INNOVATIVE SOLUTIONS FOR HIGH-POWER-DENSITY E-MOTORS FOR AEROSPACE PROPULSION

2. 1 © 2023 ANSYS, Inc. Agenda I. Introduction • History at a Glance • Ansys Capabilities and Solutions II. Ansys Solution for Electric Motor Development • Electrification Challenges • Path to High-Power Density Motors • Ansys Solution for Electric Motor Development III.Summary

3. 2 © 2023 ANSYS, Inc. History at a Glance Look back to look forward Powered flight 1903 Me 262 (First jet fighter) 1942 SR-71 (Mach 3.3) 1964 Bell X-1 (Mach 1) 1946 First commercial jet 1949 Firs commercial supersonic jet 1976 Solar powered intercontinental flight 2012 First all-electric passenger plane 2022 Structures 1970 Democratize Analysis Decarbonize Aircraft Material 2019 Fluid 2006 Electronics 2008 3D modeling 2014 Semiconductors 2017 Optics 2018 Optimization 2019 Motor-CAD 2022 Ansys Simulation Capabilities 1970 1900 1920 1940 1960 1980 2000 2020 • More electric aircraft • Full electric aircraft • Hybrid electric aircraft • Top-of-the-line tools • Training/ALH • Technical support Going green(electric)

4. 3 © 2023 ANSYS, Inc. Ansys Capabilities and Solutions Comprehensive simulation platforms for all major physics Platform Software/Systems Ansys SCADE Architect Ansys SCADE Suite Ansys SCADE Display Ansys Medini Analyze Ansys Twin Builder Semiconductors Ansys PathFinder Ansys PowerArtist Ansys RedHawk Ansys RedHawk-SC Ansys Totem Ansys Variance FX Structures Ansys Mechanical Ansys Autodyn Ansys LS-DYNA Ansys AQUA Ansys ACT Ansys nCode Optics Ansys SPEOS Ansys VRXPERIENCE Ansys Theia-RT Ansys HIM Ansys Genesis Ansys Aesthetica Electromagnetics Ansys HFSS Ansys Maxwell Ansys SI-Wave Ansys Icepak Ansys Q3D Extractor Ansys Motor-CAD Design & Additive Ansys Discovery AIM Ansys Discovery Live Ansys SpaceClaim Ansys Exasim Ansys Flex Fluids Ansys Fluent Ansys CFX Ansys Chemkin-Pro Ansys TurboGrid Ansys FENSAP-ICE Ansys BladeModeler Ansys Polyflow • Electric motor multiphysics simulation tools

5. 4 © 2023 ANSYS, Inc. High voltage system2: 28V(As is) → Over 3kV(Megawatt class) • Dielectric breakdown → Safety/Reliability • EMI/EMC → Safety/Reliability Electric motor1: 5kW/kg(Siemens) → 13kW/kg(NASA target) • High-power density/High efficiency • Fault tolerance → Safety/Reliability • Thermal management Energy storage2: 250Wh/kg(As is) → 500Wh/kg(for 150 seats) • High energy density battery pack Advanced materials • Composite material • High permeability/low loss electrical steel Structure • Lightweight/high strength Aerodynamics • Low drag design Source: 1. Z. Rahman, ARPA-E, 2019 2. Aviation Week Network, 4/30/2021 Electrification Challenges

6. 5 © 2023 ANSYS, Inc. • Interactions between different physical domains lead to conflicting performance metrics • Increasing need for multiphysics design and analysis to meet multicriteria requirements Jet Engine • 3050,000 parts • Multiple moving components Electric motor • Less than 100 parts • One moving component VS. • Electromagnetic: Torque, efficiency • Electrical: High voltage/current • Thermal: Cooling, peak/cont. ratings • Mechanical: Robustness at high speed, NVH Multiphysics problem • High Efficiency (%) • High torque/power density (kW/kg) • Reducing cost ($/kW) • Shorter development cycles Multicriteria requirements Automobile Combustion Engine • 67,000 parts • Multiple moving components Electrification Challenges Multiphysics problem & Multicriteria requirements

