High-Power Electronics Design - Ansys UK/staticassets/02... · High-Power Electronics Design ......
Transcript of High-Power Electronics Design - Ansys UK/staticassets/02... · High-Power Electronics Design ......
© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary
High-Power
Electronics Design
Leon Voss
ANSYS, Inc.
© 2010 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary
Contents
• Simplorer System Simulator
• Electrothermal Inverter Simulation
• Ansys Workbench Coupling
– Thermal Stress Simulation
– Mechanical Stress simulation
© 2010 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary
• Complex System Modelling through hybrid
simulator approach
– Multi-domain analog circuit simulator
– Digital event-based simulator
– State-graph simulator
– Block Diagram Simulator
• Interactive and Intuitive
User Interface Simplorer
Kernel
ANSYS Simplorer
Simulator Kernel
© 2010 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary
+
-
B 11A 11 C11
A 12 A 2
B 12 B 2
C12 C2
ROT2ROT1
ASMS
3~M
J
STF
M(t)
GN
D
m
STF
F(t)
GN
D
Magnetics
JA
MMF
Mechanics
L
HQ
Hydraulics, Thermal,
...
Simplorer Simulation Data Bus / Simulator Coupling Technology
Block DiagramsState-space
Models
Digital/
VHDL
JK-Flip flop with Active-low Preset and Clear
CLK
INV
CLK
CLK
J Q
QB
CLR
PST
Flip flop
K
CLK
CLK
INV
0 0 0 0 1 1 1 1 1 1X-Axis
Curve Data
ffjkcpal1.clk:TR
ffjkcpal1.j:TR
ffjkcpal1.k:TR
ffjkcpal1.clr:TR
ffjkcpal1.pst:TR
ffjkcpal1.q:TR
ffjkcpal1.qb:TR
MX1: 0.1000
PROCESS (CLK,PST,CLR)
BEGIN
IF (PST = '0') THEN
state <= '1';
ELSIF (CLR = '0') THEN
state <= '0';
ENDIF;
statetransition
AUS
SET: TSV1:=0SET: TSV2:=1SET: TSV3:=1SET: TSV4:=0
(R_LAST.I <= I_UGR)
(R_LAST.I >= I_OGR)
EIN
SET: TSV1:=1SET: TSV2:=0SET: TSV3:=0SET: TSV4:=1
State Graphs
Cxy
BuAxx
Electrical circuits
ANSYS Simplorer
Solver technologies
© 2010 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary
Kernel
Spice/PSPICE
VHDL-AMS
C/C++
Characterization
Simulink®
Maxwell transient
Multi-Body Dynamics
ANSYS Mechanical
ANSYS CFD
Maxwell Static
Q3D, HFSS
RMxprt, Pexprt
Extraction
Cosimulation
Modelling
• Simplorer System Simulator
– Advanced modelling techniques
– Model extraction from CFD, FEM, Analytic
techniques
– Co-simulation techniques to ANSYS products
and 3rd party vendors
ANSYS Simplorer
Multi-domain system simulator
© 2010 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary
• Multi-domain simulation
– Electrical supply
– Digital Control
– Mechanical / fluid
behavioural models
• Coupling to EM FEM
– Equivalent Circuit Extraction)
– Transient co-simulation
• Current work:
Extension to Multidomain model
extraction and co-simulation
plunger
limit
spring
F
F
em_force
Battery
- +
bjt1 bjt2
accumulator
Digital Control
TRIG
CTRL2
CTRL1 BS=>Q
BS=>Q
DETECT
PLUNGERI
TRIG
Solenoidmp2
pp1
75
m := 0.0066 s0 := 0.0002
gravity
v alue := 0.0066*9.8
spacer
sul := 0.0002sll_ := 0.0
Digital Electrical
Mechanical Hydraulic
Solenoid
A
orifice
75
ctrl1
ctrl2
plunger_control
ANSYS Simplorer
Example System Model
© 2010 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary
Simplorer Modelling
SPICE/PSPICE Capabilities
• Full coverage of mainstream SPICE language
– Support SPICE 3f5 & PSPICE
• Direct usage of the original SPICE text
– SPICE model can be maintained /
modified within Simplorer
© 2010 ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary
ANSYS Simplorer
Simulink®
Co-simulation
Co-simulation using
Simulink S-Function
