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Copyright © 2012 JSOL Corp. All Rights Reserved http://www.jmag-international.com/ 1 JMAG User Training RWH Künzelsau Session I - II 24 th Mar, 2014

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Page 1: JMAG User Training RWH Künzelsau - Hochschule Heilbronn · PDF fileJMAG User Training RWH Künzelsau Session I - II 24th Mar, 2014 . ... JMAG-RT Parametric Analysis Coupled Analysis

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JMAG User Training RWH Künzelsau

Session I - II

24th Mar, 2014

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Training Outline

Session I - Introduction Introduction to JMAG Product line Motor design using JMAG Express

Quick Mode Power Mode

Modifying existing templates

Session II – JMAG Designer Introduction to JMAG designer Interface Import models from Express (2D) Analysis Setup and Meshing Results & Post Processing

Session III – JMAG Tools Inductance Calculation Iron Loss Scripting JMAG-RT Parametric Analysis Coupled Analysis

Session IV –Examples PM Analysis:

No Load Load case NT curves IPM – MG-TH analysis

IM Analysis

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Introducing JMAG

Session I

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JMAG is…

FEA software for electromechanical design Created in 1983 Over 600 active customer sites A standard tool in EV/HV development

4

Applications

Motors/Generators

Actuators

Transformers

Induction heating

Sensors

EM Shields

etc.

Analysis Modules

Magnetic

Electric

Structural

Thermal

Multi-physics

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JMAG’s history

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JMAG Family

JMAG-Designer

Multi Physics

Abaqus, Virtual.Lab, AcuSolve…

Control System

JMAG-RT Viewer JMAG-RT JMAG-VTB

End User

JMAG-Bus

JMAG-Express JMAG-Express Power

Mode

Model Design

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JMAG Express

JMAG-Express enables extremely fast evaluation of basic motor performance characteristics Does not require setting analysis conditions or details of model set up (time step size, mesh size, etc) Serves as a starting point for model validation Sizing function can be used to quickly estimate model geometry based on scaling an initial design

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JMAG-Express Power Mode

Full FEA calculation in JMAG-Express Power Mode Easy and accurate

Pre-defined analysis scenarios Dashboard for result display

Scenarios for PM Machines No load analysis

Cogging torque, BEMF Load analysis

Torque, Current, Voltage, Loss Efficiency map Inductance Iron loss including the high harmonics Magnet loss Torque segregation

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JMAG-Express Power Mode Results

JMAG-Express Power Mode enables the evaluation of high accuracy machine performance parameters without having to set analysis properties.

Current phase-torque properties

Torque-Speed curve

Efficiency map

Voltage waveform Cogging torque

Magnetic flux eddy current loss

Magnetic flux distribution

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JMAG Designer

JMAG Designer is the core program in JMAG software environment. Full 2D and 3D electro-mechanical FEA design and analysis Numerous analysis tools such as inductance calculation, parametric analysis, optimization, and scripting

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JMAG Structure

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Co-simulation

Complex co-simulations require proper combination of analyses. JMAG’s pre defined scenarios can automatically apply these combinations to user’s models and achieve accurate results.

computation flow

Efficiency

calculation

loss

inductance

geometry

materials

behavior range

・・・

No-load property Cogging torque

NT curve

Efficiency map

Thermal

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JMAG VTB (Virtual Test Bench)

JMAG-VTB makes it simple to run complicated analyses, which may be multi-physics/level simulation.

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JMAG VTB (Virtual Test Bench)

JMAG-VTB requires you to know NOT how but ONLY what’s your objective.

The procedure (how) is automated with a pre-defined scenario.

Covers a wide variety of devices Customizable scenerios Simple operation

Step1: Choose a scenario Step2: Apply the scenario to your model Step3: Evaluate the results

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JMAG Express

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JMAG Express

Open JMAG Express by navigating to Start>All Programs>JMAG Express 6.0

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Basic Function

Motor model templates

Templates with basic geometry

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JMAG Express

Click on the Brushless motor(IPM) link and select the template “PM_I_D_I”

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Make sure the evaluation method is set to “Quick Mode”

JMAG Express

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JMAG Express

On the left side you will see four tabs Dimensions Materials Winding Drive

Every parameter in these tabs can be modified based on the users’ requirement Requires prior knowledge of machine dimensions

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JMAG Express

Another option is to use the sizing tool The machine dimension can be automatically generated based on certain control parameters

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JMAG Express

Desired rated power is the minimum required data to generate this model. Enter 25 kW in the highlighted text box and click [Apply]

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JMAG Express

Other optional parameters can be specified to effect the outcome of the sizing function. We will not use the optional parameters for this case. Click on the sizing button again and it will hide the sizing panel

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JMAG Express

The material properties of the parts can be modified on the materials tab. JMAG has a built in database of material properties from our partnership with material manufacturers.

