynchronous induction machine by software of finite elements 2D and 3D )
Contribution la modlisation des moteurs asynchrones par la mthode
des lments finis - thesis of Eric VASSENT 1990 - INPG (Contribution
to the modelling of asynchronous motors by the finite elements method)
Etude lectromagntique des parties frontales des alternateurs en rgime
permanent et transitoire - thesis of Stephanie RICHARD 1997 INPG
(Electromagnetic study of the frontal parts of alternators in steady state and
transitory mode)
Etude tridimensionnelle des effets dextrmit dans les parties frontales
des machines asynchrones - thesis of Christine SILVA 1994 INPG
(Three-dimensional study of the end winding effects in the frontal parts of
asynchronous machines)
Calcul des impdances de tte de bobine de machines asynchrones
partir de FLUX3D by Jean Pierre DUCREUX EDF technical note
HM-18/0235 1993 (Computation of the impedances of end winding of
asynchronous machines in FLUX3D)
Induction Machines by Philippe ALGER 1969
Theory of end winding leakage inductances by VB HONSINGER
IEEE Transactions on magnetics, pp 417-426, 1959
Proceedings ICEM by WILLIAMSON pp 480-484 1990 Boston
Calcul des machines lectriques by LIWSCHITZ Tome 1, ed DUNOD
1967 (Computation of electric machines)
END WINDING CHARACTERIZATION PAGE 1

General information FLUX10
PAGE 2 END WINDING CHARACTERIZATION

1.1. Overview of the sample problem
Introduction This section is an overview of the sample problem. It contains a brief

description of the device and of studied cases.
Contents This section contains the following topics:
Topic See Page

Foreword 4
Description of the device 6
Studied cases 10

1.1.1. Foreword
Equivalent Since the invention of asynchronous machines, the manufacturers have tried
scheme of to improve analysis techniques in order to predict the performance of their
STEINMETZ machines: voltage-current characteristic, output power, torque, power factor,
losses and efficiency.
One of them is the well-known equivalent scheme of STEINMETZ that
represents the asynchronous machine by an equivalent electrical circuit per
phase.
R1 X1 X2
Vi Xm R2/g
with:
Vi: Voltage phase i
R1: Stator phase resistance
R2/g: Squirrel cage resistance reduced to one phase
Xm: Magnetizing reactance represents the useful flux between stator and
rotor
X1: Magnetic leakage stator reactance
X2: Magnetic leakage rotor reactance
Leakage The two leakage reactances can be divided in several reactances in series
reactance according to the physical origin of the leakages:
The stator and rotor slot leakages:
concern the magnetic flux lines that shut around the slots without crossing
the air gap.
The stator and rotor differential leakages:
concern the zigzag flux that goes through one tooth to another without
crossing the air gap.
The leakages due to skew:
flux which results of the winding imperfections and which does not
contribute to the useful sinusoidal field in the air gap.
The coil end leakage:
leakages in the air created by the looping of conductors in the extremities of
machines.
These leakages are divided into:
- the end winding stator leakages
- the end ring of squirrel cage leakages
Continued on next page

Flux All the parameters of the STEINMETZ scheme can be determined with tests,
computation of analytic computations or finite element studies with Flux in 2D, except the
leakage coil end leakage.
reactance
For the end winding and the end ring inductances, because of their geometry,
only a 3D model can give good results.
This technical paper details methods for the computation of end winding
stator inductance with Flux software in 3D application.
The results will be compared with the main analytic formulas. This technical
paper also explains how to implement them in Flux 2D application for other
studies on asynchronous machines.

1.1.2. Description of the device
Studied device The device to be analyzed is a three-phase induction (asynchronous) motor.

The motor under study consists of two parts:
an outside stationary stator
having 12 coils, each passes Rotor Stator
through four stator slot
an inside squirrel-cage rotor Rotor Stator
attached to the output shaft slots slots
Shaft
Coils
Operating The operation of an induction motor is explained below:

principle The coils supplied with AC current produce a rotating magnetic field.
The secondary current is induced onto the rotor.
This current in the rotor conductors will therefore induce a magnetic field
which will be attracted to the rotating magnetic field in the stator and the
rotor will turn.

Geometry The asynchronous motor is composed of a stator and a rotor.

The stator includes 48 stator slots. The dimensions of the whole stator and
the stator slot are presented in the figures below.
3.51
240
150
22.2
30
2.5
3.21
1.28
3.2
4.6
The rotor includes a shaft and 40 rotor slots. The dimensions of the rotor and
the rotor slot are presented in the figures below.
0.4 1
149
5.25
58 2.425
8.4
2.04
26.3
0.89

Materials The different parts of the asynchronous motor are made of the following
materials:
the material of the rotor and stator is iron (Fe V1000)
the material of the bars of the squirrel cage is aluminum
the material of the shaft is steel
Electrical The electrical characteristics of the asynchronous motor are presented in the
characteristics table below.
Characteristics Value
Rated power 18.5 kW
Power supply voltage 220 V
Rated current 37 A
Speed 1450 rpm
Resistance of ring extremities 7.25 10-7
Inductance of ring extremities 3.7 10-9 H
Resistance of end windings 0.225
Winding The winding characteristics are presented in the table below.

characteristics
Characteristics Value
Type of winding Concentric with consequent poles
Average length of end windings 231 mm
Average length of the straight part of
31 mm
end windings
Number of pairs of poles 2
Number of slots per pole and per phase 4
Number of turns in series per phase 136
Diameter of a spire 1.3 mm
Number of winding in parallel per phase 2
Distribution coefficient 0.957

Winding The winding is concentric with consequent poles. It is represented in the

diagram figure below.
4 3 2 1
Winding 1
5
6
7
Winding 2
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8
V- V+

1.1.3. Studied cases
Studied cases To calculate the end windings inductance, four cases are carried out in a
Magneto Static application:
case 1: reference computation
case 2: single-phased computation
case 3: effect of the magnetic saturation
case 4: influence of the rotor
Case 1 The first case is a reference computation.

This computation can be considered as a reference computation since it is
based on the experimental test record of the end windings inductance
recognized by the IEC norms. The norms do not take the rotor into account;
we need to make computations only in the regions of the stator.
To simplify the model, we use small values of current with linear
approximation for the B(H) characteristic of magnetic materials.
Case 2 The second case is a single-phased computation.

This computation is focused on the self-inductivity, that is why only the first
phase is modeled.
Case 3 The third case is a parametric computation taking into account the effect of
magnetic saturation.
In order to evaluate the influence of the magnetic saturation, the real B(H)
characteristic of the materials is used. Two simulations with two different
current values will be made to compute the inductance of nonlinear materials
with the definition L=/I.
Case 4 The fourth case is a computation taking into account the rotor influence.
To take the rotor influence into account, the computations are made in all the
regions of the asynchronous motor.

1.2. Strategies of the geometry description, mesh

generation and physical description
Introduction This section explains the strategies of the geometry, mesh and physical
description of the motor finite element model.
Topic See Page

Main phases for geometry description and mesh generation of 12
the motor
Main phases for physical description of the motor 14

1.2.1. Main phases for geometry description and mesh generation of

the motor
2D motor An outline of the 2D geometry building and mesh generation is presented in

outline the table below.
Stage Description
The geometry description and

1 mesh preparation of a stator
slot object
The geometry description and

2 mesh preparation of a rotor slot
object
Importation of the stator slot

3
object and the rotor slot object
Creation of symmetries to X-axis symmetry

4
model a quarter of the motor Y-axis symmetry
Creation of faces by
5
propagation
6 Creation of infinite box
7 Faces building
Creation of mesh tools,

assignment of mesh
8
information and meshing of the
motor 2D geometry

3D motor An outline of the 3D geometry building and mesh generation is presented in

Importation of the 2D motor

1
object
Creation of one symmetry XY-plane symmetry

2
and one periodicity to model angular periodicity with rotation
one eighth of the motor about Z-axis
original size
Creation of faces and

3
volumes by extrusion
4 Creation of infinite box
5 Faces and volumes building
Creation of mesh tools,

assignment of mesh
6
information and meshing of
the motor 3D geometry

1.2.2. Main phases for physical description of the motor
3D motor An outline of the physical description process of the 3D motor is presented in

Stage Description
Definition of the
1 3D Magneto Static
application
symmetry:
Definition of physical Tangent magnetic field
2
aspects periodicity:
Odd (anticyclic boundary conditions)
ALUMINIUM material for squirrel
cage with a linear B(H) characteristic
STEEL material for rotor shaft with a
linear B(H) characteristic
3 Creation of materials LINEAR_IRON material for stator
and rotor with a linear B(H)
characteristic
IRON_FEV1000 material for stator
with a nonlinear B(H) characteristic
INFINITE
Creation and
4 assignment of volume EXT_AIR
(invisible)
regions
STATOR
SQUIRREL_CAGE
SLOTST
AIR_GAP
SHAFT
ROTOR
5 Creation of sources
12 non-meshed coils

1.3. Computation of end windings inductance: principle &

method
Introduction Flux gives the possibility to model the extremity of the asynchronous
machine and to represent correctly the geometry of end windings. After the
resolution, the value of magnetic field is available in each node of our finite
element model.
Then, there are several methods (based on energy and flux computation) to
extract from Flux 3D simulations the expected inductance. These methods
and the operating mode in Flux are detailed in this section.
Topic See Page

Inductance computation principle 16
Operating mode with Flux 3D application 19
Self inductance or cyclic inductance computation? 21
Symmetry and periodicity 22
Hypothesis The general working hypotheses are as follows:

there are no eddy currents and no skin effects in conducting parts:
magneto static application
the influence of the rotor is negligible:
the rotor is not modeled
there is no saturation of magnetic materials:
linear approximation of B(H) characteristic
the power supply is homopolar: the same current I passes through all the
phases (I=Itot/N)
the values of self and mutual inductances are identical for windings of the
same phase and for all the phases.

