The Reach Of A New Type ETC Motor Development

With the increasing demand of the passenger cars as well as the decreasing of the car price,the market demand of the automotive motors is great and the car makers require cheaper and lighter motors.Therefore,developing a new type of ETC(electronic throttle control)motor is critical for the survival of the engine motor business unit.ETC is a key part to control the engine working condition,there is special requirements to the PMDC motor used inside.According to the engine chamber environment,the high vibration,wide temperature range,and reliable torque output are required.The design based on experience is time consuming,is not capable of showing the fine details,and difficult to compare the long term behavior among several solutions.The computer simulation and optimization method is applied since the beginning of the development,the FEA detailed design is required in the light weight design as well as in keeping the same reliability strength,The more accurate,more reliable and faster procedure makes a great sense to the manufacturing practice.The article starts from the conceptual design for making motor light and cheap,the 3D model is built with Solidwords,then the model is introduced to the ANASYS,FEA is performed to analysis the resonance,stress distribution of the motor and the subcomponents,the “bottle neck” is defined for further optimization.Structure responding in the frequency domain under PSD(power spectral density)excision is introduced to analyze the fatigue property,with the Miner fatigue accumulation theory and Gaussian stress probability distribution,the total life of structure is worked out.Electromagnetism field is analyzed with MAG-NET which is based on Maxwell theory,the material is optimized to achieve the less weight,high output torque,less detent torque,and the de-magnetization is evaluated in the extreme temperature range.The final design achieves the reduction of cost by 23%,as well as 23% reduction of weight due to the simplified structure design.The prototype samples are made according to the design configuration,and the samples passed the electromagnetism and vibration validation,the design is a manufactural feasible solution.