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Vibro-acoustics of rotating electric machines: Prediction, Validation and Solution

par Chauvicourt, Fabien
Président du jury Bultheel, Adhemar
Promoteur Gyselinck, Johan ;Desmet, Wim
Publication Non publié, 2018-06-01

Thèse de doctorat

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Résumé :

The increase of greenhouse gas emission is commonly accepted to largely contribute to global warming, in part due to the massive use of non-renewable fossil energy sources. It is a reason why recently, beside other industrial sectors, electric mobility has been considered as the next generation for transportation systems. But the electrification of a vehicle introduces new challenges in its design since it involves different domains of expertise than the ones from Internal Combustion Engine (ICE) vehicles. In particular, Noise, Vibration and Harshness (NVH) comfort is significantly affected by powertrain changes, i.e. from ICE to electric machine. High and unpleasant acoustic noise from resonances may occur but can be addressed numerically to support decision making processes early enough in the design stages. The accurate prediction of its radiated acoustic noise then requires a thorough multi-physical understanding, from the system-level (electric machine) to the component-level (stator and rotor cores).First from a system-level point of view, two multi-physical modeling frameworks that use different model simplifications were implemented. By comparing simulated results to experimental measurements at each physical step of the modeling flow (electromagnetic, vibration, acoustic), it was shown that both models are accurate enough for pre-designing phases. It was also shown that considering only the stator core to contribute to the vibro-acoustic behavior of electric machines is a valid assumption.Second from a component-level point of view, the rotor and the stator core were investigated. The rotor influence on the complete machine structural dynamics was assessed. Beside the validated effects of different rotor topologies on the radiated noise, an analytical model was successfully developed to explain the occurrence of a particular vibration mode; whose explanation was still not offered in literature. In parallel, the stator core was studied, essentially because it is composed of hundreds of thin laminations stacked together which introduce difficulties in understanding its structural behavior. The effects of the laminations on the structural behavior of the stator core were studied numerically and experimentally as well. Two modeling guidelines were thus provided depending on the mode shape of interest and the computational resources available. The experimental studies comforted these two modeling approaches, and also permitted to highlight the importance of looking at the damping properties. Therefore it was shown that different lamination stacking techniques could affect significantly this damping.Finally the influence of the stacking technique (gluing, welding) on the structural behavior of the laminated compound motivated the implementation of an alternative solution to the mitigation of resonance phenomenon responsible for large acoustic noise. By using a skewed distribution of welding or glue lines, the technique aims at forcing laminations to vibrate with different phases which generates friction between them. The induced damping increases and then depends on the introduced asymmetry and on the mode shape considered. This innovative technique was validated experimentally and showed up to 7 times higher structural damping and 10 dB reduction in structural transfer function amplitudes.