Category Archive: E-Motor Design & Simulation

Prestressed Modal Analysis of a Rotor Assembly, E-Motor

Intro This is a short case on prestress effects for a modal analysis of a rotor. For simplification rotor assembly includes only rotor core and shaft. This example serves the purpose to demonstrate… Continue reading


Interference fit method is commonly used on electrical machines for the assembly of rotor core and shaft. Proper selection of clearance values is of vital importance for the rotor dynamic stability. There are… Continue reading

Interference Fit, Rotor Core and Shaft

Intereference fit, rotor core & shaft As it is already noted in previous posts, the rotor core is interference fitted to the shaft. This radial interference fit value is optimized in order to… Continue reading

Simulation of Rotor Core and Shaft Assembly of e-Motor

Intro Below is an example of a rotor assembly that is going to be used for the analysis.     On the following picture is a symmetric model. At the end of the… Continue reading

Stress Concentrations on Shafts

Any abrupt change in parts can capture internal stresses and cause stress concentrations. Examples of these changes are the following: grooves holes notches shoulders keyseats threads splines   The stress concentrations are localized… Continue reading

Shaft Loads & Design Criteria, e-Motor

Overview Shaft material and optimum design are important for the efficient and trouble-free operation of an e-motor. Figure below illustrates an example of shaft for e-motor. A keyed shaft for e-motor applications  … Continue reading

Into on Rotordynamic Phenomena of Rotors, e-Motors

A summary on the basic simulations to be performed are:   steady state siimulations transient simulations   Rotordynamic analysis has the following main parameters: rotating speed bearings mass distribution rotor inertia motor mounting… Continue reading

Strength Analysis of Rotor

Rotor design is a complex task which includes input from a series of analyses such as static, dynamics, electromagnetic, thermal analysis. One important factor that should be mentioned here is the aspect ratio:… Continue reading

Lamination Sheets

As noted on previous post, rotor and stator core consists of thin lamination sheets. These lamination sheets are packed together to form the stator/rotor lamination package. The rotor lamination package is then interference… Continue reading

Permanent Magnet Motor

Intro Permanent magnets are attached to the rotor in place of rotor windings to generate magnetic field. PM motors are limited to lower power motors, usually less than 50KW. In general, permanent magnets… Continue reading

Rotor Balancing, e-Motor

When a rotor has been manufactured and assembled, balancing test can be initiated. Balancing includes static and dynamic balancing. Balancing is important so various small irregularities can be minimized such as wrong manufacturing… Continue reading

Assembly Process of Rotor, Electric Motor

Intro The rotor assembly is formed when a shaft is interference fitted into a rotor core. The fitting characteristics are very important for reliable operation of motor and for secure transmission of torque.… Continue reading

Robustness and Durability simulation, e-Motor

Objective: Robustness & Durability Loads: Interference fit, bolt preload, PSD and sine sweep vibration profiles, etc. Solution type: Modal Analysis, Harmonic response Random vibration Fatigue Modeling aspects: Full e motor (~ 35 parts)… Continue reading

Protected: Random Vibration Fatigue Optimization, e-Motor

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Random Vibration Fatigue Simulation, e-Motor

Objective: Random Vibration Fatigue Damage and Life factor estimation Developed new methodology for prestress effects in structural dynamics Reduced simulation run time of large models with parallel computation techniques

Random Vibration, e-Motor

Objective: Random Vibration Modeling aspects: Full e motor (~ 35 parts) ~ 30 million dofs Test specifications of random vibration are simulated before physical test in order to develop design in early development… Continue reading

Harmonic Response, e-Motor

Objective : Harmonic response Modeling aspects: Full e motor (~ 35 parts) ~ 30 million dofs Results of unit loading harmonic response in three directions where used in subsequent solution steps of robustness… Continue reading

Modal Analysis, e-Motor ( e-Axle+GB)

Objective: Modal Analysis Modeling aspects: Full e motor (~ 35 parts) ~ 30 million dofs Modal analysis simulation as first step of random vibration fatigue studies Modal quantities used in subsequent steps

System, eAxle incl GB, Verification & Validation of Simulation Models

Optimization of Feather Key Design, Rotor of e-Motor