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JMAG Express

The following conditions can be modified in winding tab:

Coil settings (type of connection, phase resistance, and number of turns)

Phase Resistance can also be calculated based on the geometry of strands

Number of winding layers in each slot (1 or 2) Winding layout

Automatic Automatic (Concentrated Winding) Manual

For the Automatic Winding, you can set the coil pitch For the Manual Winding, you can set the “Go” and “Return” slots

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JMAG Express

In the drive tab, you can set the following

Type of power source Amplitude Current Phase Maximum Current Rotation Speed If Adaptive Analysis should be used

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JMAG Express

Now the model is ready for a basic analysis. Click on the evaluate button highlighted in red

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JMAG Express

That will open a new results tab with some basic characteristics of the 2D motor model that we just created. JMAG Express is a tool specialized to evaluate the model with high speed. More detailed analysis can be performed in JMAG Express Power mode.

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JMAG-Express Power Mode

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JMAG-Express Power Mode

To convert to power mode, select the evaluation method dropdown and choose any of the four available modes below simplified basic characteristics

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For this example we will select “Basic Characteristics” This will modify the Drive tab with some predefined scenarios:

No Load Load Inductance Efficiency Map

Each of these scenarios have some settings listed for the drive properties

JMAG-Express Power Mode

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Select the checkbox for “No Load” The analysis priority can be set to speed or accuracy. Higher accuracy will take more time to run

JMAG-Express Power Mode

Set the rotation speed to 1800 RPM

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Click on evaluate button to start the analysis. Select the destination project folder and click ok

JMAG-Express Power Mode

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Once the analysis is finished the results are displayed in the Dashboard.

JMAG-Express Power Mode

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Unlike quick mode, a full FEA calculation is performed in power mode. The results that are displayed in dashboard can directly be exported into JMAG by clicking on them. Click on the cogging torque plot will open the model and plot in JMAG-Designer Once the analysis is opened in JMAG you can observe that all the necessary study conditions are applied to the model based on the case we selected.

JMAG-Express Power Mode

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This us just one case study of what can be done using JMAG-Express Power Mode

JMAG-Express Power Mode

Scenarios available for SRM: I-Psi Characteristics Static Characteristics Drive Characteristics Dynamic Characteristics

Other scenarios available for IPM:

Load Study Inductance Efficiency map Harmonic Iron Loss Magnet Loss Torque Segregation

Scenarios available for Induction Motor:

Drive Characteristics Line Start Machine Parameters Torque Characteristics

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Analysis Database

Records all simulation tasks performed in JMAG-Express Power Mode and VTB. Searchable by design parameters as well as output value, device type, scenario and date/time. Dashboard can be directly opened from the search and linked to JMAG model.

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Editing a Template

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Template Creation

Create a double layered IPM Rotor from a single layered template.

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Template Creation

Open JMAG Express, on the “Dimensions” tab clink on the “modify” link on the rotor, and select “Edit Current Template”. Click [OK]. Now a template editor window will open. Here you have limited capabilities to add/edit constraints, change material type, etc.. To edit the geometry, open the “Edit” menu and select “Edit in JMAG-Designer”. That will open a new instance of JMAG-Geometry Editor with the current rotor sketch.

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In geometry editor window, open “Tools” menu and select “Preferences”. In the “Document Properties” tab, change the grid settings as shown below.

Template Creation

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Right click on the “2D Sketch” and select “Edit sketch” Delete the rotor core regions.

Template Creation

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The model requires strict constraint settings if you want to parameterize it using JMAG Express. Throughout this model, we will learn how constraints are set and how they can be useful.

Note: While setting a reference constraint like

distance, parallelity, perpendicularity, etc..

Always select the reference entity first

followed by the entity on which the constraint is

being set.