1.3.1. Inductance computation principle
Introduction This paragraph deals with inductance computation principles (based on

energy or flux computation).
It presents the various possible approaches to compute end windings
inductance with post processing quantities available in Flux.
Definitions With linear materials, if one phase is modeled, relations between flux (),
energy (W), current (I) and inductance (L) could be written as:
= L.I L = /I (1)
W = 1/2.L.I L = 2.W/I2 (2)
Computation It is possible to calculate inductance with FLUX using equations 1 or 2 since

with Flux Flux proposes the calculation of:
the magnetic flux viewed by a coil ()
the magnetic energy (W) in volume regions
by integrating B*H in the corresponding volumes
the current I injected in the windings (input data)
The problem is to determine which energy (or which flux) will

give you the expected inductance.
Various approaches can be considered. They are listed hereafter (in the
following blocks) and detailed (practical applications) in this document.
First approach With the first approach we assume that W in formula (1) is the energy in the
air around the end windings. The computation of the energy in the volume
regions corresponding to the air around the machine is representative of the
magnetic energy lost by the system, that is to say leakage energy.
W = WAIR (3)
This method assumes that the extremity leakages are only due to the windings
at the external of the machine but in the reality, the conductors located at the
extremity of the straight part of the machines also contribute to the extremity
leakages.

Second With the second approach, we will try to take into account extremity
approach leakages due to the conductors located at the extremity of the straight part.
In this case, we assume that W in formula (1) could be written as:
W = WTOTAL WSTRAIGHT_PART (4)
where:
WTOTAL is the energy computed in all the regions modeled in 3D, that is to
say, the air around the end windings and also the extremities of the straight
part of the stator (magnetic circuit and air gap)
WSTRAIGHT_PART is the energy computed in the straight part of the motor
without taking into account any extremity leakage (computation in 2D
conditions: see details hereafter)
We can also use the flux relation and write:

= TOTAL STRAIGHT_PART (5)
where:
TOTAL is the total flux viewed by a phase
STRAIGHT_PART is the 2D flux in the straight part of the machine viewed by
a phase (computation in 2D conditions: see details hereafter)
Third approach In the third approach, we use the relation between energy (or flux) and iron
length of the machine.
We assume that:
the energy (or field) corresponding to bi-dimensional field evolves linearly
with the length of iron (WSTRAIGHT_PART = a * liron)
the energy W in formula (1) is constant (W = b)
We can write in this case:
WTOTAL = a * liron + b (6)
Its possible to calculate the (origin coordinate) of the WTOTAL (liron) straight
line with two computations with two iron lengths (see diagram in following
block).

Graphical The different approaches to calculate W are represented on the following

aspects diagram.
WTOTAL
WTOTAL - WSTR AIGHT_P ART WSTRAIGHT_PAR T

(W3D - W2D method)
Energy (W)
Extrapolation to zero
0 10 20 30 40 50 60 70
Iron length (l)

1.3.2. Operating mode with Flux 3D application
Introduction To calculate the end windings inductance with the three previous approaches,
you need three simulations in Flux 3D application. The simulation conditions
and the available results are presented in this paragraph.
Complete 3D A first simulation is made with the straight part of the motor, the external air
simulation around the end windings and windings. We choose a first arbitrary length of
iron (l1).
We compute the following energies:

WAIR(l1) on the external volume
regions air around the end
windings
WTOTAL(l1) on all volume regions
air around the end windings,
magnetic circuit and air gap
Simulation in A second simulation is made taken into account only the straight part of the
2D conditions machine. We are working with the same length of iron (l1). In order to have
the magnetic energy corresponding only to a bi-dimensional field, we have to
calculate the energy in the motor as if we were in the middle of the straight
part. We have to deactivate all the volume regions corresponding to the
external air and to extend the conductors in order to eliminate every edge
fringing.
We compute the following energy:

WSTRAIGHT_PART(l1) on all straight
part volume regions magnetic
circuit and air gap
This computation can also be made with Flux 2D application, it will give us the
possibility to validate our results by comparing Flux 3D and Flux 2D results.

Complete 3D A third simulation, similar to the complete 3D simulation, is made modifying

simulation the iron length (l2).
modifying the We compute the following energy WTOTAL(l2) on all volume regions air
iron length around the end windings, magnetic circuit and air gap.
Summary The table below summarizes the three simulations (simulation conditions and
results) presented in this document.
Complete Simulation Complete

3D simulation in 2D conditions 3D simulation
inactive volume regions of
Conditions external air and extended size
of conductors
Iron length l1 l1 l2
WAIR(l1)
Energy computation WSTRAIGHT_PART(l1) WTOTAL(l2)
WTOTAL(l1)
Flux computation TOTAL(l1) STRAIGHT_PART(l1) TOTAL(l2)
Final results The table below summarizes the different methods for end windings
inductance computation starting from the previous results.
Method Formula Computation

Energy in the air around end
(3) W = WAIR(l1)
windings
Energy: contribution of 2D
(4) W = WTOTAL(l1) WSTRAIGHT_PART(l1)
energy and 3D energy
Flux: contribution of 2D field
(5) = TOTAL(l1) STRAIGHT_PART(l1)
and 3D field
Use of W(liron) straight line
(6) W = (l2.WTOTAL(l1) l1.WTOTAL(l2)) / (l2 l1)
function: extrapolation to zero
Caution To reduce the size of the Flux project, only part of the device is represented
(to take into account of symmetry and periodicity). It is thus necessary to
introduce some corrector coefficients into the formulas. These aspects are
described in 1.3.4.

1.3.3. Self inductance or cyclic inductance computation?
One phase or In the equivalent scheme of STEINMETZ, the value of inductances

three phases corresponds to the cyclic inductances (L-M) per phase (L being the self
inductance of the considered phase and M being the mutual inductance
coefficient) so that it is the value we will try to obtain directly. But, it could
be interesting to calculate the two values.
With the If only one phase is modeled:

energetic
method W = 1/2*L*I L = 2*W/I
If the three phases are modeled:

W=1/2*L1*I1+1/2*L2*I2+1/2*L3*I3+M12* I1* I2+M23* I2* I3+M13* I1* I3
We make the hypothesis that L1 = L2= L3= L and M12 = M13 = M23= M.
With the following values for the current: I1=Imax, I2 = I3 = -Imax/2, we obtain
directly (L-M).
W= 3/4*(L-M)* Imax (L-M) = 4/3*W/Imax
The calculated value must be multiplied by 4/3 in order to take the 3 phases into
account.
With the flux If only one phase is modeled:

method
= L*I L = /I
If the three phases are modeled, and with the triplet (Imax;-Imax/2;-Imax/2), we
have:
= (L-M)*Imax (L-M) = /Imax

1.3.4. Symmetry and periodicity
Periodicity The motor has 2 pairs of poles, the periodicity planes allow to represent only
one coil pitch, that is to say one quarter of the machine, 12 slots for the stator
and 10 slots for the rotor.
Then, anticyclic conditions of periodicities on the lateral faces of our study
domain have to be imposed in order to respect the physical reality.
The winding is constituted of 2 ways in parallel per phase with 2 coils in
series in each way. Though one coil per phase is entirely represented in the
quarter of the motor.
Energetic In this case the energy of one coil per phase is only computed.
method
So that, the calculated inductance for one coil with the total current Iphase is
equivalent to the inductance of the entire phase that is the expected value.
L L
L L I phase
I phase
Flux method If we compute magnetic flux through a coil conductor, the calculated flux is
the flux for the coils belonging to the chosen coil conductor in the study
domain.
As for the energy, if the coil in the study domain is supplied with the current
Iphase, the computation in the quarter is equivalent to the computation on the
entire machine.
Symmetry The motor has a symmetry plane, it is possible to represent one half of the
device, and to set appropriate symmetry conditions on this symmetry planes.
The calculated value must be multiplied by 2 in order to take the 2 extremities
of the machine into account.

FLUX 10 Motor 2D geometry and mesh
2. Motor 2D geometry and mesh
Introduction This chapter describes the main steps of the geometry building and the mesh
generation of the 2D finite element model of asynchronous motor.
Topic See Page

Geometry and mesh of the 2D stator slot 25
Geometry and mesh of the 2D rotor slot 33
Geometry of the motor 2D model 41
Mesh of the motor 2D model 51

Motor 2D geometry and mesh FLUX10

2.1. Geometry and mesh of the 2D stator slot
Introduction This section explains the geometry description and mesh preparation of the
2D stator slot object.
3.51
22.2
2.5
3.21
1.28
3.2
4.6
Project name The project is saved under the name 2D_STATOR_SLOT.FLU.
Topic See Page

Create geometric parameters and coordinate systems 26
Create points and basic lines 28
Create transformations 29
Create lines by propagation 30
Build faces 30
Create and assign mesh points 31

