Mark Solveson – Application Engineer - Ansys · PDF fileMaxwell Design Flow –...
68
l h Electric Machines Considering Power Electronics Mark Solveson – Application Engineer © 2011 ANSYS, Inc. May 10, 2012 1
Transcript of Mark Solveson – Application Engineer - Ansys · PDF fileMaxwell Design Flow –...
l hElectric Machines Considering Power Electronics
Mark Solveson – Application Engineer
© 2011 ANSYS, Inc. May 10, 20121
OutlineMachine Design Methodology Introduction
RMxprtMaxwellMaxwell
Advance CapabilitiesCore LossDemagnetization / Magnetization
Field‐Circuit Co‐SimulationMaxwell Circuit EditorSimplorer – Capabilities, Switches, IGBT CharacterizationSimplorer Examples
Multi‐Physics Force CouplingThermal Coupling
© 2011 ANSYS, Inc. May 10, 20122
Thermal Coupling
Introduction: Machine Introduction: Machine Design MethodologyDesign MethodologyDesign MethodologyDesign Methodology
© 2011 ANSYS, Inc. May 10, 20123
Maxwell Design Flow – Field Coupling
ANSYS CFDFluent
RMxprtMotor Design
/
g
Maxwell 2‐D/3‐DElectromagnetic ComponentsHFSS
PExprtANSYS
MechanicalThermal/Stress
pMagnetics
© 2011 ANSYS, Inc. May 10, 20124
Field Solution
Model Generation
Simplorer Design Flow – System Coupling
SimplorerSystem Design
ANSYS CFD Icepack/Fluent RMxprt
M t D i
PP := 6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
JPMSYNCIA
IB
IC
Torque JPMSYNCIA
IB
IC
TorqueD2D
Motor Design
HFSS, Q3D, SIwave
PExprt
/
pMagnetics
Maxwell 2‐D/3‐DElectromagnetic Components
ANSYS MechanicalThermal/Stress
Model order Reduction
© 2011 ANSYS, Inc. May 10, 20125
Co-simulation
Push-Back Excitation
RMxprt ‐ Initial Motor DesignAnalytical solution• 16 different Motor/Generator types• Input data• Input data• geometry, winding layout• saturation, core losses• comprehensive results– machine parameters– performance curvesperformance curves
© 2011 ANSYS, Inc. May 10, 20126
RMxprt ‐Motor DesignParametric Sweep:
Stack_Length
Skew/no Skew
Stator_ID
AirGap
Monitor:Torque
Power
Efficiency
Determine the Best Design
Create FEA Model
Export Circuit Model
© 2011 ANSYS, Inc. May 10, 20127
Export Circuit Model
Integrated EMDM FoundationsA t S t M ll D i f RM tAuto Setup Maxwell Design from RMxprt
© 2011 ANSYS, Inc. May 10, 20128
Maxwell/RMxprt V15 – Axial Flux Machine• AC or PM Rotor• Single or Double Side Stator
Sample Inputs
© 2011 ANSYS, Inc. May 10, 20129
Sample Outputs
Maxwell/RMxprt V15 – Axial Flux Machine• Maxwell 3D auto‐setup (Geometry, Motion, Master Slave, Excitations, etc. )
© 2011 ANSYS, Inc. May 10, 201210
Design Exploration
Maxwell Project
P1 ‐ cond
Workbench Schematic
© 2011 ANSYS, Inc. May 10, 201211
P2 ‐ parallelWorkbench Schematic
Design Exploration
© 2011 ANSYS, Inc. May 10, 201212
Design Exploration – Six Sigma
© 2011 ANSYS, Inc. May 10, 201213
Integrated Motor Solution
More Than 30UDP Machine
ComponentsComponentsfor 2D and 3D
© 2011 ANSYS, Inc. May 10, 201214
RMxprt Dynamic Link to Simplorer
© 2011 ANSYS, Inc. May 10, 201215
Maxwell
0.80
1.00
1.20
1.40
m] 2.00
2.50
3.00
3.50
eter
]
TRW / Ansoft Position & Current Hysteresis Control Close/Open1