Template Creation

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Template Creation

Set the magnet thickness to depend on the slit width. Right click on the constraint set across the magnet region and select “Edit” Turn on “Depends on Constraint” and select the constraint specified across slit width as highlighted in the figure and click [OK].

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Template Creation

Change the slit width to 1.5 mm by editing the constraint Click on the line button and create 8 lines as shown in the figure below. These will serve as the second layer of slit and magnet.

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Template Creation

Select the circle button and create a circle with center at origin and a radius of 27 mm Now select the “Sketch trim” button and trim out the excess parts on lines by clicking on them. (Do not trim the edges with the circle yet) Now your geometry should look as shown below. (highlighted lines)

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Template Creation

Add the constraint “Perpendicularity” to the diagonal lines representing the slit with respect to the 45o symmetry line. Geometry should look like below. (Highlighted part shows the constraints added)

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Template Creation

Add the constraint Parallelity to the lines representing magnet ends with respect to the 45o symmetry line. Geometry should look like below. (Highlighted part shows the constraints added)

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Template Creation

Select the “Break at intersection” button and select all the lines and circle that you have created + the 45o symmetry line. (make sure not to select any previously existing geometry. All the points where an intersection is found is highlighted with a yellow square Click [OK]. Select the excess lines and circle, hit delete key to delete them. The final geometry should look as below.

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Template Creation

Set the coincident constraint on each line segment that represents the magnet and the air region just beside the magnet (highlighted in green) This will allow the intersecting point to move along with the changing dimensions of the magnet.

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Template Creation

Add a distance constraint between the existing and the new slit and set it to 2 mm. Find that constraint in the treeview and rename it as “SLIT2:Distance between Slits”

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Template Creation

Add another distance constraint between the magnets and set it to depend on the Slit Width constraint. Rename the constraint as “DMAG: Distance between Magnets” Add distance constraints on the other half of the magnet and slit and set them dependent on their counterparts across the symmetry line. With the constraints added your geometry should look as below

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Template Creation

Repeat the same procedure and add constraints to the width of the slit set to 1.5mm and named “SW2: Slit2 Width”, thickness of the magnet set to depend on SW2 and named as “TMAG2: Mag2 Thickness” The geometry after applying all 8 constraints should look as shown below.

SLIT2: Distance between Slits

SW2: Slit2 Width

DMAG: Distance between Magnets

TMAG2: Mag2 Thickness

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Template Creation

Set a “Concentric” constraint on the arc representing the end of new slit and the outer arc of the rotor. Add a distance constraint between the two arcs and set it to depend on constraint “DSLIT: Slit Depth” Repeat the above steps on the arc across the opposite end.

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Template Creation

One last constraint will be the width of the magnet set to the two small lines parallel to the symmetry line. Set the distance to be 8.5mm and name it as “WMAG2 Mag2 Width”. Set a dependent distance constraint on the other side of symmetry line. The final geometry with total 10 constraints should look as shown below.

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Template Creation

Click on the “Create region” button , select all the lines that create the magnet and click [OK] to create a region. Similarly select all the lines for rotor core and create the regions in two separate parts.

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Template Creation

Right click on the “2D Sketch” in treeview and select “End Sketch” The final Geometry Editor window should look similar to the image below

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Template Creation

In the express template editor window, click on “Edit” and select “Get from JMAG-Designer” Now the geometry will be imported into Template editor window as shown in the image below.

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Template Creation

You can switch to the “Preview” tab to look at the constraints that give you control over the new geometry. Next step is to assign material properties to the new regions created. In the “Model” tab, scroll down to “Materials”.

Select any of the untitled material and change title to “Rotor Core” Change material type to “Magnetic Material”.

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Template Creation

Scroll further down to “Regions” and assign appropriate material name for all the regions.

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Template Creation Click on the “Back to Main Window” button , name the template as “Double_Layered IPM” and click [OK]. Switch to “Materials” tab in the Express window and set the following for Rotor Core:

Material category : “JSOL – Steel_Sheets” Product : 50A1000

The template creation for doubled layered IPM machine is completed.