2.1.1. Create geometric parameters and coordinate systems
Goal 16 geometric parameters and 3 coordinate systems are created to describe the
geometry of the stator.
Data (1) The geometric parameters and their characteristics are presented below.
RAD2_SLOTST
DPT_SLOTST
RAD1_SLOTST
H2_SLOTST
INTER_SLOTST/2
H1_SLOTST
WID_SLOTST/2
L2_SLOTST
Geometric parameter
Name Comment Expression
ANG Angle of the stator part to design 90
TOT_LEN Total motor length 225
DIAST_OUT Outer stator diameter 240
DIAST_IN Inner stator diameter 150
LEN_IRON Motor height 15
NBR_SLOTST Number of stator slots 48
DPT_SLOTST Stator slot depth 22.2
H1_SLOTST Height of stator slot neck 1.28
H2_SLOTST Height of stator slot bottom 3.21
L2_SLOTST Length of stator slot bottom 2.3
WID_SLOTST Width of stator slot opening 3.2
RAD1_SLOTST Fillet radius of stator slot bottom 2.5
RAD2_SLOTST Radius of stator slot top 3.51
PERI_ST Inner stator perimeter Pi()* DIAST_IN
SLOTST_GAP Angle between two stator slots 360/NBR_SLOTST
Curvilinear interval between two (PERI_ST-NBR_SLOTST*WID_SLOTST)/
INTER_SLOTST
stator slots NBR_SLOTST

Data (2) The coordinate systems and their characteristics are presented below.
CENT2 SLOTST
STATOR
SLOTST
Cylindrical coordinate system defined with respect to the Global coordinate system
Origin coordinates Rotation angle
Name Comment Units
first (R) second () about Z
Coordinate system millimeter
STATOR 0 0 0
for the stator /degree
Cartesian coordinate system defined with respect to the Local coordinate system
Parent Rotation
Origin coordinates
Name Comment coord. angle
system first (X) second (Y) about Z
180*(INTER_SLOTST
Coordinate system
SLOTST STATOR DIAST_IN/2 +WID_SLOTST)/ 0
for the stator slot
(Pi()* DIAST_IN)
Cylindrical coordinate system defined with respect to the Local coordinate system
Parent Origin coordinates Rotation angle
Name Comment coord.
system
Coordinate system
CENT2_ DPT_SLOTST-
for the stator slot SLOTST 0 0
SLOTST RAD2_SLOTST
extremity

2.1.2. Create points and basic lines
Goal First, the points of the 2D stator slot are created. Then, the line segments and
arcs of the 2D stator slot are defined as shown in the figure below.
Data (1) The characteristics of the points are presented in the tables below.
Point defined by its parametric coordinates

Coordinate Local coordinates
Number
system first (R) second ()
1 DIAST_IN/2 0
STATOR 180/(Pi()*DIAST_IN)*
2 DIAST_IN/2
(INTER_SLOTST)

Number
system first (X) second (Y)
3 0 0
4 SLOTST H1_SLOTST -WID_SLOTST/2
5 H2_SLOTST -L2_SLOTST

Number
6 CENT2_ RAD2_SLOTST 0
7 SLOTST RAD2_SLOTST -90

Data (2) The characteristics of the lines are presented in the tables below.
Segment defined by starting and ending points

Number Starting point Ending point
1 2 4
2 5 7
Arc defined by its center coordinates, starting and ending points

Coordinate Starting Ending Center point coordinates
Number
system point point first second
3 STATOR 1 2 0 0
4 STATOR 2 3 0 0
Arc defined by its radius, starting and ending points

Starting Ending
Number Coordinate system Arc radius
point point
5 SLOTST RAD1_SLOTST 4 5
6 CENT2_SLOTST RAD2_SLOTST 7 6
2.1.3. Create transformations
Goal One geometric transformation is created to describe the geometry of the 2D

stator slot.
Data The characteristics of the transformation are presented in the table below.
Affine transformation with respect to a line defined by 2 points

First Second Scaling
Name Comment
point point factor
Affine transformation to
SLOTST_MIRROR 3 6 -1
build the stator slot

2.1.4. Create lines by propagation
Goal The other lines of the 2D stator slot are created by propagation from lines.
Data/Action The SLOTST_MIRROR transformation is applied once to the 6 previously

created lines.
Line created with command Propagate lines

Number Transformation Reference line Number of times
1, 2, 3, 4, 5, 6
7 12 SLOTST_MIRROR 1
(select all)
2.1.5. Build faces
Goal The face of the 2D stator slot is built using the algorithm of automatic
construction.
Action The face is automatically built.

2.1.6. Create and assign mesh points
Goal One mesh point is created and assigned to define the mesh of the 2D stator
slot.
Data The characteristics of the mesh point are presented in the table below.
Mesh point
Name Comment Unit Value Color
SLOTST Mesh point of the stator slot millimeter 1.8 Green
Action The SLOTST mesh point is assigned to the points as shown in the figure
below.


2.2. Geometry and mesh of the 2D rotor slot
Introduction This section explains the geometry description and mesh preparation of the
2D rotor slot object.
0.4 1
5.25
2.425
8.4
2.04
26.3
0.89
Project name The project is saved under the name 2D_ROTOR_SLOT.FLU.
Topic See Page

Create geometric parameters and coordinate systems 34
Create points and basic lines 36
Create lines by propagation 38
Build faces 38

2.2.1. Create geometric parameters and coordinate systems
Goal 14 geometric parameters and 4 coordinate systems are created to describe the
geometry of the rotor.
Data (1) The geometric parameters and their characteristics are presented below.
H1_SLOTROT WID_SLOTROT INTER_SLOTROT/2
H2_SLOTROT
RAD1_SLOTROT
H3_SLOTROT
RAD2_SLOTROT
DPT_SLOTROT
RAD3_SLOTROT
Geometric parameter
DIAROT Rotor diameter 149
NBR_SLOTROT Number of rotor slots 40
DPT_SLOTROT Rotor slot depth 26.3
DIASHAFT Shaft diameter 58
H1_SLOTROT Height of rotor slot opening 0.4
H2_SLOTROT Height of rotor slot top bar 5.25
H3_SLOTROT Height of rotor slot neck 8.4
RAD1_SLOTROT Radius of rotor slot top bar 2.425
RAD2_SLOTROT Radius below the neck 2.04
RAD3_SLOTROT Radius of rotor slot bottom bar 0.89
WID_SLOTROT Width of rotor slot opening 1
SLOTROT_GAP Angle between two rotor slots 360/NBR_SLOTROT
PERI_ROT Rotor perimeter Pi()*DIAROT
Curvilinear interval between two rotor (PERI_ROT-NBR_SLOTROT*
INTER_SLOTROT
slots WID_SLOTROT)/NBR_SLOTROT

Data (2) The coordinate systems and their characteristics are presented below.
SLOTROT
CENT2 SLOTROT
CENT3 SLOTROT
ROTOR
Rotation
Origin coordinates
Name Comment Units angle
Coordinate system millimeter/
ROTOR 0 0 0
for the rotor degree
Cartesian coordinate system defined with respect to the Local coordinate system
Parent Rotation
Origin coordinates
system first (X) second (Y) about Z
180*
Coordinate system (INTER_SLOTROT
SLOTROT ROTOR DIAROT/2 180
for the rotor slot + WID_SLOTROT)/
(Pi()*DIAROT)
Parent Rotation
Origin coordinates
system first (R) second () about Z
Coordinate system
CENT2_ H3_SLOTROT+
for the rotor slot SLOTROT 0 0
SLOTROT RAD2_SLOTROT
bottom beginning
Coordinate system
CENT3_ DPT_SLOTROT-
for the rotor slot SLOTROT 0 0
SLOTROT RAD3_SLOTROT
bottom extremity

2.2.2. Create points and basic lines
Goal First, the points of the 2D rotor slot are created. Then the line segments and
arcs of the 2D rotor slot are created as shown in the figure below.
Data (1) The characteristics of the points are presented in the tables below.

Number
1 DIAROT/2 0
ROTOR 180/(Pi()*DIAROT)*
2 DIAROT/2
(INTER_SLOTROT)

Number
system first (X) second (Y)
3 0 0
4 H1_SLOTROT WID_SLOTROT/2
SLOTROT

Number
CENT2_
7 RAD2_SLOTROT 90
SLOTROT

Number
8 CENT3_ RAD3_SLOTROT 0
9 SLOTROT RAD3_SLOTROT 90

Data (2) The characteristics of the lines are presented in the tables below.

1 9 7
2 6 5
3 4 2
Arc defined by its center coordinates, starting and ending points

Coordinate Starting Ending Center point coordinates
Number
system point point first second
4 ROTOR 1 2 0 0
5 ROTOR 2 3 0 0
Arc defined by its radius, starting and ending points

Starting Ending
Number Coordinate system Arc radius
point point
6 SLOTROT RAD1_SLOTROT 5 4
7 CENT2_SLOTROT RAD2_SLOTROT 7 6
8 CENT3_SLOTROT RAD3_SLOTROT 8 9
Goal One geometric transformation is created to describe the geometry of the 2D

rotor slot.
Data The characteristics of the transformation are presented in the table below.
Affine transformation with respect to a line defined by 2 points

Second Scaling
Name Comment First point
point factor
SLOTROT_ Affine transformation
8 3 -1
MIRROR to build the rotor slot

2.2.4. Create lines by propagation
Goal The other lines of the 2D rotor slot are created by propagation from lines.
Data/Action The SLOTROT_MIRROR transformation is applied once to the 8 previously

created lines.
Line created with command Propagate Lines

1, 2, 3, 4, 5, 6, 7, 8
9 16 SLOTROT_MIRROR 1
(select all)
2.2.5. Build faces
Goal The face of the 2D rotor slot is built using the algorithm of automatic
construction.
Action The face is automatically built.

Goal Two mesh points are created and assigned to define the mesh of the rotor slot.
Data The characteristics of the mesh points are presented in the table below.
Mesh point
Mesh point of the rotor
SLOTROT_INT millimeter 1.3 Cyan
slot top
Mesh point of the rotor
SLOTROT_EXT millimeter 2.8 Turquoise
slot bottom
Action (1) The SLOTROT_INT mesh point is assigned to the points as shown in the
figure below.
Action (2) The SLOTROT_EXT mesh point is assigned to the points as shown in the
figure below.


