Low Frequency Electromagnetic Design Assessment

Assessment

You will be provided with a preliminary design of a synchronous generator. Your task is to improve the design using Ansys RMxprt and to carry out a magnetic design verification using Ansys Maxwell. Please see table 1 below for your allocated machine 

Table 1: Preliminary Design Allocation

Table 2: Critical Design Criteria (for the purpose of this assignment only)

Part A 

You are expected, taking into consideration the criteria of table 2, to go through several steps as you proceed from your allocated preliminary design to your final design. For each step, please use RMxprt and report your results as per the tables on pages 3 to 5. Also, for each step include in your report: (a) a concise statement of your rationale behind your design decision and the significant positive and/or negative outcome(s) of that decision and an explanation of the reasons behind the significant outcomes you observed. Your explanation should be supported by relevant equations and/or diagrams. (Please take into consideration the additional instructions on page 2 before proceeding with your design modifications).

Part B

For your final design only, use Ansys Maxwell 2D (magnetostatics) to verify the no-load magnetic data from RMxprt. Include in your report: (a) a table comparing results from RMxprt and results from Maxwell 2D (b) a flux plot representing the no-load magnetic field (c) brief comments on your results and (d) a list of three additional studies that you would recommend assuming you had access to the full version of Ansys AEDT.

Table 3: Colour code used for entries in the design tables on

Important Note: 

• You can change the rotor pole size, but not its shape. This means that you can increase or decrease the rotor size, but you have use a single scale factor for all of the following: Outer rotor diameter, Inner rotor diameter, Polar Arc Offset, Pole-Shoe Width, Pole-Shoe Height, Pole-Body Width, and Pole-Body Height. (Note the rotor axial length can be increase or decrease independently independently) 
• You can change the axial length of the stator core and the axial length of the rotor. However, you have to keep them equal. 
• It is best to arrange your inner diameter of the stator core and the outer diameter of the rotor so that the airgap length is maintained at 3.55 mm 
• The number of significant figures in the values obtained directly from RMxprt may be considered excessive. For the purpose of this assignment, please report values exactly as you get them from RMxprt. There is no need to reduce the number of SF. This can help with diagnosis if a problem is suspected.

Assessment Summary

The assessment involves improving a preliminary design of a synchronous generator using Ansys RMxprt and verifying the magnetic design using Ansys Maxwell 2D (magnetostatics). The primary goal is to optimize the generator design while adhering to specific critical design criteria.

Key Pointers to be Covered in the Assessment:

1. Design Modification using RMxprt

   • Evaluate the allocated preliminary generator design.
   • Modify design parameters such as rotor size, stator and rotor axial lengths, maintaining the airgap at 3.55 mm.
   • Record results at each step in the design tables, including rationale, outcomes, and supporting calculations/diagrams.

2. Magnetic Design Verification using Maxwell 2D

   • Verify no-load magnetic performance of the final design.
   • Compare RMxprt and Maxwell 2D results.
   • Generate flux plots to visualize the magnetic field distribution.
   • Suggest three additional studies if full Ansys AEDT were available.

3. Reporting and Analysis

   • Provide concise explanations of design decisions.
   • Discuss positive/negative outcomes and their causes.
   • Include tables, diagrams, and equations as supporting evidence.

Approach by Academic Mentor

The Academic mentor guided the student step by step to ensure a structured workflow and understanding of both the design process and simulation verification:

Step 1: Understanding the Preliminary Design and Design Criteria

• The mentor reviewed the allocated machine and critical design parameters (rotor, stator, airgap, axial lengths).
• Key focus was to understand which parameters could be adjusted (rotor size scale factor, axial lengths) and which were fixed (rotor shape).

Step 2: Using Ansys RMxprt for Design Optimization

• Stepwise modifications:
  • Adjusted rotor size using a single scale factor for all dimensions.
  • Modified stator and rotor axial lengths equally to maintain correct airgap.
• Recording results:
  • Each modification was documented in RMxprt tables.
  • Mentor guided the student to note outcomes and explain any observed changes in performance using diagrams and equations.

Step 3: Final Design Selection

• After iterative modifications, the optimized design was selected based on efficiency, flux density, and other performance indicators.
• Mentor ensured that the student provided clear rationale for each decision and highlighted the trade-offs encountered.

Step 4: Verification with Ansys Maxwell 2D

• The final design was imported into Maxwell 2D for no-load magnetic analysis.
• The mentor guided the student to:
  • Generate flux plots.
  • Compare RMxprt results with Maxwell 2D outputs.
  • Comment on any discrepancies or confirmations of the design’s magnetic performance.

Step 5: Recommendations for Further Study

• Mentor instructed the student to propose three additional studies possible with full Ansys AEDT access, such as thermal analysis, harmonic analysis, and full 3D electromagnetic simulation.

Outcome Achieved

• The student successfully optimized the synchronous generator design while maintaining critical design constraints.
• Magnetic verification confirmed the validity of the design under no-load conditions.
• Comprehensive reporting included tables, flux plots, calculations, and design rationales, demonstrating both practical and theoretical understanding.

Learning Objectives Covered

1. Apply Ansys RMxprt for synchronous generator design and optimization.
2. Verify magnetic performance using Ansys Maxwell 2D.
3. Document design modifications with rationale and evidence.
4. Interpret results and identify potential areas for further study.
5. Develop structured problem-solving and analytical skills in electrical machine design.

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