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JMAG Designer

Session II

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JMAG Designer

JMAG Designer is the core program in JMAG software environment. Full 2D and 3D electro-mechanical FEA design and analysis Numerous analysis tools such as inductance calculation, parametric analysis, optimization, and scripting

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Analysis Setup in JMAG-Designer

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Drive settings

In the Express window, switch to “Drive” tab and set the following: Drive Circuit mode: Current Current Amplitude: 10 Check “Do not use Adaptive Analysis”

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Export to JMAG Designer

From the File menu, select “Send to JMAG Designer” and save the project as “IPM_AdvTraining” on your desktop

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JMAG Designer Main Window

Now the 2D model should be opened in JMAG Designer window.

Project Manager

Main Menu

Toolbox

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Study Conditions

All the conditions and circuit for the study are already set. This is done by JMAG Express and imported along with the geometry into Designer. We will look at few of these condition settings in detail.

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Groups and Sets

Grouping works best for similar components (i.e. all the Coils) In the Assembly tab, you can group components by:

Material Name Number of characters (4 or 6)

Sets are simply sub groups where the components are grouped by conditions that apply to them For custom templates, JMAG automatically creates the groups by part names and conditions are assigned using sets created by user.

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The size of the analysis model can be reduced when the model has rotational periodicity. This model has a rotational periodicity of 90o and the periodicity nature is set to be “Antiperiodic”

Rotational Periodic Boundary

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The periodic boundary condition means that flux is the same for each period The anti-periodic boundary condition means that flux is reversing each period The axial reverse boundary condition applies to models whose cross section vertically reverses each period (claw pole motor)

Periodic Versus Antiperiodic

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Symmetry Boundary: Magnetic flux flow parallel and current flows perpendicular to the symmetry boundary. Natural Boundary: Magnetic flux flow perpendicular and current flows parallel to the natural boundary.

Note: The boundary conditions set field properties, but in terms of results are purely mathematical constraints

Types of Boundary

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Periodic Boundary: Multiplies the result by the periodicity.

Symmetry Boundary: If sufficient air region is not created surrounding the model the flux is forced to flow parallel to external boundary

Natural Boundary: Magnetic flux is forced to flow perpendicular to the boundary even if it is not perpendicular in reality

Notes on Boundaries

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Rotational Motion Condition

Defines motion in a rotating model Can be in various forms:

Constant Revolution Speed Constant displacement Speed point sequence Displacement point sequence Cumulative displacement point sequence Equation of motion Link to external simulator

Can add rotor eccentricity Both static and dynamic eccentricity

Can set the initial rotor position Set RPM to 1800 and set initial position to 0

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Nodal Force: calculates the torque based on the electromagnetic force acting on each node. This method works best for electric machine rotors Lorentz Force: calculates the Lorentz force and the torque based on that force. This method is used to calculate the torque in a non magnetic material such as a coil. Surface Force: calculates the torque based on the integral value of electromagnetic force acting on a face of edge. This condition can be used when the magnetic material is in contact with another magnetic material, or where the electromagnetic force is acting on a part of the magnetic material.

Torque

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Mesh Tips

Areas where flux is changing rapidly usually require a finer mesh The air gap mesh of an electric machine is critical

Make sure that the mesh is uniform in the stator and rotor sections closest to the air gap Each time step should move the rotor approximately 1 element

Adaptive meshing is useful in 2D but may take too long in 3D A course mesh will run quickly, but may not be accurate while a fine mesh will run more slowly and may or may not be more accurate. Mesh is highly controllable in JMAG

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Basic Settings: Right Click on Mesh and select Properties This opens the Basic Settings Tab Meshing types:

Standard Mesh Slide Mesh

Choose the Generation Method Method 2 is currently the most efficient method

Scale controls the size of the air region generated outside the model. Change this to 1.05 Slide division is applicable if slide mesh is selected

Specify the Radial Divisions (between rotor and stator) to 5 Specify the Circumferential Divisions (from the first periodic boundary to the second periodic boundary) to 180

If the model has multiple rotating parts, multiple slide planes can be created

Mesh Properties

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Element Size: A global element size can be specified for parts and air region Set element size for

parts as 1 mm air region as 2mm

Adaptive Adaptive meshing can be toggled On/Off from here.