2.3. Geometry of the motor 2D model
Introduction This section shows how to build the complete geometry of the motor 2D
finite element model by importing the two previous projects into a new
project.
Project name The project is saved under the name 2D_GEO_MESH.FLU.
Topic See Page

Import into a new project 42
Create coordinate systems 42
Create symmetries 43
Create lines and faces by propagation 44
Add an infinite box 46
Create points and lines 47
Build faces 49

2.3.1. Import into a new project
Goal The two preliminary projects 2D_STATOR_SLOT.FLU and

2D_ROTOR_SLOT.FLU are imported into the new project
2D_GEO_MESH.FLU.
Result After importation, the geometry of the project looks like the figure below.
2.3.2. Create coordinate systems
Goal One coordinate system is created to describe the geometry of the 2D motor.
Data The coordinate systems and their characteristics are presented below.
2D
Name Comment Units
Coordinate system millimeter
2D 0 0 0
for the 2D motor /degree

2.3.3. Create symmetries
Goal Two symmetries are created to describe one quarter of the motor 2D
geometry.
Data The characteristics of the symmetries are presented in the tables below.
Symmetry versus X-axis

Name Geometrical aspects Physical
(automatic) Type Y offset position aspects*
SymmetryXaxis_1 Versus X-axis 0 -
Symmetry versus Y-axis

(automatic) Type X offset position aspects*
SymmetryYaxis_1 Versus Y-axis 0 -
*
Physical aspects of the symmetries are defined in the section concerning physical
description.
Goal Two geometric transformations are created to describe the geometry of the 2D
motor.
Data The characteristics of the transformations are presented in the table below.
Rotation defined by an angle and an existing pivot point

Pivot point
Coord. Rotation angle
Name Comment coordinates
system about Z
first second
SLOTST_ Rotation transformation
2D 0 0 SLOTST_GAP
ROTATION to build the 2D stator
SLOTROT_ Rotation transformation
2D 0 0 SLOTROT_GAP
ROTATION to build the 2D rotor

2.3.5. Create lines and faces by propagation
Goal The other faces / lines of the 2D motor are created by propagation from faces
/ lines.
Data/Action (1) The SLOTST_ROTATION transformation is applied 11 times to the stator

slot face.
Face created by command Propagate Faces

Number Transformation Reference face Number of times Building options
Add faces and
SLOTST_
3 13 1 11 associated linked
ROTATION
mesh generator
Data/Action (2) The SLOTROT_ROTATION transformation is applied 9 times to the rotor

slot face.
Face created by command Propagate Faces

Number Transformation Reference face Number of times Building options
Add faces and
SLOTROT_
14 22 2 9 associated linked
ROTATION
mesh generator

Data/Action (3) The SLOTST_ROTATION transformation is applied 11 times to the two

lines as shown in the figure.

269 290 SLOTST_
3, 9 11
(22 lines) ROTATION
Data/Action (4) The SLOTROT_ROTATION transformation is applied 9 times to the two

lines as shown in the figure.

291 308 SLOTROT_
16, 28 9
(18 lines) ROTATION

2.3.6. Add an infinite box
Goal In order to automatically impose the natural condition of a zero magnetic field
at infinity, the studied device is placed inside an infinite box. One quarter of
the device is modeled because of the symmetries.
Data The infinite box and its characteristics are presented below.
Infinite box of Disc type

Name
Internal radius External radius
(automatic)
InfiniteBoxDisc 1.5*DIAST_IN 2*DIAST_IN

2.3.7. Create points and lines
Goal 5 points, 10 segments and 2 arcs are created to close the 2D motor domain.
Data (1) The created points and their characteristics are presented below.

Number
291 0 0
292 DIAST_OUT/2 0
293 2D DIASHAFT/2 0
294 DIASHAFT/2 ANG
295 DIAST_OUT/2 ANG

Data (2) The created lines (the 2 air gap lines are in detail) and their characteristics are
presented below.

309 291 293
310 293 13
311 13 1
312 1 292
313 292 29
314 291 294
315 294 290
316 290 281
317 281 295
318 295 31
Arc defined by its starting, ending and center points

Number Coordinate system Starting point Ending point Center point
319 2D 293 294 291
320 2D 292 295 291

2.3.8. Build faces
Goal The face of the 2D rotor slot is built using the algorithm of automatic
construction.
Action The faces of the 2D motor are automatically built.


2.4. Mesh of the motor 2D model
Introduction This section shows how to generate the mesh of the motor 2D finite element
model.
Project name The project is saved under the name 2D_GEO_MESH.FLU.
Topic See Page

Generate the mesh 54
Create the basic 2D motor object 55

Goal 5 mesh points are created and assigned to define the mesh of the 2D motor.
Data The characteristics of the mesh points are presented in the table below.
Mesh point
CENTER Mesh point of the center point millimeter 3 Red
FRAME Mesh point of the stator frame millimeter 10 Magenta
AIRGAP Mesh point of the air gap millimeter 1.1 Yellow
SHAFT Mesh point of the rotor shaft millimeter 6.47 Magenta
INFINITE Mesh point of the infinite box millimeter 37 White
Action (1) The mesh points are assigned as follows:

the CENTER mesh point is assigned to the center point
the SHAFT mesh point is assigned to the points of the rotor shaft
the FRAME mesh point is assigned to the points of the stator frame
FRAME
CENTER SHAFT

Action (2) The AIRGAP mesh point is assigned to the points of the air gap. The points
of the air gap are selected by means of the relation that the points belong to
the air gap face.
Air gap
face
Action (3) The INFINITE mesh point is assigned to the points of the infinite box as
shown in the figure below.

2.4.2. Generate the mesh
Goal Lines and faces of the computation domain are meshed using the algorithm of
automatic mesh generator to generate the second order elements.
Result The resulting mesh and the evaluation of the mesh quality are shown in the
figures below.
Number of excellent quality elements : 96.65 %

Number of good quality elements : 2.76 %
Number of average quality elements : 0.59 %
Number of poor quality elements : 0 %
Number of abnormal elements : 0 %

2.4.3. Create the basic 2D motor object
Goal The new project to import the motor 2D geometry into the 3D project is
created as follows:
The project of 2D motor is saved under the new name.
The following imposed modifications of the 2D motor project are made:
- the removal of the mesh
- the destruction of the 2D domain infinite box
- the destruction of the 2D domain symmetries
Project name The 2D_GEO_MESH.FLU project is saved under the new name
2D_MOTOR.FLU.
Action (1) The mesh is deleted.
Action (2) The InfiniteBoxDisc infinite box, SymmetryXaxis_1 and SymmetryYaxis_1

symmetries are deleted.


FLUX 10 Motor 3D geometry, mesh and physical description
3. Motor 3D geometry, mesh and physical

description
Introduction This chapter describes the main steps of the geometry building, the mesh
generation and physical description of the 3D model of asynchronous motor.
Topic See Page

Geometry of the motor 3D model 59
Mesh of the motor 3D model 65
Physical description of the motor 3D model 71

Motor 3D geometry, mesh and physical description FLUX10

3.1. Geometry of the motor 3D model
Introduction This section shows how to build the complete geometry of the 3D motor by
importing the previous project into a new project and generate the mesh.
Project name The project is saved under the name 3D_GEO_MESH_PHYS.FLU.
Topic See Page

Import into a new project 60
Create coordinate systems 60
Create symmetries / periodicities 61
Create volumes by extrusion 62
Add an infinite box 63
Create lines 64
Build faces and volumes 64

3.1.1. Import into a new project
Goal The 2D_MOTOR.FLU project is imported into the new project

3D_GEO_MESH_PHYS.FLU.
Result After importation the geometry of the project looks like the figure below.
3.1.2. Create coordinate systems
Goal One coordinate system is created to describe the geometry of the 3D motor.
Data The coordinate system and their characteristics are presented below.
3D
Name Comment Units first second third about about about
(R) () (Z) X Y Z
Coordinate
millimeter
3D system for the 3D 0 0 0 0 0 0
/ degree
motor

3.1.3. Create symmetries / periodicities
Goal The following symmetries / periodicities are created to describe the geometry
of the 3D motor:
one symmetry plane parallel to the main XY-plane
one circular periodicity defined by the rotation angle
Data The characteristics of the symmetry / periodicity are presented in the tables
below.
Symmetry versus XY-plane

(automatic) Type Z offset position aspects*
SymmetryXYplane_1 Versus XY-plane 0 -
Rotation about Z-axis with angle of the domain

Geometrical aspects
Name Physical
Included Offset
(automatic) Type aspects*
angle angle
PeriodicityAngularZaxis about Z-axis ANG 0 -
*
Physical aspects of the symmetries / periodicities are defined in the section
concerning physical description.

Goal Two transformations are created to describe the geometry of the 3D motor.
Data The characteristics of the transformations are presented in the tables below.
Translation vector
Coord. Translation vector
Name Comment
system DX DY DZ
Translation transformation to
EXTRU 3D 0 0 LEN_IRON
build the motor volumes
Rotation defined by angles and pivot point coordinates

Pivot point
Rotation angle
Coord. coordinates
Name Comment
system about about about
1st 2nd 3rd
X Y Z
Rotation transformation
PERIODICITY which links the lateral 3D 0 0 0 0 0 ANG
surfaces
3.1.5. Create volumes by extrusion
Goal The other faces and volumes of the 3D motor are created by extrusion of
faces.
Data/Action (1) The EXTRU transformation is applied once to all the faces.
Volume created with command Extrude Faces

Number Extrusion
Number Transformation Reference face Building options
of times type
Add volumes and
1 26
1 26 EXTRU 1 Standard associated extrusion
(select all)
mesh generator

3.1.6. Add an infinite box
Goal In order to automatically impose the natural condition of a zero magnetic field
at infinity, the studied device is placed inside an infinite box. One eighth of
the infinite box is modeled because of the presence of symmetries and
periodicities.
Data The infinite box and its characteristics are presented below.
Infinite box of Z Cylinder type

Name Inner size, Outer size,
Inner radius Outer radius
(automatic) height height
InfiniteBoxCylinderZ DIAST_IN 1.5*DIAST_IN DIAST_IN 1.5*DIAST_IN

3.1.7. Create lines
Goal 3 line segments are created to close the study domain.
Data The lines and their characteristics are presented below.