Curve Info
Position
Coil Current
Diode Current
0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00Time [ms]
0.00
0.20
0.40
0.60
0.80
Pos
ition
[mm
0.00
0.50
1.00
1.50
2.00
Coi
l Cur
rent
[me
© 2011 ANSYS, Inc. May 10, 201216
Automatic Adaptive Meshing
© 2011 ANSYS, Inc. May 10, 201217
Advanced CapabilitiesAdvanced CapabilitiesCorelossCoreloss ComputationComputationCorelossCoreloss ComputationComputation
© 2011 ANSYS, Inc. May 10, 201218
Lamination Core Loss in Time Domain
• Instantaneous hysteresis loss
• Instantaneous classic eddy current lossdtdBH
dtdBBktp irrmhh
cos1)(
y
I t t l
2
221)(
dtdBktp cc
• Instantaneous excess loss21)(
ddBk
Ctp ce
where
dC 2/ 5.15.1 cos22
)(dtC
p ce
e
© 2011 ANSYS, Inc. May 10, 201221
dCe 0 cos2
Observation
• As a post‐processing step• Including eddy, hysteresis
with minor loop and excess losses
• Applicable to soft ferromagnetic and power ferrite materialsferrite materials
• Practical as it is based on available manufacturer‐
d d d h
Computed core loss with time
provided data sheet
© 2011 ANSYS, Inc. May 10, 201222
Core Loss Effects on Field Solutions
•Basic concept: the feedback of the core loss is t k i t t b i t d itaken into account by introducing anadditional component of magnetic field H in core loss regions This additional componentcore loss regions. This additional componentis derived based on the instantaneous core loss in the time domain
© 2011 ANSYS, Inc. May 10, 201223
Model Validation by Numerical Experiment
The effectiveness of the model can be validated by the power balance experiment from two test cases: p pconsidering core loss feedback and without considering core loss feedback. The increase of input electric power and/or input mechanical power between the two casesand/or input mechanical power between the two cases should match the computed core loss.
160 12
80
100
120
140
oss
(W)
6
8
10
Loss
(W)
Th h t f Three‐phase motor
0
20
40
60
Lo
Input power increaseCore loss 0
2
4
0 5 10 15 20 25 30 35 40
Time (ms)
Core lossInput power increase
Three‐phase transformer Three phase motor
© 2011 ANSYS, Inc. May 10, 201225
0 20 40 60 80 100
Time (ms)
Time (ms)
Advanced CapabilitiesAdvanced CapabilitiesDemagnetization ModelingDemagnetization ModelingDemagnetization ModelingDemagnetization Modeling
© 2011 ANSYS, Inc. May 10, 201226
Modeling Mechanism
• The worst demagnetization point for each element is dynamicallyfor each element is dynamically determined from a full transient process
BBr
• The demagnetization point is source, position, speed and
Br'
temperature dependent
• Each element uses its own recoil
Kp Recoil lines
curve derived at the worst demagnetization point in subsequent transient simulation
HHc 0
Worst demagnetizing point
© 2011 ANSYS, Inc. May 10, 201227
subsequent transient simulation
Irreversible Demagnetization If a demagnetizing point P goes below the knee point K, even after the load is reduced or totally removed, the
b t ki i t ill l l thB
Br'
Br
subsequent working points will no longer along the original BH curve, but along the recoil line.