and Simplorer kernel
Co-simulation using
RTW and C-Interface
1
2
© 2010 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary
ANSYS Simplorer
VHDL-Based Digital Simulator
• Integrated digital simulator with hybrid synchronisation
algorithm for mixed signal models
0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]
Curve Data
adc1.clk:TR
adc1.input:TR
adc1.val[0]:TR
adc1.val[1]:TR
adc1.val[2]:TR
adc1.val[3]:TR
dac1.val:TR
cntb41.q:TR
1
-2.2304
0
1
1
0
-2.5000
0000
Simplorer1Digital Plot5 ANSOFT
MX1: 3.4988
0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]
-4.00
-2.00
0.00
-1.60
-0.60
1.00
5.00
9.00
0.00 0.01 0.10 1.0010.00100.00
Curve Info
AM1.ITR
AM2.ITR
SIMPARAM1.IterationsTR
SIMPARAM1.StepsizeTR
Simplorer1XY Plot 4 ANSOFT
© 2010 ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary
ANSYS Simplorer
FEM Co-simulation for HEV
270.00 275.00 280.00 285.00 290.00 295.00 300.00Time [ms]
-375.00
-175.00
25.00
225.00
375.00
Y1 [rp
m]
-40.00
-20.00
0.00
20.00
40.00
I_m
eas.I_B
Ansoft LLC 05_UMR_RMxprt_SMLMotor Currents
270.00 275.00 280.00 285.00 290.00 295.00 300.00Time [ms]
1400.00
1450.00
1500.00
1550.00
Y1 [rp
m]
-10.00
2.50
15.00
27.50
40.00
50.00
FM
_R
OT
1.T
OR
QU
E [N
ew
tonM
ete
r]
Ansoft LLC 05_UMR_RMxprt_SMLMotor Torque and Rotor Velocities
Study of Interaction of Power electronics and Electromechnical system
© 2010 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary
Electrothermal System Simulation
Available Technologies
• Necessary techologies available for efficient electrothermal
inverter simulation at the system level
• CFD for heat flow simulation
• Model Order Reduction
• Efficient state-space model in the system simulation
• Electrothermal model of power electronics
• Effective representation of remaining system components
Thermal Domain
Electrical Domain MechanicalDomain
0
R1 R2 R3
MASS_ROT1
DR1
SINE2
SINE1
A
A
A
IN_A
IN_B
IN_C
OUT_A
OUT_B
OUT_C
I_motSimplorer4
A
B
C
N
ROT1
ROT2
Induction_Motor_20kW
Q
Ambient
P1
P2
P3
P4
P5
P6
P7
P8 P
9
P1
0
P1
1
P1
2
P_
RE
F
z_um z_vm z_wm
z_wpz_vpz_up
+
V
VM311 R6 R5 R4
E1
RZM
DR1
RZM
0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]
-500.00
-250.00
0.00
250.00
500.00
Y1 [
V]
Curve Info rms
R1.VTR 230.9405
R4.VTR 313.3812
0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]
1475.00
1485.00
1495.00
1500.00
MA
SS
_R
OT
1.O
ME
GA
[rp
m]
0.00
50.00
100.00
150.00
180.00
MA
SS
_R
OT
1.P
HI
[deg]
Curve Info
MASS_ROT1.OMEGATR
MASS_ROT1.PHITR
© 2010 ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary
Physics &
Geometry
Heat-Flow
Simulation
Reduced-order
State-spaceCFD MOR
Electrothermal Simulation with IGBTs:
From ANSYS Workbench to System Level in ANSYS Simplorer
Thermal Domain
Electrical Domain MechanicalDomain
0
R1 R2 R3
MASS_ROT1
DR1
SINE2
SINE1
A
A
A
IN_A
IN_B
IN_C
OUT_A
OUT_B
OUT_C
I_motSimplorer4
A
B
C
N
ROT1
ROT2
Induction_Motor_20kW
Q
Ambient
P1
P2
P3
P4
P5
P6
P7
P8 P
9
P1
0
P1
1
P1
2
P_
RE
F
z_um z_vm z_wm
z_wpz_vpz_up
+
V
VM311 R6 R5 R4
E1
RZM
DR1
RZM
0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]
-500.00
-250.00
0.00
250.00
500.00
Y1 [
V]
Curve Info rms
R1.VTR 230.9405
R4.VTR 313.3812
0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]
1475.00
1485.00
1495.00
1500.00
MA
SS
_R
OT
1.O
ME
GA
[rp
m]
0.00
50.00
100.00
150.00
180.00
MA
SS
_R
OT
1.P
HI
[deg]
Curve Info
MASS_ROT1.OMEGATR
MASS_ROT1.PHITR
Electrothermal Simulation
Model Order Reduction - Thermal
