Romax Solutions: ELECTRIFICATION

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1 Romax Solutions: ELECTRIFICATION

2 The world is changing; the increasing demand for energy efficiency and CO 2 emission reduction has made electric drives the future of technology within the automotive sector and across other industries. Services Overview Concept design Holistic design for all performance targets of durability, efficiency, NVH and power density Innovation-Driven, Applied Research Team Continuously ensuring Romax software and services are at the forefront of modern technologies, is our team of industry-leading minds working full-time on R&D. Over half have PhDs, and they are behind hundreds of publications, dozens of patents, and decades of industry experience working with marketleading OEMs and universities, including: the University of Cambridge, Technische Universität Darmstadt, and the University of Nottingham. Collaborative research with these institutes covers high speed dynamics, thermal and fluid dynamics, and efficiency. R&D Investment (per year) > 3.5m For nearly 30 years, Romax Technology has led the world in developing methods that consider system interactions within mechanical transmissions. Now, Romax leads the world into electrification; we have applied and extended our state-ofthe-art engineering approach to electric drive systems. For the first time, the crucial interactions between the electric machine and the gearbox can be considered and analysed. Romax's electrification experts have unrivalled expertise and experience in developing complete electro-mechanical drivelines, ensuring whole system integration is done right from the start. Our software is both developed and used by our in-house experts, allowing us to offer a uniquely strong combination of cutting-edge simulation technologies and proven consultancy expertise within the field of electric drivelines. Underpinning our software and services departments is Romax s world-leading R&D team, who build partnerships and collaborations with leading OEMs and universities, including the University of Sheffield, whose Electric Machines Group hosts a facility staffed by Romax employees. Sizing and optimisation trade-off between motor and gearbox Turnkey offering Bespoke design of electric machine and gearbox System integration, accounting for all major electro-mechanical design interactions Prototyping and testing of gearboxes, electric machines, and complete electric drive systems Software Overview Specialised tool for motor and gearbox design and simulation Sizing, concept and detailed design in a smooth process flow System interactions between gearbox and motor Advanced dynamic simulation of electro-mechanical system Romax's R&D team are constantly researching new ways to further characterise the behaviour of motors, gearboxes, and their interactions, to continuously develop and improve the simulation, design and analysis of novel electric machines for the automotive and renewable industries. Specifically, their expertise ranges from stability of roller bearings in high speed machines, to motor-gearbox dynamic interactions, to thermal modelling of electric machines. Our R&D electrification team is a global network of researchers, the majority of whom are based together at Romax (HQ and Germany) and the University of Sheffield, a collaboration which began in June 2011 and which focuses on developing Romax s mechanical and electric machine capabilities across various sectors. The University of Sheffield undertakes world-renowned research on technologies for the future of electrical power engineering, with a focus on applying and commercialising their methods, across a broad range of industries. The Romax Technical R&D Centre at Sheffield has access to facilities for electric machine testing with a wide range of dynamometers and test rigs, covering: high speed, high load and NVH behaviour. Romax R&D experts underpin all of our electrification services and products. From specifying the development of new features in our software suite, to acting as system integration partners for our clients, or delivering turnkey consultancy projects for electro-mechanical design and analysis, their expertise is at the very heart of all Romax s offerings. Combined Years Industry Experience Patents Publications Collaboration with University Of Sheffield >200 >10 > "GKN Driveline has to get Right First Time TM to the required product performance, and Romax helps us achieve that." Theo Gassmann, Vice President Advanced Engineering, GKN Driveline "We use RomaxDESIGNER so that we can perform accurate simulation of these new gearbox designs, and assess the NVH performance." Volkswagen AG

3 Example R&D Projects High speed electric machine design projects including electro-magnetic and mechanical aspects, ranging from: Concept design using analytical/fea simulation Detailed design of selected machine topology Testing and validation on in-house dynamometers Electric machine assessment of high speed shaft including static and dynamic analysis in RomaxDESIGNER Electric machine design and prototyping including exhaust gas energy recovery, electric torque boost for supercharged engines, electric power-assisted steering, starter-generator for large civil turbo-fan engine Our Software Customers use our software tools across the concept design, detailed design, test correlation and troubleshooting phases to speed up product development. Romax provides the right design tools and expertise for each stage of the process, to achieve an appropriate balance of accuracy, insight and simulation speed. Analyses available are suitable for each design stage, and enable confident engineering decisions to be made for mechanical, electric and system components, and information to be provided to design departments at an early stage. Using traditional simulation methods, even when the gearbox and motor perform well in isolation, there can be issues when the two are connected together... ProtoDrive: Simulation Tool for Rapid System Architecture Selection and Concept Design: Simulation tool for fast and accurate assessment and comparison of concept designs Vary parameters e.g. level of hybridisation, operating voltage, driving behaviour, component size, gear/emotor topology and complexity, gear ratios, number of gear stages, power ratings for electric machine and energy storage components Generate efficiency maps to compare candidate efficiency and fuel/energy economy Simultaneously consider multiple optimisation targets e.g. energy economy, cost, packaging, mass, durability, NVH Minimal input data required to obtain accurate results, to support architecture decisions and initial down- Electric machine meets its design requirements Transmission meets its design requirements Combined system fails due to subsystem interactions selection Account for real world driving behaviour, using test data drive cycles Validated against customer test data, and developed during project work with leading UK partners: Robust definition of optimum architecture by varying key design parameters over many real-life drive cycles. Validation of fuel consumption results against measured data, for a mild hybrid the results were found to be within 2% of certification tests. Romax's unique software approach enables you to: Design and analyse the complete electromechanical drivetrain, including bespoke electric machines Capture electro-mechanical interactions from the start - target Right First Time TM design Efficiency maps generated using ProtoDrive for internally mounted permanent magnet motor - left - measured, right - predicted Holistically design for NVH, efficiency, durability and power density Our world-leading researchers support the development of our software suite and its unique capabilities for electro-mechanical drivelines...