935 578 580
936 286 581
937 289 585
3.1.8. Build faces and volumes
Goal The faces and volumes of the computation domain are built using the
algorithm of automatic construction.
Action The faces and volumes of the complete 3D geometry are automatically built.

3.2. Mesh of the motor 3D model
Introduction This section shows how to generate the mesh of the 3D motor.
Topic See Page

Assign mesh points 65
Create and assign mesh lines 67
Create and assign the mesh generator 68
Generate the mesh 69

3.2.1. Assign mesh points
Goal One existing mesh point is assigned to the points of the infinite box to define
the mesh of the 3D motor.
Data: reminder The characteristics of the mesh point are presented in the table below.
Mesh point
INFINITE Mesh point of the infinite box millimeter 37 White
Action The INFINITE mesh point is assigned to the points of the infinite box as
shown in the figure below.

3.2.2. Create and assign mesh lines
Goal One arithmetic mesh line is created and assigned to lines to define the mesh
of the 3D motor.
Data The characteristics of the mesh line are presented in the table below.
Arithmetic mesh line

Name Comment Number of elements Color
HEIGHT Mesh line on the height of the motor 4 Green
Action The HEIGHT mesh line is assigned to one vertical line of the motor as shown
in the figure below.

3.2.3. Create and assign the mesh generator
Goal The linked mesh generator is created and assigned to faces to define the mesh
of the 3D motor.
Data The characteristics of the mesh generator are presented in the table below.
Linked mesh generator

Name Comment Transformation
Mesh generator to link the
PERIODICITY PERIODICITY
mesh of the lateral faces
Action The PERIODICITY mesh generator is assigned to the lateral faces on the left
side of the model viewed from the center of the figure. The faces are selected
by means of the relation that the faces belong to the same surface.

3.2.4. Generate the mesh
Goal Lines, faces and volumes of the computation domain are meshed using the
algorithm of automatic mesh generator to generate the first order elements.
Then the second order elements are generated.
Result The resulting mesh is shown in the figure below.


3.3. Physical description of the motor 3D model
Introduction This section presents the definition of the physical application and physical
properties materials, regions, coils used for all the studied cases.
Topic See Page

Define the physical application 72
Create materials 73
Create and assign volume regions 73
Create geometric parameters and coordinate systems for non- 77
meshed coils
Create electric components 78
Create non-meshed coils 79
Define sensors 92

3.3.1. Define the physical application
Goal First, the physical application is defined. The required physical application is
the 3D Magneto Static application.
Data The characteristics of the application are presented in the table below.
3D Magneto Static application

Formulation model
Order of finite Order of nodal finite Coils
Formulation
element functions element functions for coefficient
model
for scalar potential vector potential
Automatic Automatic
Automatic Automatic
formulations coefficient
3.3.2. Define physical aspects of symmetries / periodicities
Goal Physical aspects of symmetries / periodicities are defined.
Data The characteristics of the symmetries / periodicities are presented in the tables
below.
Symmetry versus XY-plane

Name (automatic) Geometrical aspects Physical aspects
Tangent magnetic field,
SymmetryXYplane_1 See 3.1.3 normal electric field,
adiabatic condition
Rotation about Z-axis with angle of the domain

Name (automatic) Geometrical aspects Physical aspects
Odd (anticyclic boundary
PeriodicityAngularZaxis See 3.1.3
conditions)

3.3.3. Create materials
Goal Four materials are directly created to use in all the studied cases.
Data The characteristics of the materials are presented in the tables below.
Material
B(H) magnetic property: linear isotropic
Name Comment Initial relative permeability
ALUMINIUM Squirrel cage material 1
STEEL Rotor shaft material 100
LINEAR_IRON Stator and rotor material 4420
Material
B(H) magnetic property: isotropic analytic saturation
Initial relative Saturation
Name Comment
permeability magnetization (T)
Stator nonlinear
IRON_FEV1000 4420 2
material
3.3.4. Create and assign volume regions
Goal Eight volume regions, necessary for the physical description of the
asynchronous motor, are created and assigned to volumes.
Data The characteristics of the volume regions are presented in the table below.
Volume region
Name Comment Type Material Color
INFINITE Infinite box region Air or vacuum region - Turquoise
EXT_AIR External air region Air or vacuum region - Turquoise
Magnetic non-
STATOR Stator region LINEAR_IRON Red
conducting region
SLOTST Stator slot region Air or vacuum region - Yellow
Magnetic non-
SHAFT Shaft region STEEL White
conducting region
Magnetic non-
ROTOR Rotor region LINEAR_IRON Magenta
conducting region
Magnetic non-
SQUIRREL_CAGE Squirrel cage region ALUMINIUM Green
conducting region
AIRGAP Air gap region Air or vacuum region - Cyan

Action (1) The INFINITE volume region is assigned to the 2 volumes of the infinite box.
Action (2) The EXT_AIR volume region is assigned to the volume of the air surrounding
the motor.
Action (3) The STATOR volume region is assigned to the stator volume.

Action (4) The SLOTST volume region is assigned to the twelve stator slot volumes.
Action (5) The SHAFT volume region is assigned to the rotor shaft volume.
Action (6) The ROTOR volume region is assigned to the rotor volume.

Action (7) The SQUIRREL_CAGE volume region is assigned to the ten rotor slot
volumes.
Action (8) The AIRGAP volume region is assigned to the air gap volume.

3.3.5. Create geometric parameters and coordinate systems for non-

meshed coils
Goal Five geometric parameters and six coordinate systems are required to build
coils.
Data (1) The characteristics of the geometric parameters are presented in the table
below.
Geometric parameter
DELTA Distance between two turns of a coil 2
HW_1 Height of winding 1 of each phase 2*H2_SLOTST
HW_2 Height of winding 2 of each phase 15.5
LEN_POS Length of coil above reference base LEN_IRON+17
LEN_NEG Length of coil under reference base (TOT_LEN-LEN_IRON)+17
Data (2) The characteristics of the coordinate systems are presented in the table below.
Parent Origin coordinate Rotation angle
Name Comment coord. about about about
1st 2nd 3rd
system X Y Z
180*(INTER_SLOTST
Coord. system
+WID_SLOTST) /
PHASE1 for the first 3D 0 0 0 0 0
(Pi()*DIAST_IN) +
coil of Phase 1
4*SLOTST_GAP
Coord. system 180*(INTER_SLOTST
PHASE2 for the first 3D 0 0 0 0 0 +WID_SLOTST) /
coil of Phase 2 (Pi()*DIAST_IN)
180*(INTER_SLOTST
Coord. system
+WID_SLOTST) /
PHASE3 for the first 3D 0 0 0 0 0
(Pi()*DIAST_IN) +
coil of Phase 3
8*SLOTST_GAP
Coord. system
PHASE1B for the second PHASE1 0 0 0 0 0 180
coil of Phase 1
Coord. system
coil of Phase 2
Coord. system
coil of Phase 3

3.3.6. Create electric components
Principle The current source is modeled using a non-meshed coil. The value of the
current is fixed via an electric component (of coil conductor type) associated
to the coil.
Goal Three electric components one electric component per phase are created
for the physical description of the asynchronous motor.
Data The characteristics of the electric components (of coil conductor type) are
presented in the table below.
Stranded coil with imposed current (A)

Name Comment Value
PHASE1 Current source for the first phase 1
PHASE2 Current source for the second phase -1/2
PHASE3 Current source for the third phase -1/2

3.3.7. Create non-meshed coils
Goal 12 non-meshed coils are created for the physical description of the
asynchronous motor.
Winding: The 12 coils are distributed as follows:

reminder 2 parallel windings per phase
2 coils in series per winding
Methods to To create the coils, there are two possibilities:

build coils the first one is to directly create the coils by defining the points of the path
the second one is to execute the command file created by using the Python
command language
Python files The Python files to build the coils of the asynchronous motor are presented in
the table below.
Coil number File name
1 coil_1.py
2 coil_2.py

12 coil_12.py
Data (1) The characteristics of the non-meshed coils (Coil 1 and Coil 2) of the first
winding for Phase 1 are presented in the tables below.
Composed coil: geometric definition

Coil Coil section
Number Coord. system Path of coil Points of the path Type Wire radius
Disc with the mean
1 PHASE1 Open path see next block 1.3
fiber displaying
Disc with the mean
2 PHASE1B Open path see next block 1.3
fiber displaying
Composed coil: electrical definition

Symmetries and
Electric component Number Conductors in series
periodicities:
associated with the coil of turns or in parallel
duplication or none
PHASE1 17 in series no duplication
Composed coil: appearance

