Mechanical simulation of 3D motor structure for lifting application

In this thesis work, a mechanical analysis of a permanent magnet synchronous reluctance motor SynRM2 has been presented. This work is collaboration between ABB Italy and an elevator producer company. The corresponding motor is a new generation which has high performances in terms of efficiency and low torque ripples, which make it suitable for the lifting applications. Static, fatigue, and modal analysis has been performed thorough FEM for the rotor, shaft, and the frame of the motor. The proposal rotor designed by electrical team, has been simulated and analyzed numerically Through ANSYS. Both lamination and stack of the rotor has been subjected to the centrifugal forces to calculate the corresponding stresses. Considering the fact that there is a conflict between rotor electrical performances and mechanical strength, the electromechanical optimization has to be performed to find the best compromise configuration of the rotor. The motor shaft structure has been analyzed through the FEM software, COMSOL Multiphysics. It has been simulated statically, considering the most critical load cases prepared by the customer specifications. The cabin weight and counterweight are applied through the traction belts on the shaft and it is supported by two middle and end bearings. Due to the presence of alternating loads in the lifting application, the fatigue problem has to be analyzed for the shaft and frame. The frame of the motor has been analyzed with numerical simulation through COMSOL Multiphysics. The motor frame is designed due to the application restrictions such as belts exits, the thermo-fluid dynamic criteria limitations, the customer specification, and the manufacturing cost considerations. Several modifications and reinforcements have been done simultaneously on the preliminary model to reach the optimal motor frame. Finally, the modal analysis has been investigated for the shaft and the frame according to guaranty that the natural frequencies are far enough from the actual operation frequency range of the motor. The final design of the motor has achieved the expectations of the customer and the prototypes have been manufactured based on the analysis to be delivered for the acceptance tests.