7. 6 © 2023 ANSYS, Inc. High-Energy Density Battery Electrochemistry Battery cell 0 Y t driving_cycle 0.00 200.00 400.00 600.00 800.00 1000.00 1200.00 1400.00 Time [s] 0.00 5.00 10.00 15.00 20.00 25.00 30.00 driving_cycle.VAL Curve Info driving_cycle.VAL TR v_ref mech_tv c_s c_b sta rt sto p d rive id le driver_hev c_in_s c_in_b start stop drive c_out_m_s c_out_m_b idle c_controller_ev 0.00 500.00 1000.00 1400.00 Time [s] 0.00 0.25 0.50 0.75 1.00 c_controller_ev.bat_soc Curve Info c_controller_ev.bat_soc TR Electrode_negative Electrode_positive Pack Battery + V Battery_voltage CONST wind_velocity C ON ST grading_angle vw a lp h a mech_tv stop idle chassis_hev1 alpha stop mech_rv mech_tv idle wheel_hev control stop mech_rv idle brake_hev free a b l_ d o l_ q o la mb d a _ p mo o me g a _ e o p _ o p h i_ e o power_o r_ so rpm c mech_rv pmsm_hev c_brake c_velo l_d l_q la mb d a _ p m o me g a _ e p p h i_ e power_m r_s rpm idle start stop a b c free plus_b minus_b pmsm_controller_hev GAIN A Battery_current BMS contactor BMS_Code S1 BMS High-Efficient Energy Conversion Power Electronics High voltage High frequency Electric Motors High efficiency High power density High power AC (High voltage/current/frequency) High power DC (High voltage/current) Safety/Reliability • EMI/EMC → Critical component malfunction • Dielectric breakdown → Catastrophic failure Electrification Challenges High voltage & High frequency

8. 7 © 2023 ANSYS, Inc. Efficiency • Lcopper: Copper loss( Current2) • Liron : Rotor/stator iron loss( flux density2, frequency2) • Lsolid : Solid loss( flux density2, frequency2) • Lmech : Mechanical loss( Speed) 𝜂 = 𝑃𝑜𝑢𝑡 𝑃𝑖𝑛 = 𝑃𝑖𝑛−𝐿𝑡𝑜𝑡𝑎𝑙 𝑃𝑖𝑛 , 𝐿𝑡𝑜𝑡𝑎𝑙 Path to High-Power Density Motors Multiphysics simulation Power • B1 : Fundamental airgap flux density • D 2L : Rotor volume • A : Electrical loading(Heat generation source) • 𝝎: Speed( Voltage, frequency) Power = Torque x Speed 𝑇𝜔 = 𝜋 2 2 𝑘𝑤1𝐵1𝐷2𝐿𝐴 𝜔 → EM design(Motor-CAD/Maxwell), Material(Granta), Optimization(OptiSlang) → EM/Structural design(Motor-CAD/Maxwell/Mechanical), Material(Granta), Optimization(OptiSlang) → Thermal design(Motor-CAD/Fluent), Optimization(OptiSlang) → Thermal design(Motor-CAD/Fluent), EMI/EMC/Dielectric(EMA3D) Heat generation: Power/efficiency decrease

9. 8 © 2023 ANSYS, Inc. Durability & NVH Simulation Electromagnetic Analysis Thermal Management Operational Performance Mapping System Integration Process Integration and Design Optimisation Concept Detailed Design & Verification Ansys Solution for Electric Motor Development End-to-end electric motor design toolchain: Concept to detailed design & Verification

10. 9 © 2023 ANSYS, Inc. 1999 THERMAL module 2013 LAB module 2014 EMAG module 2015 Full Multiphysics 2018 MECH module 2022 NVH The evolution of Motor-CAD Over 20 Years Democratizes Electric Motor Design Ansys Solution for Electric Motor Development Multiphysics concept design: Motor-CAD • Dedicated class-leading tool for electric motor design • Front-end multiphysics motor design tool • Fast, template-based Emag performance predictions • Thermal performance predictions and advanced cooling design • Mechanical rotor stress analysis and NVH predictions • Efficiency mapping and drive cycle performance analysis MOTOR-CAD NOW • Multiphysics • Wide operating range • Rapid development • System integration THEN • Single physics (Emag) • Fixed operating conditions

11. 10 © 2023 ANSYS, Inc. • Optimization via meta-model in optiSLang: - Powerful optimization algorithms and automated workflow generation - Perfect balance between accuracy and computation time - In-depth investigation of the design space - Efficient Multiphysics, multi-objective design optimization Data-driven optimization using Motor-CAD and optiSLang 10,000 designs Best designs Ansys Solution for Electric Motor Development Multiphysics/Multi-objective optimization: Motor-CAD & optiSLang optiSLang