© 2010 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary
• A thermal model is defined with 12 power “inputs” and 12
temperature “outputs”
• The convection model in ANSYS with 900.000 DoF is used
• The reduced model has 15 DoFs per input = 15*12 = 180 DoF
• The reduced model is formulated in the general state-space
form:
Cxy
BuAxx
Temperature
Power
(heat flow)
Electrothermal Simulation
Heat-Sink Model Reduction
© 2010 ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary
Sub circuit of the Basic Dynamic IGBT modelIGBT Characterisation
Electrical Topologies
Average Model
=> Suitable for Electrothermal
(Basic) Dynamic Model
=> Suitable for Electrical Dynamics in System
i.e. EMC/EMI issues due to Parasitics
© 2010 ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary
IGBT Characterisation
The IGBT Switching Transient
• Example: Turn-off (switching time e.g. 40ns)
– Electrical dynamic: Rise Time, Voltage Overshoot, …
– Switching Loss due to v(t) * i(t)
© 2010 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary
• Common Thermal Circuit
• Parameters can be extracted from
• R/C values from the data sheet
• Curve fitting of the thermal impedance Zth(t)
(measured or datasheet)
IGBT Characterisation
IGBT Thermal Circuit Topologies
cth1 cth2 cth3 cth4
rth1 rth2 rth3 rth4
H
h1cth_sinkrth_sinkTjunction
Tcase
© 2010 ANSYS, Inc. All rights reserved. 17 ANSYS, Inc. Proprietary
Electrical System ElectrothermalSwitch Model
Thermal System
0
E1
R1
E2
0
Simplorer: Conservative
State-Space Formulation
Fully coupled conservative electrothermal (multidomain) solution
CxT
hBAxx
tuFi ,
tTuFi
tTiuFh
,,
,,,
h
T
i
u
Electrical System Electrothermal
TransformationThermal System
© 2010 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary
Thermal Domain
Electrical Domain MechanicalDomain
0
R1 R2 R3
MASS_ROT1
DR1
SINE2
SINE1
A
A
A
IN_A
IN_B
IN_C
OUT_A
OUT_B
OUT_C
I_motSimplorer4
A
B
C
N
ROT1
ROT2
Induction_Motor_20kW
Q
Ambient
P1
P2
P3
P4
P5
P6
P7
P8 P
9
P1
0
P1
1
P1
2
P_
RE
F
z_um z_vm z_wm
z_wpz_vpz_up
+
V
VM311 R6 R5 R4
E1
RZM
DR1
RZM
0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]
-500.00
-250.00
0.00
250.00
500.00
Y1 [
V]
Curve Info rms
R1.VTR 230.9405
R4.VTR 313.3812
0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]
1475.00
1485.00
1495.00
1500.00
MA
SS
_R
OT
1.O
ME
GA
[rp
m]
0.00
50.00
100.00
150.00
180.00
MA
SS
_R
OT
1.P
HI
[deg]
Curve Info
MASS_ROT1.OMEGATR
MASS_ROT1.PHITR
IcePak/MOR
Average IGBT Application
Cxy
BuAxx
Average IGBT Model
© 2010 ANSYS, Inc. All rights reserved. 19 ANSYS, Inc. Proprietary
Thermal MOR Coupling
Simplorer Results
© 2010 ANSYS, Inc. All rights reserved. 20 ANSYS, Inc. Proprietary
Ansys Workbench Couplings
Workflow
Simplorer V9Solve IGBT
Circuit
Terminal Current
(Manual Input)
Maxwell V14Solve for
Magnetostatics
Switching Losses
(Manual Input) ANSYS MechanicalSolve
Steady State Thermal
Temperature
Distribution
ANSYS MechanicalSolve
Static Structural
Stress and
Deformation
ANSYS
Workbench R13
Lorentz
Forces
Ohmic
Losses
© 2010 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary
ANSYS Workbench R13 Interface
Maxwell 2D and 3D ,
Simplorer and RMxprt all
available under ANSYS
Workbench R13
© 2010 ANSYS, Inc. All rights reserved. 22 ANSYS, Inc. Proprietary
Steps
• Solving Simplorer Circuit
• Maxwell Solution for Forces and Ohmic Losses
• Thermal Solution using ANSYS Mechanical
• Structural Solution using ANSYS Mechanical
© 2010 ANSYS, Inc. All rights reserved. 23 ANSYS, Inc. Proprietary