Color Visibility
Cyan Visible
Cyan Visible

Points of the The points of the path for Coil 1 / Coil 2 are presented in the table below.
path (1)
Composed coil: Points of the path

st
1 coordinate 2nd coordinate 3rd coordinate Curvature radius
DIAST_IN/2+HW_1 0 -LEN_NEG 0
DIAST_IN/2+HW_1 0 LEN_POS+9*DELTA 0
(DIAST_IN/2+HW_1)/
7.5*SLOTST_GAP LEN_POS+9*DELTA DIAST_IN/2+HW_1
COSD(7.5*SLOTST_GAP)
DIAST_IN/2+HW_1 15*SLOTST_GAP LEN_POS+9*DELTA 0
DIAST_IN/2+HW_1 15*SLOTST_GAP -LEN_NEG-9*DELTA 0
(DIAST_IN/2+HW_1)/
8*SLOTST_GAP -LEN_NEG-9*DELTA DIAST_IN/2+HW_1
COSD(7*SLOTST_GAP)
DIAST_IN/2+HW_1 SLOTST_GAP -LEN_NEG-9*DELTA 0
DIAST_IN/2+HW_1 SLOTST_GAP LEN_POS+8*DELTA 0
(DIAST_IN/2+HW_1)/
(DIAST_IN/2+HW_1)/
COSD(6*SLOTST_GAP)
(DIAST_IN/2+HW_1)/
(DIAST_IN/2+HW_1)/
COSD(5*SLOTST_GAP)
(DIAST_IN/2+HW_1)/

Data (2) The characteristics of the non-meshed coils (Coil 3 and Coil 4) of the second

Coil Coil section
Disc with the mean
fiber displaying
Disc with the mean
fiber displaying

Symmetries and
periodicities:
duplication or none

Color Visibility
Cyan Visible
Cyan Visible

path (2)

st
DIAST_IN/2+HW_2 0 -LEN_NEG 0
(DIAST_IN/2+HW_2)/
-4.5*SLOTST_GAP LEN_POS+6*DELTA DIAST_IN/2+HW_2
DIAST_IN/2+HW_2 -9*SLOTST_GAP LEN_POS+6*DELTA 0
DIAST_IN/2+HW_2 -9*SLOTST_GAP -LEN_NEG-6*DELTA 0
(DIAST_IN/2+HW_2)/
-4*SLOTST_GAP -LEN_NEG-6*DELTA DIAST_IN/2+HW_2
COSD(5*SLOTST_GAP)
(DIAST_IN/2+HW_2)/
(DIAST_IN/2+HW_2)/
COSD(6*SLOTST_GAP)
(DIAST_IN/2+HW_2)/
(DIAST_IN/2+HW_2)/
COSD(7*SLOTST_GAP)
(DIAST_IN/2+HW_2)/

Result (2) The 4 non-meshed coils (Coil 1, Coil 2, Coil 3, Coil 4) of the first phase are
represented in the figure below.

Coil Coil section
Disc with the mean
fiber displaying
Disc with the mean
fiber displaying

Symmetries and
periodicities:
duplication or none

Color Visibility
Magenta Visible
Magenta Visible

path (3)

st
DIAST_IN/2+HW_1+19 -12*SLOTST_GAP LEN_POS+3*DELTA 0
(DIAST_IN/2+HW_1+19)/
-4.5*SLOTST_GAP LEN_POS+3*DELTA DIAST_IN/2+HW_1+19
DIAST_IN/2+HW_1+19 3*SLOTST_GAP LEN_POS+3*DELTA 0
DIAST_IN/2+HW_1+19 3*SLOTST_GAP -LEN_NEG-3*DELTA 0
-4*SLOTST_GAP -LEN_NEG-3*DELTA DIAST_IN/2+HW_1+19
COSD(7*SLOTST_GAP)
DIAST_IN/2+HW_1+19 -11*SLOTST_GAP -LEN_NEG-3*DELTA 0
COSD(6*SLOTST_GAP)
DIAST_IN/2+HW_1+15 SLOTST_GAP LEN_POS+3*DELTA 0
DIAST_IN/2+HW_1+15 SLOTST_GAP -LEN_NEG-3*DELTA 0
COSD(5*SLOTST_GAP)
DIAST_IN/2+HW_1+13 0 LEN_POS+3*DELTA 0
DIAST_IN/2+HW_1 0 -LEN_NEG-3*DELTA 0

Data (4) The characteristics of the non-meshed coils (Coil 7 and Coil 8) of the second

Coil Coil section
Disc with the mean
fiber displaying
Disc with the mean
fiber displaying

Symmetries and
periodicities:
duplication or none

Color Visibility
Magenta Visible
Magenta Visible

path (4)

st nd
1 coordinate 2 coordinate 3rd coordinate Curvature radius
7.5*SLOTST_GAP LEN_POS+2*DELTA DIAST_IN/2+HW_2+13
8*SLOTST_GAP -LEN_NEG-2*DELTA DIAST_IN/2+HW_2+15
COSD(5*SLOTST_GAP)
COSD(6*SLOTST_GAP)
COSD(7*SLOTST_GAP)

Result (4) The 4 non-meshed coils (Coil 5, Coil 6, Coil 7, Coil 8) of the second phase
are represented in the figure below.

Coil Coil section
Disc with the mean
fiber displaying
Disc with the mean
fiber displaying

Symmetries and
periodicities:
duplication or none

Color Visibility
Green Visible
Green Visible

path (5)

st
COSD(7*SLOTST_GAP)
COSD(6*SLOTST_GAP)
COSD(5*SLOTST_GAP)
(DIAST_IN/2+HW_1+9)/C
OSD(4.5*SLOTST_GAP)

Data (6) The characteristics of the non-meshed coils (Coil 11 and Coil 12) of the
second winding for Phase 3 are presented in the tables below.

Coil Coil section
Disc with the mean
fiber displaying
Disc with the mean
fiber displaying

Symmetries and
periodicities:
duplication or none

Color Visibility
Green Visible
Green Visible

path (6)

st
COSD(5*SLOTST_GAP)
COSD(6*SLOTST_GAP)
COSD(7*SLOTST_GAP)

Result (6) The 4 non-meshed coils (Coil 9, Coil 10, Coil 11, Coil 12) of the third phase
are represented in the figure below.
Final result The 12 non-meshed coils are represented in the figure below.

3.3.8. Define sensors
Goal Three sensors are created to measure out quantities.
Data The characteristics of the sensors are presented in the tables below.
Predefined sensor: Magnetic energy

Computation domain
Name Comment
Type Volume region
Magnetic energy in the air Volume
ENERGY_AIR EXT_AIR, INFINITE
surrounding the motor regions
Magnetic energy in the stator Volume EXT_AIR, INFINITE,
ENERGY_TOTAL
volume regions regions STATOR, SLOTST, AIRGAP
Predefined sensor: Flux through a coil conductor

Name Comment Coil conductor
FLUX_PHASE1 Flux through phase 1 PHASE1

FLUX 10 Case 1: reference computation
4. Case 1: reference computation
Case 1 The first case is a reference computation.

This computation can be considered as a reference computation since it is
based on the experimental test record of the end windings inductance
recognized by the IEC norms. The norms do not take the rotor into account;
we need to make computations only in the regions of the stator.
To simplify the model, we use small values of current with linear
approximation for the B(H) characteristic of magnetic materials.
Project name The projects are saved under the following names:
Simulation Starting Flux project New Flux project

A Complete 3D simulation 3D_GEO_MESH_PHYS.FLU 3D_CASE1A.FLU
B Simulation in 2D conditions 3D_CASE1A.FLU 3D_CASE1B.FLU
Topic See Page

Case 1: physical properties (continued) and solving process 94
Case 1: results post-processing 97

Case 1: reference computation FLUX10
4.1. Case 1: physical properties (continued) and solving

process
Introduction This section explains how to prepare and solve 2 projects of case 1.
Topic See Page

Complete 3D simulation: Modify the physical properties 95
Define the solving scenario 95
Simulation in 2D conditions: Modify the physical properties 96

4.1.1. Complete 3D simulation: Modify the physical properties
Goal The volume regions of the rotor are modified to do not take into account the
rotor.
Data The characteristics of the modified volume regions are presented in the table
below.
Volume region
Magnetic non-
conducting region
SHAFT Shaft region Air or vacuum region - White
ROTOR Rotor region Air or vacuum region - Magenta
SQUIRREL_CAGE Squirrel cage region Air or vacuum region - Green
4.1.2. Define the solving scenario
Goal The solving scenario with one controlled geometric parameter for the rotor
height is defined for a solving process.
Data The characteristics of the solving scenario are presented in the table below.
Solving scenario
Name Comment Type
CASE1 Reference computation Multi-values
Solving scenario
Parameter control
Interval
Controlled
Lower Upper
parameter Method Values
endpoint endpoint
LEN_IRON 15 60 List of steps 30

4.1.3. Simulation in 2D conditions: Modify the physical properties
Goal The physical properties are modified as follows:

the geometric parameter corresponding to the length of the end windings is
increased
the two air volume regions surrounding the motor are deactivated
Data (1) The characteristics of the modified geometric parameter are presented in the
table below.
Geometric parameter
LEN_POS Length of coil above reference base 300
Data (2) The characteristics of the modified volume regions are presented in the table
below.
Volume region
INFINITE Infinite box region Inactive region - Turquoise
EXT_AIR External air region Inactive region - Turquoise
Magnetic non-
conducting region

4.2. Case 1: results post-processing
Introduction This section explains how to analyze the principal results of case 1.
Topic See Page

Inductance computation: main results 98
Inductance computation: additional results 99

4.2.1. Inductance computation: main results
Goal Current values of the sensors ENERGY_AIR, ENERGY_TOTAL and

FLUX_PHASE1 are getting for the iron length equal 15 mm.
Results (1) The principal results of the complete 3D simulation (3D_CASE1A.FLU) are
LEN_IRON ENERGY_AIR ENERGY_TOTAL FLUX_PHASE1

[mm] [J] [J] [Wb]
15 696 847 1398
Results (2) The principal results of the simulation in 2D conditions (3D_CASE1B.FLU)

are presented in the table below.
LEN_IRON ENERGY_TOTAL FLUX_PHASE1

[mm] [J] [Wb]
15 143 499
Cyclic The values of cyclic inductance of end windings calculated with the different
inductance of methods are presented in the table below (for details on formulas, refer to
end windings 1.3).
Cyclic inductance: (L-M)end windings

Method Formula * Value [mH]
WAIR L-M=2*4/3*WAIR/Imax2 1.86
W3D W2D L-M=2*4/3*(W3D W2D)/Imax2 1.88
3D 2D L-M=2*(3D 2D)/Imax 1.80
*
Reminder:
the coefficient 2 has been introduced to take into account the 2 extremities of the
machine
the coefficient 4/3 has been introduced to calculate cyclic inductance with the three
phases of the machine
Imax = 1 A

4.2.2. Inductance computation: additional results

FLUX_PHASE1 are getting for different iron lengths (15, 30 and 60 mm).
The results for the length l1 = 15 mm are the previous results.

