Methodology for thermal optimization of motor spindles

Heat losses in motor spindles lead to thermal loads and thus to undesired effects on the spindle performance. To minimize these effects, the development of spindles must ensure a thermally advantageous design. Nowadays, a variety of software tools exist to support the design process. In particular, simulation models based on the Finite Element Method (FEM) have become widely established. Some commercially available simulation software offer specific tools for time-efficient optimization of multi-physical tasks. This article describes a methodology for an iterative optimization of the thermal behavior of a newly developed motor spindle applying these tools. An initial spindle is modelled, parameterized and thermally advantageous modification potential is identified by means of a parameter correlation analysis. The spindle is thermally optimized by appropriate adjustments to the design. The validity of the simulation model is evaluated by comparing the simulation results with experimental data of prototype analysis. The experimental findings are used to improve the simulation model by applying a parameter optimization. Lastly, improvements that could be achieved in the scope of an exemplary design iteration applying this methodology are shown.