Imagine wasting 30% of food on your plate, every time you eat. That's pretty much what's happening with over 50% of world's electricity used to run electric motors operating at inadequate efficiencies. Abhinava Rizel is challenging this by constantly developing and optimizing electric motor technologies for higher efficiency and torque density.
Company Description
Abhinava Rizel is driven by a singular purpose to make the world energy efficient. Their Mission is to make Electric Vehicles efficient and affordable by providing leading-edge Electric Powertrain Technologies with High Efficiency at affordable costs for the Global Automotive Market.
Business Challenges
The industry demands a continuous improvement in efficiency and performance while still meeting competitive cost targets which requires engineers to extract perform every ounce of optimization with their product designs. Each electric motor design undergoes countless optimizations in its geometry and material selection which are then rigorously tested through prototypes to guarantee their effectiveness before reaching the final production stage. To be competitive in the market, it is essential to ensure that the revision cycles are kept to a bare minimum, cutting down development time and costs.
Engineering Solution
- Performed extensive design optimization using Ansys Motor-CAD to create torque-dense Motor designs containing lesser quantities of rare earth magnet, eventually lowering product costs.
- Used Ansys Motor-CAD and Ansys Fluent to accurately simulate multiple variations of thermal designs in Electric Motor housings to extract maximum possible performance.
- Created an Oil-cooled Motor design, optimized input parameters to study different flow patterns and interaction of oil with internal components in Ansys Fluent.
- Extracted Harmonic forces from Ansys Maxwell and coupled the same with Ansys Mechanical to study and optimize the NVH characteristics of Motor designs.
Benefits
- Used a platform approach to develop Electric Motor designs from 250W to 180kW peak power by scaling up or down existing designs, helping satisfy variety of customer needs without requiring significant design time.
- Achieved a 20% reduction in Torque Ripple between two generations of the same Electric Motor design by tooth shape optimization leading to smoother operation and improved controllability.
- Utilized the extensive material library in Ansys Granta Selector to iterate and assess designs without requiring repetitive material testing, hence cutting down overall design cycle time significantly.
- Improved noise characteristics of Electric Motor design by 13% by optimization of electromagnetics and mechanical design in Ansys Motor-CAD and Ansys Mechanical.
"Achieving consistent performance improvements with pinpoint accuracy while minimizing design and development time and cost has always been a key objective for us. Integrating Ansys in our workflows has helped us greatly streamline our development process with an arsenal of tools to validate almost all aspects of Motor operation before actual prototypes are tested. Throughout the process, CADFEM's support and expertise on Multiphysics simulation relevant to Motor design has significantly accelerated the implementation of Ansys in our development workflow.