2011 Altair Optimization Contest

- Battery Tray Design

- Induction Motor

CAE
Member 1 : (Graduate)

Member 2 : (Undergraduate)
Advisor : Prof.



1.
- Battery Tray
- ( Modeling, Analysis Setting, Mesh Information, FRF Solution
Condition, Modal Method, Result )
- ( Problem Formulation, Optimization Process, Optimization
Result )
- ( , Result, Conclusion)
2.
- Background( Induction Motor Housing )
- Induction Motor Housing
- ( Modeling, Analysis Setting, Mesh Information, FRF Solution
Condition, Modal Method, Result )
- ( Problem Formulation, Optimization Process, Optimization
Result )
- ( , Result, Conclusion)

Hyper Optistruct FRF Magnitude

Battery Tray Design

Engine running Battery

Rib Battery Tray

Induction Motor

Motor running Housing

Topology Optimization Housing

1.
Battery Tray Design
By Topology Optimization

1.1 Battery Tray

Tray Rib
Engine running Battery
Rib Battery Tray

Battery Tray Rib Embossing
11 %, 0.644 %

Meshing

Solve/Opt

Rib 1

Rib /

11.7.4

11.7.11

11.7.18

11.7.25

1.2 Modeling
Modeling
ISO View

Front View

Bottom View

Right View

1.3 Analysis Setting

Material Property
STEEL

Young's Modulus (N/mm^2)

Poisson Ratio

Density (N-s2/mm^4)

2.1E+10^5

0.3

7.8E-10^9

Sheet Metal Thickness

- Thickness : 2 mm
Boundary Condition & Loading Condition
Loading Condition

Boundary Condition
Constraint
Fixed 123456

Force : 50 N

1.4 Mesh Information

Mesh
- : 5 mm
ISO View

Mesh

Front View

Bottom View

Mesh Quality

Right View

1.5 FRF(Modal Method) Solution Condition

- FRF(Frequency Response Function)
- Modal method(Lanczos) : Eigen Value Range(EIGRL) 0 ~ 3,000 Hz
- Result Range : 0 ~1,000 Hz 21 step(50 Hz )
- Structure Damping Coefficient : 0.05
- Output : Displacement Magnitude
FRF Displacement Output Location
- FRF Displacement magnitude
Battery Tray
(FRF Displacement)
Node 5871

< >

1.6 Modal Method

Mode
Mode Frequency(Hz)
1
3.47E+01
2
6.46E+01
3
9.01E+01
4
1.44E+02
5
1.96E+02
6
1.99E+02
7
2.04E+02
8
2.09E+02
9
2.26E+02
50
9.28E+02
51
9.36E+02
52
9.49E+02
53
9.70E+02
54
9.88E+02
55
9.97E+02
56
1.03E+03

Eigenvalue
4.75E+04
1.65E+05
3.21E+05
8.14E+05
1.51E+06
1.56E+06
1.64E+06
1.72E+06
2.01E+06
3.40E+07
3.46E+07
3.55E+07
3.71E+07
3.86E+07
3.92E+07
4.21E+07

1.7 Result
Node 5871() Displacement Magnitude

X, Y, Z Z

< X, Y, Z Displacement >

Z
0 Hz : 0.278 mm > 0.25 mm
200 Hz : 0.275 mm > 0.25 mm

< Z Displacement >

1.8 Problem Formulation

Optimization Problem
- :
- : 0 ~1,000 Hz FRF Displacement 0.25 mm
(Node 5871 < 0.25 mm)
- Design Area : Bottom Plate
Element Density Rib
Topology Optimization
Design Area & Mesh Information
Non-Design Area

Design Area

/
Mesh

Mesh

1.9 Optimization Process

Iteration
- 14

Iteration 1

Iteration 3
Iteration 5

Iteration 14

Iteration 9

1.10 Optimization Result

Topology Iteration Result
Node 5871()
(Hz)

(mm)

(mm)

(%)

0
200

0.278
0.275

0.249889
0.249578

10.39
9.24

Result Contour & Objective Function History

Objective Function History

Result Contour
Pattern Option
1-Pln Sym
Anchor node
- 8799
First node
- 8800

Rib : Element Density Y

1.11 - Rib
Rib
- Rib , Original Model , Mode ,

- Battery Tray Rib
Rib
- Rib Z
(Battery )
- Rib 3 mm
Battery

. Rib

1.11 - Rib

- 2 mm (Sheet metal working)

Deep drawing
(Shearing)

Embossing

Rib
- Rib
(Embossing) :

< Embossing >

1.12 - Rib Modeling

Rib
- : 2 mm, : 3 mm

: 3 mm
: 2 mm

Modeling

< Rib Modeling >

< Rib Modeling >

1.13 - Analysis Setting

Material
STEEL

Young's Modulus (N/mm^2)

Poisson Ratio

Density (N-s2/mm^4)