4 5 Reasons to use Romax Software Consider motor dynamics and gear transmission error Complete system: electro-mechanical Design and analyse electro-mechanical drivelines as part of a complete system, rather than in isolation. Capture key electro-mechanical interactions in simulation, and continue to monitor and mitigate these interactions throughout the design process. Complete process: concept to manufacturing Multi-fidelity simulation tools analyse the complete electro-mechanical drivetrain from an early stage, providing maximum engineering insight by simulation. A comprehensive design process for electric drivetrains, optimized for performance and cost, running throughout the process from concept selection through to prototyping. Gearbox Ratios Topology Sizing - 1 Topology Sizing - 2 Vehicle Concept Layout Electric Machine Rating Topology Sizing - 1 Topology Sizing - 2 Complete solution: all design targets Results include response to... Stator radial excitation Torque ripple Combined responses Rotor imbalance Gear transmission error Holistic, multi-physics design, analysis and optimisation solution for all performance targets in dynamics, efficiency, durability, cost, mass etc., ensures that no aspect of the design is ever unknowingly compromised. Fast, accurate: no compromise Models are appropriate for each stage, according to the level of detail available and the accuracy/speed trade-off required. Analyses output are also relevant for the design stage, so that the results can be meaningful and useful, ensuring an optimum simulation speed and the maximum insight. Advanced dynamics: electro-mechanical interaction in one model A specific solution has been developed for dynamic analysis of electro-mechanical drives in response to the demands of leading OEMs: full system NVH analysis, including excitations from the motor and gearbox (crucial for capturing system interactions). Response to excitations due to torque ripple, airgap radial forces, imbalance and gearbox transmission error can all be analysed, without an external FE package. With results that correlate test data and our experience in this field, the analysis allows design for low noise from the start; NVH simulation upfront decreases time and cost spent doing NVH troubleshooting later on. Bearings Concept Housing Detailed Housing CAD Concept Design Tolerances and Sign-off Detailed Design Materials Winding 2D/3D EM FEA Thermal Final Specification Considering interactions at each stage of the design process for the electric machine and gearbox