[mm] [J] [J] [Wb]
15 696 847 1398
30 707 1001 1910
60 706 1286 2906


[mm] [J] [Wb]
15 143 499
30 286 998
60 573 1996
inductance of methods are presented in the table below. (For details on formulas, refer to
end windings 1.3).
Additional Additional simulations are made with different iron lengths. The results are
results presented in the table below

Value [mH]
Method Formula
l1 = 15 mm l2 = 30 mm l2 = 60 mm
WAIR L-M=2*4/3*WAIR/Imax2 1.86 1.89 1.88
W3D W2D L-M=2*4/3*(W3D W2D)/Imax2 1.88 1.91 1.90
3D 2D L-M=2*(3D 2D)/Imax 1.80 1.82 1.82
Extrapolation to 0 1.87

Graphical The results found with several lengths of iron are presented in the figure
presentation of below.
results
Comparison The results found with analytic formulas are compared with the Flux results
in the following table.
Methods Result Difference with Flux results
ALGER 1.1 mH -42 %
LISCHWITZ 2.25mH +18 %
Comments Whatever the method used, the results are close to the value 1.87 mH that
shows their precision. Moreover, the results are stable for the three lengths of
iron that confirm the hypothesis that the end winding leakage is independent
of the length of the machine.
As expected the method based on the simulation of energy in the air around
the end windings gives inferior results. But the difference is very small (0.002
to 0.05 mH) and it is difficult to distinguish the physical origin of this
difference (contribution of conductors at the extremity of the straight part to
the 3D leakage flux) from a numerical error. For this machine, this method
gives good results so that you may use it instead of the three other ones,
which need 2 resolutions. But the fact to use at least 2 methods allows to
check the values and to understand better what is computed.
Compared with the analytic values, the results are relatively close to the
LISCHWITZ formula, which is generally expected for the finite elements
methods.
The ALGER result shows that the analytic formulas give results in the same
order of magnitude but the precision is not very important.
Finally, the results show that LEN_IRON=15 is enough to have reliable
results with all the methods.

FLUX 10 Case 2: single-phased computation
5. Case 2: single-phased computation
Case 2 The second case is a single-phased computation.

This computation is focused on the self-inductivity, that is why only the first
phase is modeled.

Topic See Page


Case 2: single-phased computation FLUX10

process
Topic See Page


Goal First, the two electric components are deleted to compute the self-inductivity
of one modeled phase.
Then, the volume regions of the rotor are modified to do not take into account
the rotor.
Action (1) The non-meshed coils 5, 6, 7, 8, 9, 10, 11, 12 are deleted; then the PHASE2
and PHASE3 electric components are deleted.
Data (1): The characteristics of the electric component (of coil conductor type) are
reminder presented in the table below.

Name Comment Value
PHASE1 Current source for the first phase 1
below.
Volume region
Magnetic non-
conducting region

Goal The solving scenario with one controlled geometric parameter for the rotor
height is defined for a solving process.
Solving scenario
Name Comment Type
CASE2 Single-phased computation Multi-values
Solving scenario
Parameter control
Interval
Controlled
Lower Upper
endpoint endpoint
LEN_IRON 15 60 List of steps 30


increased
table below.
Geometric parameter
below.
Volume region
Magnetic non-
conducting region


Topic See Page



FLUX_PHASE1 are getting for the iron length equal 15 mm.

[mm] [J] [J] [Wb]
15 343 442 1132


[mm] [J] [Wb]
15 92 429
Self inductance The values of self inductance of end windings calculated with the different
of end windings methods are presented in the table below. (For details on formulas, refer to
1.3).
Self inductance: Lend windings

WAIR L=2*2*WAIR/Imax2 1.37
W3D W2D L=2*2* (W3D W2D)/Imax2 1.40
3D 2D L=2*(3D 2D)/Imax 1.41
*
Reminder:
machine
Imax = 1 A


FLUX_PHASE1 are getting for different iron lengths (15, 30 and 60 mm).
The results for the length l1 = 15 mm are the previous results.

[mm] [J] [J] [Wb]
15 343 442 1132
30 348 542 1571
60 348 732 2430


[mm] [J] [Wb]
15 92 429
30 190 859
60 381 1718
Self inductance The values of self inductance of end windings calculated with the different
of end windings methods are presented in the table below. (For details on formulas, refer to
1.3).
Self inductance: Lend windings

Value [mH]
Method Formula*
l1 = 15 mm l2 = 30 mm l2 = 60 mm
2
WAIR L=2*2*WAIR/Imax 1.37 1.39 1.39
W3D W2D L=2*2* (W3D W2D)/Imax2 1.40 1.41 1.40
3D 2D L=2*(3D 2D)/Imax 1.41 1.42 1.42
Extrapolation to 0 1.40

Graphical The evolution of results, found with several lengths of iron, are presented in
presentation of the figure below.
results
Comments From this result, we can deduce the value of the mutual inductance!
M = L-(L-M) = 1.40-1.87
M = -0.47 mH

FLUX 10 Case 3: effect of the magnetic saturation
6. Case 3: effect of the magnetic saturation
Case 3 The third case is a parametric computation taking into account the effect of
magnetic saturation.
In order to evaluate the influence of the magnetic saturation, the real B(H)
characteristic of the materials is used.
The classical definition of the inductance =L*I is not valid any more with
nonlinear materials. In this case we can use a second definition: L=d/dI.
To compute the inductance with this second definition L=/I, we need two
simulations with two different current values.

Topic See Page


Case 3: effect of the magnetic saturation FLUX10

process
Topic See Page



one I/O parameter is created to manage the parametric simulation
the stator volume region is modified to use the nonlinear material
the three current coil conductors are modified to make the supply current a
parameter
Data (1) The characteristics of the I/O parameter are presented in the table below.
Parameter controlled via a scenario

Name Comment Reference value
IMAX Value of the supply current 100 A
below.
Volume region
Magnetic non-
STATOR Stator region IRON_FEV1000 Red
conducting region
Air or vacuum
SHAFT Shaft region - White
region
Air or vacuum
ROTOR Rotor region - Magenta
region
Air or vacuum
SQUIRREL_CAGE Squirrel cage region - Green
region
Data (3) The characteristics of the modified electric components (of coil conductor
type) are presented in the table below.

Name Comment Value
PHASE1 Current source for the first phase IMAX
PHASE2 Current source for the second phase -IMAX/2
PHASE3 Current source for the third phase -IMAX/2

Goal The solving scenario with one controlled physical parameter for the supply
current and one controlled geometric parameter for the rotor height is defined
for a solving process.
Solving scenario
Name Comment Type
CASE3 Effect of magnetic saturation Multi-values
Solving scenario
Parameter control
Interval
Controlled
Lower Upper
endpoint endpoint
IMAX 30 106 List of steps 36, 100


increased
table below.
Geometric parameter
below.
Volume region
Magnetic non-
STATOR Stator region IRON_FEV1000 Red
conducting region


Introduction This section explains how to analyze the results of case 3.
Topic See Page

Compute and display isovalues of the magnetic flux density on 120
volume regions

Goal Current values of the sensor FLUX_PHASE1 are getting for 2 computation
steps 100 and 106.
IMAX [A] FLUX_PHASE1 [mWb]

100 126.902
106 132.279


100 49.196
106 51.946
Cyclic The calculated value (simulations between 100 A and 106 A) of cyclic
inductance of inductance of end windings is presented in the table below. (For details on
end windings formulas, refer to 1.3).

L-M=/I
3D 2D with = I1 I2 0.876
and I = 2*(3D(I) 2D(I))
*
Reminder:
machine

Goal Current values of the sensor FLUX_PHASE1 are getting for 2 computation
steps 30 and 36.
Results (3D) The principal results of the complete 3D simulation (3D_CASE3A.FLU) are

30 42.213
36 50.637
Results (2D) The principal results of the simulation in 2D conditions (3D_CASE3B.FLU)


30 14.958
36 17.949
Cyclic The calculated value (simulations between 30 A and 36 A) of cyclic

inductance of inductance of end windings is presented in the table below. (For details on
end windings formulas, refer to 1.3).

Method Formula Value [mH]
L-M=/I
3D 2D with = I1 I2 1.811
and I = 2*(3D(I) 2D(I))
Comments We can notice that the influence of saturation around 30 A is not perceptible,
whereas around 100 A the value of the inductance is significantly reduced.
30 A approximately corresponds to the rated current; the result is the same
with 1A and a linear material.
100 A corresponds to levels of currents in transient state, that is to say a state
where the value of end winding inductance is particularly important, the
inductance is divided by 2 compared with its value in steady state.
On the following figures, you can see the shading of the induction on the
external faces of the machine. You can evaluate the importance of saturation
regarding that the material FEV1000 saturates beyond 1 Tesla. You will note
that around Imax=30 A, there is saturation, whereas the influence on end
windings inductance is negligible.