2.1E+10^5

0.3

7.8E-10^9

Sheet Metal Thickness

- Thickness : 2 mm
Boundary Condition & Loading Condition
Loading Condition

Boundary Condition
Constraint
Fixed 123456

Force : 50 N

1.14 - Mesh Information

Mesh
- : 5 mm
- Rib : 4 mm

< Add Rib Model Mesh >

Mesh Quality
-

< Add Rib Mesh >

1.15 - Result
Mode
-
Mode Frequency(Hz)
1
3.47E+01
2
6.46E+01
3
9.01E+01
4
1.44E+02
5
1.96E+02
6
1.99E+02
7
2.04E+02
8
2.09E+02
9
2.26E+02
49
9.10E+02
50
9.28E+02
51
9.36E+02
52
9.49E+02
53
9.70E+02
54
9.88E+02

Eigenvalue
4.75E+04
1.65E+05
3.21E+05
8.14E+05
1.51E+06
1.56E+06
1.64E+06
1.72E+06
2.01E+06
3.27E+07
3.40E+07
3.46E+07
3.55E+07
3.71E+07
3.86E+07

< Mode >

Mode
1
2
3
4
5
6
7
8
9
49
50
51
52
53
54

Frequency(Hz) Eigenvalue
3.57E+01
5.03E+04
6.57E+01
1.70E+05
9.05E+01
3.23E+05
1.46E+02
8.38E+05
1.98E+02
1.55E+06
2.01E+02
1.59E+06
2.06E+02
1.67E+06
2.13E+02
1.79E+06
2.24E+02
1.98E+06
9.12E+02
3.28E+07
9.28E+02
3.40E+07
9.37E+02
3.47E+07
9.50E+02
3.56E+07
9.73E+02
3.74E+07
9.90E+02
3.87E+07
< Mode >

1.15 - Result
Result
- Node 5871() Displacement
Z
0 Hz : 0.2498 mm < 0.25 mm
200 Hz : 0.2495 mm < 0.25 mm

< Topology Result(Z ) >

Topology Rib

Z
0 Hz : 0.2477 mm < 0.25 mm
200 Hz : mm 0.2435 < 0.25 mm

< Rib Result(Z ) >

1.16 Conclusion
Comparison
Model

Model

Model

Rib
0 Hz : 11.2 %
200 Hz : 11.4 %

Displacement
(mm)
0 Hz : 0.278875
0 Hz : 0.249889
200 Hz : 0.274999 200 Hz : 0.249578
Mass (kg)

3.913

0 Hz : 0.247734
200 Hz : 0.24354
3.939

Rib
0.664 %

Conclusion
- 0.664 %, FRF Displacement magnitude
Engine running Battery Tray

2.
Induction Motor Housing
By Topology Optimization

2.1 Background

- Topology Optimization
4
Housing
< 4 >

< >

2.1 Background
3-Phase Induction Motor
(Stator)
- :
- ( )
(Coils)
-

< >

(Rotor)
-

< >

3-Phase Induction Motor

- (Stator) (Rotor)
- ,
Induction Motor
-
-

2.2 Induction Motor Housing

Motor Rpm Housing Displacement

magnitude Mass
Motor running Housing
Topology Optimization Housing

Topology Optimization Motor Housing Pattern
Housing
mm, kg, Pattern

Meshing
11.7.15

Solve/Opt
11.7.22

Opt 1
11.7.29

Opt /
11.8.4

2.3 Modeling
Model
- 3 6 36 Slots Induction Motor
3Phase Induction Motor

< >

Stator
Bars

Rotor
Coils
Housing

< >

2.3 Modeling
Model
Housing

- Outer Diameter : 210 mm

- Inner Diameter : 177 mm
- Length : 180 mm

Stator

- Outer Diameter : 177 mm

- Inner Diameter : 117 mm
- Length : 100 mm

Stator
Slots

Hs0 : 1 mm
Hs2 : 13 mm
Bs0 : 2 mm
Bs1 : 5.58 mm
Bs 2 : 9 mm

2.3 Modeling
Model
- Outer Diameter : 115 mm
- Inner Diameter : 28 mm
- Length : 100 mm

Rotor

Rotor
Slots

End
Ring

Hs0 : 0.1 mm
Hs01 : 0.1 mm
Bs2 : 15 mm
Bs0 : 1 mm
Bs1 : 4 mm
Bs2 : 1 mm

- Width : 10.5 mm
- Height : 18.24 mm

2.4 Analysis Setting

- Motor (By Maxwell)
- : Motor Spec (, )
- (B-Field)
Magnetic Flux Magnetic Force

RPM
(Hz)
2,000
100

(Nm)

2,000

40

89%

- : B = B0sin(P-2FLt)
- : F = (B0^2/20){1-cos(P-2FLt)
B0 : , P : , FL : ,
:

< , , >

Magnetic Force(Normal )
- 3(6) Magnetic Force 3
Degree()
Force(N)

30 60 90 120 150

100 86 50

180

210 240 270 300 330

-50 -86 -100 -86 -50

50

86

< B-Field >

2.4 Analysis Setting

Material & Property
Young's Modulus

(kgf/mm^2)

Poisson Ratio

Density

(kg/mm^3)