5 Key Features by Product RomaxDESIGNER The world-leading solution for: Whole system simulation, including prediction of loads, deflections, misalignments and interactions between all components (bearings, gears, shafts, housings and FE) Durability, with accurate analysis of component life, stress, contact and fatgue Efficiency, through analysis at a component and system level for prediction of fuel consumption and CO 2 emissions Dynamics, by predicting transmission error for gear pairs and complex planetary systems, analysing gear whine and rattle analysis, and exporting MBD models for system-level, user-defined targets, which can be automated or run automatically through third party tools RomaxDESIGNER s capabilities have now been applied to the electro-mechanical world: the future of driveline simulation. Analysis of all interactions, ensuring optimum performance in efficiency, durability and NVH. Functionality includes: Full system frequency response including all major mechanical and electric components and housing stiffnesses Define or import stator and rotor geometry, combine with FE model of housing, apply static forces and torques Import motor excitation data from third party tools and define electric machine dynamic excitations Simultaneous analysis of vibration response caused by excitations from gear mesh TE, imbalance, electric machine torque ripple and radial forces These features are available in two new modules: C18-1 Electrical Machine Structural Modeller (to model the electric machine assembly within a RomaxDESIGNER CONCEPT Fast assessment and comparison of a large number of concept designs to enable architectural decisions to be made Exploration of the design space, and investigation of layout options for different speeds/ratios, and system packaging/ mass Gear ratio optimisation for design targets Initial component selection and design including gears and bearings Quick and accurate system-level analysis for assessment based on user-defined design targets, such as: System efficiency Durability analysis, including the high speed rotor shaft components of the electric machine Packaging, cost and mass requirements NVH performance Benchmarking of existing products CAD FUSION Import and automesh motor geometry from 2D and 3D CAD geometry (STEP/IGES and all major CAD packages) Automated repair and defeaturing of over-complex or poor quality models Export single components or whole gearboxes to CAD for packaging checks or to create 2D component engineering drawings Fast and accurate simulation of early stage designs, with minimal input data required to perform analysis in NVH, durability and efficiency. Romax enables the analysis and calculation of the entire system. We can carry out a simultaneous design assessment between concept and detailed design, with the opportunity to review the various specifications involved. The process is simple and easy to show. Without CONCEPT, this would be impossible. Kisung Lee, Senior Research Engineer, Hyundai WIA A fast, repeatable and reliable process to transfer 2D and 3D geometry between Romax software and CAD packages. model, and incorporate the stator into an FE housing) S06-18 Electrical Machine Dynamic Analysis (to capture system response to both gear and electrical machine excitations) Dynamic FUSION Intelligent auto creation of multibody dynamics models with appropriate degrees of freedom and optimal computational times for specific problems, which can be imported into MSC Adams, GT SUITE, Modelica and Simscape Enables driveability investigations and control system design e.g. Automated generation of multibody dynamic models from Romax models, optimised to be as simple as possible and as accurate as necessary for the task in hand. We have created a promising powertrain concept, offering high efficiency in both electric and hybrid NVH is such an important issue in the industry today because of the rise in electric motor developments anti-jerk control, response to high torque ripple at low speed and high torque driving, good driving performance, and simple transmission technology. All design and efficiency calculations, as well as modelling and simulations, and the production of complex gearboxes. We use RomaxDESIGNER so that we can perform accurate Enables export for optimisation of control parameters as well as thermal behaviour combined with associated NVH effects were done using Romax. simulation of these new Ruben König, Research Associate, Technische Universität Darmstadt gearbox designs, and assess the NVH performance. Volkswagen AG Complementing our software at all stages of the process is our team of expert electrification engineers, offering flexible consultancy services...

6 RomaxDESIGNER Launched HEV NVH E-AWD Rear Gearbox Design and Support HEV APU HEV Efficiency HEV EDU Design Assessment Our Engineering Services HEV Gearbox Efficiency Improvement EV Gearbox Durability, Efficiency and NVH EV Gearbox Concept Design Off Road ecvt Noise Troubleshooting HEV Gearbox Motor Design and Control EV Gearbox and Motor Noise, Thermal and Efficiency EV Differential Design and Analysis e-awd Bearing Analysis EV Gearbox Design EV Gearbox Design Assessment EV FDU Gear Whine Analysis PTU for HEV Hybrid Vehicle Gearbox EV NVH Troubleshooting EV Gearbox Design Process HEV Concept and Detailed Design and System Integration EV NVH at Concept Design EV Concept Selection We provide consultancy in both mechanical transmissions and electric machines to deliver bespoke designs, prototyping and testing of motors and gearboxes. We offer complete turnkey solutions for electro-mechanical drivelines, including simulation, optimisation, prototype manufacture and rig testing. Supporting the holistic and efficient optimisation of the designs of the future, we provide our customers with a better understanding of systems from the concept stage, leading to Right First Time TM development. Our flexible services can be adapted to the specific needs and timescales of our customers, and vary from building partnerships to offering expertise, experience, skills and resource to solve continuous challenges and efficiently move into the electrification market. Combining our proven expertise in mechanical engineering, our R&D electrification experts and consultants, and our market-leading software, we can provide: Concept system efficiency optimisation Detailed electric machine design Validation of dynamic performance Electric machine testing System dynamic response Electric machine prototype manufacture Motor being tested at Sheffield facility Electro-mechanical FE simulation run by Romax design team In the testing and manufacturing phases, we can support with design validation from prototype through to production in rig or vehicle: Component procurement through proven local manufacturing partners Supplier management Transmission build according to customer requirement Birth certificates for every unit Rework or upgrade of systems or sub-systems Instrumentation Operating Air Gap High Speed Dynamics Gear Noise Thermal Distortion Oil/Component Interactions Contact Mechanics Gearbox/Motor/ Vehicle Efficiency Fluid-Structural Interactions Thermal Behaviour Oil Flow/Splashing Motor Control/ Stability Motor Noise Static deflections Shock Loads Vehicle Driveability Component Stress/ Fatigue Romax consultancy services offer a complete solution for electromechanical problems, from investigation of concept designs, to prototyping or troubleshooting existing products. Read overleaf to find out how our customers have benefited from Romax s solution...