Steps
• Solving Simplorer Circuit
• Maxwell Solution for Forces and Ohmic Losses
• Thermal Solution using ANSYS Mechanical
• Structural Solution using ANSYS Mechanical
© 2010 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary
Create Simplorer Solution
• Launch ANSYS
Workbench R13
• Drag and Drop a
Simplorer Analysis
System onto the project
page
• Right click on Setup and
select Edit to launch
Simplorer V9
© 2010 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary
IGBT Circuit
• Input Pulse
• IGBT Unit
• Ammeter (Gives Terminal Current through IGBT)
• Multiplier (Gives Switching Losses across IGBT)
© 2010 ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary
Transient Solution
• Transient Solution was run for time of 40 ms
with settings as shown in image
• Following results were obtained
– Max Current reported by
Ammeter = 20 A
– Average Losses reported by
multiplier = 49.5057 Watts
© 2010 ANSYS, Inc. All rights reserved. 27 ANSYS, Inc. Proprietary
Steps
• Solving Simplorer Circuit
• Maxwell Solution for Forces and Ohmic Losses
• Thermal Solution using ANSYS Mechanical
• Structural Solution using ANSYS Mechanical
© 2010 ANSYS, Inc. All rights reserved. 28 ANSYS, Inc. Proprietary
Create Maxwell System
• Select a Maxwell
Analysis System
• Drag and drop it on
Project Schematic
page as a Standalone
system
• Right click on
“Geometry” tab and
select Edit to Launch
Maxwell
© 2010 ANSYS, Inc. All rights reserved. 29 ANSYS, Inc. Proprietary
Complete IGBT Module
12 IGBT’s
12 Diodes
The Current through
one phase is shared
equally between two
IGBT’s
© 2010 ANSYS, Inc. All rights reserved. 30 ANSYS, Inc. Proprietary
Material Definition
• For simulation purposes,
consider only one IGBT
• Import the IGBT model
• Set Solution type to
“Magnetostatic”
• Set material properties of all
the objects
• Diodes and IGBT units
which are OFF mode are
applied with Vacuum
material
© 2010 ANSYS, Inc. All rights reserved. 31 ANSYS, Inc. Proprietary
Set Current Excitations
• Maximum current
through IGBT was
calculated by Simplorer
which will be set as
terminal current
• Set Current excitations of
20A to positive terminals
• Set Current excitation of
40A as Phase current
– The value is set as
twice the terminal
current
© 2010 ANSYS, Inc. All rights reserved. 32 ANSYS, Inc. Proprietary
Solve
• Add solution Setup and solve the case with
proper settings
• Plot J field to check the results
• Close Maxwell and return to Project Page
© 2010 ANSYS, Inc. All rights reserved. 33 ANSYS, Inc. Proprietary
Steps
• Solving Simplorer Circuit
• Maxwell Solution for Forces and Ohmic Losses
• Thermal Solution using ANSYS Mechanical
• Structural Solution using ANSYS Mechanical
© 2010 ANSYS, Inc. All rights reserved. 34 ANSYS, Inc. Proprietary
Create Steady State Thermal
System
• Select Steady State
Thermal Analysis
system
• Drag and drop it on
Solution tab of
Maxwell 3D
• This will enable
transfer of Ohmic
losses calculated in
Maxwell to ANSYS
Mechanical
© 2010 ANSYS, Inc. All rights reserved. 35 ANSYS, Inc. Proprietary
Creating Material Data
• Right click on
Engineering Data and
select Edit to access
Material database
• Add needed required
material from database
to the project and return
to project page
• Right click on
“Geometry” tab and
select “Import
Geometry”
© 2010 ANSYS, Inc. All rights reserved. 36 ANSYS, Inc. Proprietary
Steady State Thermal Setup
• Double click on “Model”