6.2.3. Compute and display isovalues of the magnetic flux density on

volume regions
Goal First, the computation step of the physical parameterized study is selected;
then, the scalar quantities of the magnetic flux density are computed on the
selected volume regions and displayed via isovalue plots of color shadings.
Data (1) The characteristics of the computation step selection and the isovalues are
presented in the tables below.
Scenario and computation step selection

Computation step
Scenario
Parameter name Value
CASE3 IMAX 100
Isovalues on volume regions

Volume region Formula
AIRGAP
ROTOR
SHAFT
Mod(B)
SLOTST
SQUIRREL_CAGE
STATOR
Result (1) The following chart shows the magnetic flux density on the volume regions of
the motor for the current value of 100 A.

Data (2) The characteristics of the computation step selection and the isovalues are
Scenario and computation step selection

Computation step
Scenario
Parameter name Value
CASE3 IMAX 30
Isovalues on volume regions

Volume region Formula
AIRGAP
ROTOR
SHAFT
Mod(B)
SLOTST
SQUIRREL_CAGE
STATOR
Result (2) The following chart shows the magnetic flux density on the volume regions of
the motor for the current value of 30 A.


FLUX 10 Case 4: influence of the rotor
7. Case 4: influence of the rotor
Case 4 The fourth case is a computation taking into account the rotor influence.
To take the rotor influence into account, the computations are made in all the
regions of the asynchronous motor.

Topic See Page


Case 4: influence of the rotor FLUX10

process
Topic See Page

Solving scenario 125

Goal The physical properties are not modified.
Data: reminder The characteristics of the volume regions are presented in the table below.
Volume region
Magnetic non-
conducting region
Magnetic non-
conducting region
Magnetic non-
conducting region
Magnetic non-
conducting region
7.1.2. Solving scenario
Goal The default solving scenario with reference values is used to solve case 4.


increased
Modify the The characteristics of the modified geometric parameter are presented in the
geometric table below.
parameter
Geometric parameter
Modify the The characteristics of the modified volume regions are presented in the table
volume regions below.
Volume region
Magnetic non-
conducting region
Magnetic non-
conducting region
Magnetic non-
conducting region
Magnetic non-
conducting region

Topic See Page

Inductance computation 128

7.2.1. Inductance computation
Goal Current value of the sensor ENERGY_TOTAL is getting.
Results (1) The principal result of the complete 3D simulation (3D_CASE4A.FLU) is:
W3D = 13.791 mJ
Results (2) The principal result of the simulation in 2D conditions (3D_CASE4B.FLU)

is: W2D = 12.577 mJ
inductance of methods are presented in the table below. (For details on formulas, refer to
end windings the introduction of this technical paper 1.2).

Method Formula* Value [mH]
W3D W2D L-M=2*4/3* (W3D W2D)/Imax2 3.237
*
Reminder:
machine
Imax = 1 A
Comments The value is very different from the previous ones, so that we can assert that
the influence of the rotor is really important on the extremity 3D leakages.
Indeed, the presence of the rotor makes that the flux lines are canalized in the
center of the machine whereas it is not the case with air in the center.
However, we have to be careful:
The computation of energy takes the external air into account that encloses
the air above the rotor, which can be considered as rotor leakage flux even
if the rings of the squirrel cage are not modeled.
When you model the rotor, the proportion of the leakage energy in the total
energy is very less important. The magnetizing reactance becomes the
dominant reactance. That is why the uncertainty in the result is really larger
than in the previous simulations.
In computation 1, the energy corresponding to the leakage represents 705J
on 848 J of total energy, that is to say 83.1%. In the case of the entire
machine, the energy corresponding to leakage represents 1.185 mJ on
13.707 mJ of total energy that is to say only 8.6%.

FLUX 10 Inductance computed values for a Flux 2D study
8. Inductance computed values for a Flux 2D study
Introduction In a 2D simulation (Flux 2D application), the end windings and end rings
reactance are usually added in the electric circuit. Thus the end windings
inductance value calculated previously can be introduced in the circuit for a
complete 2D simulation of the machine.
An overview of the principal phases is presented in this section.
Topic See Page

Physical description 130
Electric circuit description 131

Inductance computed values for a Flux 2D study FLUX10
8.1.1. Physical description
Starting Flux The starting project is the Flux project 2D_GEO_MESH.FLU that contains:
project the geometry description of the 2D motor
the mesh of the 2D motor
Overview You have the possibility to take the end winding into account in a Flux 2D
study due to the module ELECTRIFLUX (Circuit).
The main steps of the physical description are presented in the table below.
Step Action Module

1 Define the application Geometry & Physics
2 Create materials* Geometry & Physics
3 Create and assign the surface regions* Geometry & Physics
4 Create an electric circuit Circuit
5 Import the electric circuit Geometry & Physics
Complete the definition of
6 Geometry & Physics
components of electric circuit
*
Use the same data as in Flux 3D application.

FLUX 10 Inductance computed values for a Flux 2D study
8.1.2. Electric circuit description
Introduction From the definition of the following electric circuit and of the corresponding
finite element model in the Flux 2D application you can realize a complete
study on the asynchronous machine.
Electric circuit The electric circuit is created in the ELECTRIFLUX (Circuit).

The asynchronous machine is represented in the figure below.
End winding End winding

Voltage sources Coils resistances inductances
Squirrel cage
Component Module of definition

Squirrel cage Circuit
Voltage sources Geometry & Physics
Coils Geometry & Physics
End winding resistances Circuit
End winding inductances Circuit
The characteristics of the electrical components are described in the following

blocks.
All these data can be calculated by analytic formulas with software for motor
analysis such as SPEED.
Squirrel cage The characteristics of the squirrel cage are presented in the table below.
Number of Ring resistance Ring inductance

Name Closing type
bars [] [H]
Q1 10 0.725E-6 3.7E-9 anticyclic

Inductance computed values for a Flux 2D study FLUX10
Voltage sources The characteristics of the voltage sources are presented in the table below.
Name Frequency [Hz] Magnitude [V] Phase

V1 50 110 0
V2 50 110 -120
V3 50 110 +120
Coils The coils are attached to the three corresponding surface regions.
The characteristics of the coils are presented in the table below.
Name Total resistance [] Number of turns

B1 0.18 136
B2 0.18 136
B3 0.18 136
End winding The characteristics of the end winding resistances are presented in the table
resistances below.
Name Value []
R1 0.225
R2 0.225
R3 0.225
End winding The value computed with Flux 3D is assigned to this component.
inductances The characteristics of the end winding inductances are presented in the table
below.
Name Value [H]

L1 1.73E-3
L2 1.73E-3
L3 1.73E-3

End Winding Characterization

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End Winding Characterization

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CAD Package for Electromagnetic and Thermal

Analysis using Finite Elements

Copyright - October 2009

FLUX software : COPYRIGHT CEDRAT/INPG/CNRS/EDF

This technical paper was edited on 7 October 2009

the user can

* Flux files are ready to be meshed and then solved.

END WINDING CHARACTERIZATION PAGE A

3.3. Physical description of the motor 3D model................................................................................71

PAGE B END WINDING CHARACTERIZATION

Contents This chapter contains the following topics:

Topic See Page

Bibliography Complementary information is available in the following documents:

END WINDING CHARACTERIZATION PAGE 1

PAGE 2 END WINDING CHARACTERIZATION

1.1. Overview of the sample problem

Introduction This section is an overview of the sample problem. It contains a brief

Contents This section contains the following topics:

Topic See Page

END WINDING CHARACTERIZATION PAGE 3

Continued on next page

PAGE 4 END WINDING CHARACTERIZATION

END WINDING CHARACTERIZATION PAGE 5

1.1.2. Description of the device

Studied device The device to be analyzed is a three-phase induction (asynchronous) motor.

Operating The operation of an induction motor is explained below:

Continued on next page

PAGE 6 END WINDING CHARACTERIZATION

Geometry The asynchronous motor is composed of a stator and a rotor.

Continued on next page

END WINDING CHARACTERIZATION PAGE 7

Winding The winding characteristics are presented in the table below.

Continued on next page

PAGE 8 END WINDING CHARACTERIZATION

Winding The winding is concentric with consequent poles. It is represented in the

END WINDING CHARACTERIZATION PAGE 9

1.1.3. Studied cases

Case 1 The first case is a reference computation.

Case 2 The second case is a single-phased computation.

PAGE 10 END WINDING CHARACTERIZATION

1.2. Strategies of the geometry description, mesh

Contents This section contains the following topics:

Topic See Page

END WINDING CHARACTERIZATION PAGE 11

1.2.1. Main phases for geometry description and mesh generation of

2D motor An outline of the 2D geometry building and mesh generation is presented in

The geometry description and

The geometry description and

Importation of the stator slot

Creation of symmetries to X-axis symmetry

6 Creation of infinite box

Creation of mesh tools,

Continued on next page

PAGE 12 END WINDING CHARACTERIZATION

3D motor An outline of the 3D geometry building and mesh generation is presented in

Importation of the 2D motor

Creation of one symmetry XY-plane symmetry

Creation of faces and

4 Creation of infinite box

5 Faces and volumes building

Creation of mesh tools,

END WINDING CHARACTERIZATION PAGE 13

1.2.2. Main phases for physical description of the motor

3D motor An outline of the physical description process of the 3D motor is presented in