Tech Briefs Magazine - June 2021 - 18

Simulating Electric Vehicle Motors
Figure 1. Schematic of the MEB, with the optional all-wheel drive (left, front of the vehicle) and the main drive (right, rear of the vehicle).
operation. However, evaluating the
strength of rotor laminations is timeconsuming.
VW Kassel is automating
this test process for rotors, as well as re -
ducing development costs and in -
creasing product quality, by building
simulation applications with COMSOL
Multiphysics®
software.
Balancing Electromagnetic
and Mechanical
Requirements
In 2015, Volkswagen began developing
a modular system - called the
Modular Electrification Toolkit (MEB)
- to optimize EV design and make the
manufacturing process more efficient.
The MEB accounts for the torque,
power, and speed for the main rearwheel
drive and for the optional frontwheel
drive used in all-wheel drive versions
(Figure 1).
Among other requirements - such
R
Rotorblech
Magnet
Rotorwelle
M
R
Figure 2. A typical rotor setup with the rotor
plates, shaft, and magnet.
18
Cov
as the ratios for the axles, drive units,
weight, and wheelbases - the design
and placement of the high-voltage
drive battery plays a major role in the
overall MEB concept. While the MEB
helps to optimize individual components
and the system as a whole, balancing
these requirements takes careful
consideration on the part of the
designer, especially when accounting
for new technologies like digitalizawww.techbriefs.com
ToC
tion,
autonomous driving, and electric
drives.
From the very beginning of the
electric drive development process,
there has been close cooperation
among staff involved in design, simulation,
and testing at VW Kassel. First,
the simulation experts review the
perfor mance specifications for an
electric drive and use simulation to
investigate how to best approach the
design. For example, modeling the
drive greatly reduces the number of
variants and distributing a simulation
application based on this model
enables the designers to then benchmark
different variants and choose
the best one.
This collaboration is vital and beneficial
to all, as simulation cannot cov -
er all of the real-world issues. Hence,
the test process plays an important
role in the development process. In
addition, the experimental test procedure
helps to improve the simulation
models.
" In the development process of
electrical machines, one has to fulfill
many requirements, " explained Dr.
Steffen Rothe, simulation engineer of
component development at VW Kas -
sel. " On one hand, the machine has to
match electrical requirements for the
torque and power. On the other hand,
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Tech Briefs Magazine - June 2021

Table of Contents for the Digital Edition of Tech Briefs Magazine - June 2021

Tech Briefs Magazine - June 2021 - Intro
Tech Briefs Magazine - June 2021 - Sponsor
Tech Briefs Magazine - June 2021 - Band1
Tech Briefs Magazine - June 2021 - Band2
Tech Briefs Magazine - June 2021 - Cov1
Tech Briefs Magazine - June 2021 - Cov2
Tech Briefs Magazine - June 2021 - 1
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Tech Briefs Magazine - June 2021 - Cov3
Tech Briefs Magazine - June 2021 - Cov4
Tech Briefs Magazine - June 2021 - MD-Cov1
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Tech Briefs Magazine - June 2021 - ST-Cov1
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Tech Briefs Magazine - June 2021 - ST-1
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