tab to launch ANSYS
Mechanical
• Specify appropriate
materials to all objects
– Diodes and IGBT units
which are under OFF
mode are also applied
with Silicon material
• Apply mesh sizes on
required objects and
Generate Mesh
© 2010 ANSYS, Inc. All rights reserved. 37 ANSYS, Inc. Proprietary
Setup (Contd…)
• Ohmic Losses from Maxwell
are already link to Steady
State Thermal solver as Load
• Right Click on “Imported Load
(Maxwell3DSolution) tab and
select “Insert Heat
Generation”
• Under “Geometry”, select all
the volumes from the
geometry and select “Import
Load”
• Conduction losses will be
mapped from Maxwell to
ANSYS Mechanical
© 2010 ANSYS, Inc. All rights reserved. 38 ANSYS, Inc. Proprietary
Setup (Contd…)
• In addition to conduction losses,
we also need to apply switching
• The switching losses which we
calculated using Simplorer was
49.5 Watts
• We need to divide the switching
losses by the volume of all
bodies which carry current as the
losses will be shared among
them
• The resulting value is around
0.01683 W/mm3
• We will apply this value through
command line as this value
should add with the conduction
losses to give actual thermal
load.
© 2010 ANSYS, Inc. All rights reserved. 39 ANSYS, Inc. Proprietary
Solve
• Apply Convective boundary to all external faces of
geometry with Film Co-efficient of 1e-4 W/mm2 ̊C
• Run the solution
• Plot Temperature distribution on Objects
• Close ANSYS Mechanical and return to Project Page
© 2010 ANSYS, Inc. All rights reserved. 40 ANSYS, Inc. Proprietary
Temperature Distribution
© 2010 ANSYS, Inc. All rights reserved. 41 ANSYS, Inc. Proprietary
Steps
• Solving Simplorer Circuit
• Maxwell Solution for Forces and Ohmic Losses
• Thermal Solution using ANSYS Mechanical
• Structural Solution using ANSYS Mechanical
© 2010 ANSYS, Inc. All rights reserved. 42 ANSYS, Inc. Proprietary
Create Static Structural System
• Select Static Structural
system from Analysis System
• Drag and drop it on the
“Solution” tab of Steady State
Thermal System
• This will enable data transfer
between two system
• Select “Solution” tab of
Maxwell 3D system, drag and
drop it on “Setup” tab of
Static Structural
• This will create a link between
Maxwell 3D and Static
structural enabling Force data
transfer from Maxwell
© 2010 ANSYS, Inc. All rights reserved. 43 ANSYS, Inc. Proprietary
Setup
• Right click on “Setup” and
select “Edit” to launch ANSYS
Mechanical
• Right Click on “Imported Load
(Maxwell3DSolution) tab and
select “Insert Body Force
Density”
• Under “Geometry”, select
Bondwires to which we want
to apply Lorentz Forces
• The forces calculated by
Maxwell will be applied to the
Bondwires
© 2010 ANSYS, Inc. All rights reserved. 44 ANSYS, Inc. Proprietary
Solve
• Specify Frictionless Support to the Bottom
faces of the plates
• Run the solution
• Plot Equivalent Stress and Deformation
images
• Compare Max. Stress values with material
properties to predict failure
© 2010 ANSYS, Inc. All rights reserved. 45 ANSYS, Inc. Proprietary
Results
Equivalent Stress
Max Value: 211 MPa
Deformation
Max Value: 0.088 mm
© 2010 ANSYS, Inc. All rights reserved. 46 ANSYS, Inc. Proprietary
Summary
• ANSYS Workbench is used to simulate
multiphysics problem of IGBT accurately
taking into account:
– Electric Circuits
– Electromagnetics
– Thermal
– Stress
• On the workbench platform, Simplorer,
Maxwell3D and ANSYS Mechanical were used
for various simulations and data transfer