7 With the aim of delivering turnkey projects, Romax electro-mechanical analysis is integrated in the design and development process... Investigation of design targets from the start System architecture System Detailing / Sub-system Design Concept driveline dynamics Efficency analysis over a range of drive cycles System concept Driveline testing through partnerships Test-based lubrication and efficiency mapping High speed dynamometer testing of prototype electric machines NVH correlation and validation Integration to reduce size and cost Simulation of structural, dynamic, thermal Sub-system Detailing / Component Selection Sub-system Test System Test influences between the motor and gearbox Design for high efficiency and durability, and low NVH Component Detailing Component Test Design, prototype and test of high speed motors Novel, non-rare earth, machine topologies

8 Romax consulting and software support GKN Driveline to design low noise high efficiency edrive gearboxes Client: The world s leading manufacturer of automotive driveline components: 24,000 employees at 45 manufacturing facilities and three product development centres in 22 countries. Task: Develop more powerful and efficient transmissions for greener electric-driven vehicles, capitalize on new market opportunities without trade-offs in durability and dynamics. Solution: Approximately 10 year relationship with Romax, using RomaxDESIGNER software and consulting expertise for advanced modelling, simulation and analysis of geared systems. Outcome: One of the best-in-class whole system approaches for faster and more effective Right First Time designs of low noise gearboxes for hybrids and EVs; tests showed a 2% gain in overall gearbox efficiency without compromising on durability or dynamics. We re moving into a new era of hybrids and electric cars. Genuinely high-performance products demand the effective application of system know-how from concept to production, so you can find the best possible balance. To meet increasing customer expectation and faster development cycles, GKN Driveline has to get right first time to the required product performance, and Romax helps us achieve that - so we can continually improve our methodologies and products for our customers. Theo Gassmann, Vice President Advanced Engineering, GKN Driveline. Our Customers We work with many customers across a wide variety of industries, who use a combination of our software and services to find solutions to their mechanical or electro-mechanical problems. Many of our electromechanical customers face issues such as: Integrating the transmission and electric machine (which may have been designed in isolation, and performed well when tested independently) Obtaining useful, relevant and actionable information as early as possible in the development Understanding full system behaviour Troubleshooting existing issues Integrating motor and transmission departments, upskilling mechanical engineers, looking to improve processes and self-mobilizing as they move into the electric market Specific technical issues such as thermal management of high speed motors Examples of some of the applications which have been achieved through using our software and services are: Constructing a model of an existing motor design and analysing noise behaviour alongside gear and imbalance excitations ODIN Powering the electric car market through innovative integrated powertrains Client: Project for European Collaborative Project ODIN (Optimised electric Drivetrain by Integration), co-funded by the EU (FP7), consortium partners include Bosch, GKN, Renault, Fuchs, Romax, CIE Automotive, ISEA (RWTC Aachen University). Task: Reducing the cost of electric vehicles and enabling sustainable manufacturing while ensuring high performance and meeting automotive quality standards. The goal was to stimulate the EV marketplace and enable mass production in the EU of cheap, durable, high-speed vehicles. Solution: Detailed system level engineering of the electromechanical package to control key attributes of cost, efficiency and NVH by using Romax technical consulting services, CONCEPT and RomaxDESIGNER software tools throughout the design cycle. Deliverables for the period under analysis were received on time and they are all at a high level of quality and clarity. The expected outcomes will provide significant innovation in the domain of EVs and related fullyintegrated complex systems and more generally to the automotive community. FP7 (co-funder of ODIN project). Analysis of different stator designs to assess noise performance Efficiency improvements through gear redesign Efficiency optimisation of the driveline including thermal behaviour Outcome: Speeding development towards an optimal solution a significant cost reduction and an improvement in overall efficiency was achieved.

9 Romax Electrification Solutions Our powerful software, proven industry experts and cutting-edge researchers offer a complete turnkey solution for electro-mechanical drivelines, leading to better understanding of systems and resulting in holistically and efficiently optimised future products that are Right First Time TM. Romax software can design and analyse the complete electro-mechanical drivetrain, allowing full system analysis from the concept stage throughout the design process, and avoiding integration issues Unique simulation capabilities can accurately predict interactions between the gearbox and electric machine, and allow simultaneous analysis and optimisation for durability, efficiency and dynamics A single analytical model facilitates the communication of inter-disciplinary information, such as motors versus gearboxes, and electro-magnetic versus structural Such intelligent simulation leads to reduced costs, optimised design performance, better engineering decisions and shorter times to market Romax experts can provide support or deliver complete turnkey projects, allowing you to move into the electric market confidently, quickly and easily An end-to-end integrated and Right First Time TM solution, which streamlines development, saves time, reduces costs, and improves final product quality Romax Technology Limited University of Nottingham Innovation Park, Triumph Road, Nottingham NG7 2TU United Kingdom +44 (0) campaigns@romaxtech.com Follow us on Like us on Facebook RomaxTechnology Follow us on LinkedIn company/romax-technology