STEEL

2.1E+10^4

0.3

7.8E-10^6

35Pn230
Copper
Aluminum

2.1E+10^4
1.1E+10^4
0.68E+10^4

0.3
0.35
0.36

7.6E-10^6
9.0E-10^6
2.7E-10^6

Property
Housing, Shaft,
Housing Cover,
Stator, Rotor
Coils
Rotor Bar

Boundary Condition & Loading Condition

Loading Condition

Boundary Condition
Constraint

Force

Fixed 123456

Table

2.5 Mesh Information

Mesh
- : 4 mm
2D Shell Mesh

3D Solid Mesh
elem off
- shell layers
linear solid

Mesh

Part
Mesh
< Cover L> < Housing >

< Stator >

< Coils >

< Rotor > < Bar >

< Shaft > < Cover R >

2.6 FRF(Modal Method) Solution Condition

- FRF(Frequency Response Function)
- Modal method(Lanczos) : Eigen Value Range(EIGRL) 0 ~ 5,000 Hz
- Result Range : 0 ~2,000 Hz 200 step(10 Hz )
- Structure Damping Coefficient : 0.06
- Output : Displacement Magnitude
FRF Displacement Output Location
- FRF Displacement magnitude

Motor Cover Bearing

(FRF Displacement)
Node 70777

2.7 Result
Mode
Mode Frequency(Hz)
1
1.17E+02
2
4.26E+02
3
6.45E+02
4
7.41E+02
5
1.05E+03
6
1.17E+03
7
1.25E+03
8
1.73E+03
9
2.18E+03
10
2.27E+03
11
3.12E+03
12
3.18E+03
13
4.04E+03
14
4.51E+03

Eigenvalue
5.41E+05
7.16E+06
1.64E+07
2.17E+07
4.34E+07
5.36E+07
6.15E+07
1.18E+08
1.88E+08
2.04E+08
3.84E+08
3.99E+08
6.46E+08
8.03E+08

2.7 Result
Node 70777() Displacement Magnitude

X, Y, Z

< X, Y, Z Displacement >

(X,Y)

X
430 Hz : 0.0586 mm
Y
120 Hz : 0.021 mm
X
< X Displacement >

2.7 Result
Motor Displacement Magnitude

430 Hz : 0.0586 mm
1050 Hz : 0.0150 mm
1730 Hz : 0.0209 mm

< 430 Hz : ALL >

< 1050 Hz : ALL >

< 1730 Hz : ALL >

< 430 Hz : Cover >

< 1050 Hz : Cover >

< 1730 Hz : Cover >

- (100 Hz) 430 Hz
Fk2 = {R/P(1-s) 2}FL = {36/6(1-0.05)-2} X 100 = 430 Hz
430 Hz X

2.8 Problem Formulation

Optimization Problem
- :
- : 0 ~2,000 Hz FRF Displacement 0.035 mm
(Node 70777 < 0.035 mm)
- Design Area : Motor Housing Volume( : 8.3 mm)
Design Area & Mesh Information
Design Area

< Design Area>

Non-Design Area
Design Area
Housing

/
Mesh
Mesh

2.9 Optimization Process

Iteration
- 30

Iteration 1

Iteration 5
Iteration 10

Iteration 30

Iteration 20

2.10 Optimization Result

Topology Iteration Result

Node 70777()
(Hz)

(mm)

(mm)

(%)

430

0.0586

0.0382

34 %

Result Contour & Objective Function History

Result Contour

Objective Function History

XZ Displacement Volume

2.11 - Housing Remodeling

Modeling
- Housing

ISO View

Model

Model

Model

Top View

Bottom View

Right View

2.12 - Analysis Setting

Material & Property
Young's Modulus

(kgf/mm^2)

Poisson Ratio

Density

(kg/mm^3)

STEEL

2.1E+10^4

0.3

7.8E-10^6

35Pn230
Copper
Aluminum

2.1E+10^4
1.1E+10^4
0.68E+10^4

0.3
0.35
0.36

7.6E-10^6
9.0E-10^6
2.7E-10^6

Property
Housing, Shaft,
Housing Cover,
Stator, Rotor
Coils
Rotor Bar

Boundary Condition & Loading Condition

Loading Condition

Boundary Condition
Constraint

Force

Fixed 123456

Table

2.13 - Mesh Information

Mesh
- : 4 mm
3D Solid Mesh

Mesh

Mesh Quality
-

3D Solid Mesh - Housing

2.14 - Result
Result
- Node 70777() Displacement

X( )
430 Hz : 0.0386 mm

< Topology Result(X ) >

Topology

X( )
430 Hz : 0.0536 mm

< Housing Result(X ) >

2.15 Conclusion
Comparison
Model

Model

Model

Displacement
(mm)

Housing
430 Hz : 9.0 %
430 Hz : 0.0586

Mass (kg)

42.558

430 Hz : 0.0386

430 Hz : 0.0536

40.145

Housing
5.7 %

Conclusion
- FRF Displacement magnitude
9.0 % , 5.7%

Thank You~