The Numerical Simulation Technology Research Based On Reverse Engineering Of BSG Motor

Automobile generator is an important part of automotive electrical systems, providing energy for electrical equipment and charging the battery. With the progress of technology, to meet with people’s request of vehicle’ safety and comfort, more automobile electrical equipments are set in the car, such as signal device(horns, and all kinds of lights, etc.) radio, air conditioning, starting device and so on, thus higher performance of the motor is put forward. BSG(Belt Driven Starter Generator)generator has the advantages of high efficiency, low noise, etc, which has become one of the research focuses. In this paper, the performance test of a certain imported BSG motor is carried out at first. The reverse engineering technology is used to model the BSG motor. Then the electromagnetic analysis and thermal analysis of the motor are carried out. The overall performance of the motor is analyzed from the design method and working mechanism, providing the design theory reference for the optimization of the structure of the motor. It has important significance for the realization of the domestic product localization, the shortening of the generator development cycle, and the improvement of the technical level of the generator manufacturing. The research contents are as follows:(1)The BSG motor performance is tested, including generator starting performance, generator power performance and the generator cold thermal performance test and so on. The test result is corresponding analyzed, providing comparative validation data for simulation experiments.(2)Reverse modeling of BSG motor. Reverse engineering technology is used to reverse modeling of the main parts of BSG motor. First of all, the 3D Handyscan is used to obtain the point cloud data. The point cloud data are preprocessed by using reverse software Studio Geomagic. The three-dimensional information of the physical model of the BSG parts is converted into a high accuracy 3D digital model which can be directly processed by computer. Then the BSG motor’s reconstruction is reversed by CATIA. Finally, the reconstruction model of BSG motor with high accuracy is obtained.(3)Electromagnetic analysis of generator. By means of the finite element software Ansoft Rxmprt, the reconstruction model built by using reverse engineering is improved, and the electromagnetic analysis model is established. Electromagnetic analysis is analysised by using Maxwell module. The correctness of the simulation is verified by comparing with the experimental data. Using the Ansoft software of the Simplore module, the simulation analysis of the motor rectification system is carried out. The electromagnetic performance of the BSG motor is analyzed from the design method and the working mechanism, which provides a reference for the optimization of the structure of the motor.(4)Heat dissipation analysis of generator is carried out based on the basic theory of fluid mechanics and heat transfer theory, considering the complex distribution of fluid flow field and the diffierence temperature field in different parts. Using the finite element method, the temperature field of the motor is simulated. The temperature distribution of the internal parts of the motor is analyzed, and the temperature distribution of the stator winding with the highest temperature is obtained. By comparing with the experimental data, the calculation error is within 0.4%, which verifies the accuracy of the numerical model and the calculation method. The numerical simulation method provides a simple and efficient method for the motor temperature field analysis, which can improve the efficiency of the motor performance and promote the localization of foreign products.(5)The electrode structure was improved and optimized. Steel sleeve is provided for the bearing chamber of the end cover of the motor, Overcomes the shortcomings of the ordinary bearing sleeve easy to shake under high temperature and high load, makes the motor bearing can run stably, thereby prolonging the service life of the motor. Design a steel plate for permanent magnet. It can not only solve the problem that the magnet is fixed poor stability but also protect the magnet well. The structure of claw pole alternator is improved and optimized, and the performance is improved.Through the combination of reverse technology and traditional design technology, accelerate the localization process of mechanical products. Wide application of reverse engineering technology and numerical simulation technology is used in the automotive industry, which has important significance to the introduction of advanced technology and the digestion and absorption of foreign products, improving the manufacturing technology level of domestic generator.