Mesh Properties

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Setting Mesh Features

Running the analysis through Express will use Adaptive mesh. Since we will not use adaptive meshing, some mesh settings need to be specified Right click on “Mesh” and select “Add Size Control” on part. Select the Magnets as target and specify a size of 0.5 mm

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Setting Mesh Features

Similarly add a size control on the edge feature and select all the edges of rotor and stator next to the air gap. Also select the edges at the barrier of the magnet. Right click on the Mesh and select “Rotating Periodic Mesh” with “Automatic”. This will enable JMAG meshing algorithm to automatically detect periodic geometry and apply similar mesh to each segment.

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Right click Mesh and select Generate Click OK if there is are any warnings Click on the Mesh View button Toggle the air regions on. The meshed model should look as in the figure below:

Generating a Mesh

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Right click the study and select Properties Set the Steps to 361

180 steps per 90 mechanical degrees Model 1 electrical cycle (180 mechanical degrees)

Set the type to Regular Intervals Set the unit to seconds Set the end time as 1 second Set 21600 division

There are 720 steps (180steps*4periods) per revolution Rotor is spinning at 30 revs/sec (1800revs/60) which implies 720*30 = 21600 steps per second. The end time is 1 second so that means there are 21600 divisions.

Model Properties- Steps

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You can set the model height for a 2D analysis. This value of 37.5mm is set in Express window. For this case, there would not be any other conversions

Model Properties - Conversion

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The circuit in our model has only series connections Therefore there are no other conditions to set

Model Properties - Circuit

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Toggle the Advanced Properties on Under Solver the following settings can be changed:

Parallel computing conditions using Shared memory multiprocessing (SMP) Massively Parallel Processing (MPP) Utilize GPU

The Steady State Approximate Transient Analysis is for modeling induction machines in steady state Time Periodic Explicit Error Correction can force a transient model into steady state more quickly

Model Properties - Solver

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Increasing the tolerance on the ICCG can increase the model’s accuracy I do not recommend changing the acceleration coefficient

Model Properties - ICCG

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Change the number of non-linear iterations if the materials are non-linear This will ensure an accurate calculation for saturated regions For this model the default settings will be adequate. Turn on the “Use High Speed Solver” checkbox.

High-speed solver can be used when the flux vector in the mesh element does not change rapidly.

Model Properties - Nonlinear

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You can select what the output of the analysis is Removing features will shrink the solved file size and help the simulation run faster

Model Properties - Output

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Restart will continue a calculation using the previous study as the starting point You can also restart an analysis by right clicking on the Study and selecting “Restart”

Model Properties - Restart

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Right click on the Study and select Run Active Case The project can also be run from a Scheduler or Batch processor

The Scheduler Tool creates a job queue The batch processor can farm jobs to separate computers

Run the Analysis

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While the model is running you can view various parameters progress Press the Customize Monitor button

Select the parameters you would like to observe Can observe more than one

Solver Dialog shows the simulation’s progress

Results Monitor

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Analysis Results

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Under Study right click on Results and select “New Contour Plot” Various settings can be changed:

Type of result in the contour plot and its component Type of contour Scaling Color scale for the contour plot

Currently it is set to create a contour plot for Magnetic Flux Density. Click [OK].

Plotting Contour Plot

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Plotting Contour Plot

Select the display contour result button

Rotor can be moved with the slider bar Rotor motion can be seen as an animation using the animation control bar Similarly, vector plots and flux line plots can be created and displayed using the vector result and flux line buttons

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The Graph manager contains the results of all the studies in a project The results can be sorted into groups You can also select multiple results to display at the same time A transform function can perform a FFT or combine two graphs.

Graph Manager

FFT

Combine

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Section Graph

Section Graphs can be used to plot quantities like magnetic flux across a line or an arc specified for a model. This example shows the section graph of Flux density across the air gap for step 1.

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Probe

Probe can be used to plot quantities at a desired point in the model. Multiple points can be specified. This example shows field strength variation across the barrier.

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3D Modeling

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3D Modeling

A 2D model can be converted into 3D by using the extend model to 3D option.

The stack length used in 2D model will be used for the extrude length

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3D Modeling

JMAG has special meshing functions, like the Extruded Mesh, which can substantially reduce the number of elements without degrading the accuracy Analysis time is also reduced and the solution more stable with extrude mesh

Standard Mesh – 81,262 Elements Extruded Mesh – 43,734 Elements

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Coil End Modeling

Complicated End winding geometries can be created easily using the coil template It supports following type of coils

Concentric Spiral Rectangular