12. 11 © 2023 ANSYS, Inc. Ansys Solution for Electric Motor Development Detailed electromagnetic analysis: Maxwell 2D/3D 10.00 15.00 Time [ms] -1.00 -0.80 -0.60 -0.40 -0.20 0.00 0.20 0.40 0.60 0.80 1.00 NodeVoltage(IVa) [kV] -150.00 -100.00 -50.00 0.00 50.00 100.00 150.00 -BranchCurrent(VIA) [A] Ansoft LLC 4_Partial_Motor_TR_PWM Phase Voltage / Current Circuit model/PWM voltage excitation Universal motor Claw pole motor Axial gap motor 3D PM eddy loss 2D/3D electromagnetics • General 2D/3D electromagnetic FEA tool - Arbitrary geometries and flux path - End-effects and axial segmentation - Various machine topologies in Maxwell(RMxprt) - Multiple types of motion • Detailed loss modeling - Eddy current - Circulating current • Circuit modeling - Circuit (e.g., power electronic switching) - Fault conditions (e.g., sudden short-circuit) Maxwell

13. 12 © 2023 ANSYS, Inc. Ansys Solution for Electric Motor Development Detailed mechanical analysis: Mechanical(Rotor sleeve design & NVH) • Rotor Sleeve design - It is crucial to retain magnets at high speeds to ensure the durability and safety of the rotor. - Ansys offers a composite material PrePost (ACP) solution, which can account for rotor stress analysis at high speed. • NVH analysis - NVH plays a crucial role in ensuring passenger comfort, crew health, safety, and maintenance in aircraft. - Ansys provides a seamless multiphysics simulation workflow to account for electric motor NVH analysis. Electric motor NVH analysis Rotor sleeve design(composite material) Mechanical

14. 13 © 2023 ANSYS, Inc. Ansys Solution for Electric Motor Development Detailed thermal analysis: Discovery & Fluent • Temperature determines the continuous and peak performance of a motor. • Rising temperature in the motor results in increased losses and decreased both torque and efficiency. • Ansys provides multi-fidelity thermal design solutions: - Motor-CAD: Concept design by LPTN - Discovery: Macro design by CHT analysis - Fluent: High-fidelity design by full FEA Fluent advanced CFD Discovery GPU accelerated CHT Motor-CAD design trade-off Fluent

15. 14 © 2023 ANSYS, Inc. Ansys Solution for Electric Motor Development System design via ROM(Reduced Order Model): Twin Builder System model in Ansys Twin Builder Electric machine ROM Electric machine FEA model • A large complex system comprises various components including electric motors. • System simulation and optimization using FEA models is computationally inefficient. • Ansys Twin Builder enables system simulation using ROMs(Reduced Order Model): - Fast design iterations - Improved accuracy - Reduced complexity - System-level optimization Twin Builder

16. 15 © 2023 ANSYS, Inc. Ansys Solution for Electric Motor Development EMI/EMC, Dielectric breakdown mitigation solution: EMA3D Cable harness shielding in EMA3D • EMI/EMC Issues: - Systems with high power and voltage levels increase the risk of EMI/EMC problems. - EMI/EMC mitigation is critical since EMI/EMC problems in electric aircraft cause interference with the aircraft’s electronic systems and can cause sensor/control malfunction. • Dielectric breakdown can lead to catastrophic motor/power electronics failure. • What EMA3D can do: - ANSYS EMA3D is a powerful tool that enables the prediction and mitigation of EMI/EMC issues and dielectric breakdown in electric aircraft. Dielectric breakdown on PCB EMA3D

17. 16 © 2023 ANSYS, Inc. Ansys Solution for Electric Motor Development Material properties: Granta • ANSYS Granta provides a comprehensive solution for managing materials information, improving the accuracy and efficiency of simulations. - Centralized material information stored in a single organized system - Consistency and accuracy in material properties across all simulations - Easy to share material data, improving collaboration • Over 4000 materials and properties including: - Mechanical, electrical, thermal, optical, chemical, environmental, and processing properties ESDU Medical Eco Additive MFG Polymers Metals Composites Aero EMAG GRANTA Cobalt iron • Higher permeability/saturation • 20~25% higher power density Magnet BH curve vs. Temp Structures Electromagnetics Fluids Granta

18. 17 © 2023 ANSYS, Inc. Summary • The design process for electric motors requires a true multiphysics solution across various disciplines. • Ansys Motor-CAD is the front-end multiphysics electric motor design tool that allows full design space exploration. • Ansys end-to-end electric motor design toolchain enables comprehensive analysis from an early design stage, leading to better electric motor designs.

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INNOVATIVE SOLUTIONS FOR HIGH-POWER-DENSITY E-MOTORS FOR AEROSPACE PROPULSION

INNOVATIVE SOLUTIONS FOR HIGH-POWER-DENSITY E-MOTORS FOR AEROSPACE PROPULSION

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INNOVATIVE SOLUTIONS FOR HIGH-POWER-DENSITY E-MOTORS FOR AEROSPACE PROPULSION