K
p Recoil line
HHc 0
p Recoil line
© 2011 ANSYS, Inc. May 10, 201228
The animation shows how the demagnetization permanently occurs with varying load current
Temperature Dependent Model
• Work on intrinsic Bi‐H, instead of B‐H curveinstead of B H curve
B = Bi + μo H
• T t t d d t t• Two temperature dependent parameters:Remanent flux density Br and Intrinsic coercivity Hci
)()(1)()( 02
02010 TPTBTTTTTBTB )()(1)()( 002010 TPTBTTTTTBTB rrr
)()( 1)()( 02
02010 TQTHTTTTTHTH cicici
where T0 is the reference temperature, and α1, α2, β1 and β2
© 2011 ANSYS, Inc. May 10, 201230
0 1 2 1 2are coefficients which are provided by vendors
Temperature Dependent Model
• Once a model at T0
is constructed, any
Copied from vendor datasheet
is constructed, any Bi‐H curves at other T can be recovered in terms of P(T) Q(T)in terms of P(T), Q(T)
• B‐H curve in the 2nd and 3rd quadrantsand 3rd quadrants can be further recovered by
Derived from our implemented temperature dependent model
B = Bi + μo H
© 2011 ANSYS, Inc. May 10, 201231
Benchmark Example
• 8-pole, 48-slot, 50 KW, 245 V, 3000 rpm Toyota Prius IPM motor with imbedded NdFeB magnet
• Two steps in 3D transient FEA: 1. Determine the worst operating point element by element
during the entire transient processduring the entire transient process 2. Simulate an actual problem based on the element‐based
linearized model derived from the step 1
• To further consider the impact of temperature, element-based average loss density over one electrical cycle is used as the thermal load in subsequent thermal analysisused as the thermal load in subsequent thermal analysis
• The computed temperature distribution from thermal solver is further feedback to magnetic transient solver to consider
© 2011 ANSYS, Inc. May 10, 201232
is further feedback to magnetic transient solver to consider temperature impact on the irreversible demagnetization
Hc' change in one element during a transient process:
The 1st cycle (0 to 5ms) doesn’t consider temperature impact. The 2nd l (5 t 10 ) h id d th f db k f th l l ticycle (5 to 10ms) has considered the feedback from thermal solution
based on the average loss over the 1st cycle
Observation: Hc' has dropped from 992,755 A/m to 875,459
© 2011 ANSYS, Inc. May 10, 201233
c pp , / ,A/m, which is derived from the worst operating condition
Contours of loss density distribution Static temperature distribution (K)
© 2011 ANSYS, Inc. May 10, 201234
Torque profiles showing demagnetization and temperature dependence:
Torque profiles derived from without considering demagnetization,
© 2011 ANSYS, Inc. May 10, 201235
considering demagnetization but no temperature impact and considering demagnetization as well as temperatures dependence
Magnetization
• Compute magnetization based on the original non remanenton the original non‐remanent B‐H curve
• Find operating point p from nonlinear solutions
• Construct line b at the operating point p, which is parallel to the B Slope of line a at saturation pointp p pline a at saturation point
• Br is the intersection of line bwith B‐axis
p p
pwith B axis• Element by element
Br Line bp
© 2011 ANSYS, Inc. May 10, 201236
H0
What is the Difference between Using Magnetostatic and Transient solver?
• Magnetostatic case: the
Magnetostatic and Transient solver? B
operating point used for computing magnetization (Br) is from single source point;
Br p
• Transient case: the operating point used for H0operating point used for computing magnetization (Br) is the maximum operating point with the largest (B H)
B
Brpoint with the largest (B,H) during the entire transient simulation. p
© 2011 ANSYS, Inc. May 10, 201237
H0
Anisotropic or Isotropic Magnetization
• Anisotropic magnetization: magnetization direction is determined by the orientation of the magnet material and the direction is specified by a user;
• Isotropic magnetization:Isotropic magnetization: magnetization direction is determined by the orientation of the magnetizing field and is
P(T) input Q(T) input
the magnetizing field and is determined during the field computation.
Q( ) p
For isotropic magnetization, all threecomponents have to be set to zero
© 2011 ANSYS, Inc. May 10, 201238
components have to be set to zero
FieldField‐‐CircuitCircuitCoCo‐‐simulationsimulationCoCo simulation simulation
© 2011 ANSYS, Inc. May 10, 201239
Co‐simulation Mechanism
Thevenin equivalentThevenin equivalent(impedance matrix,source voltages)
Convert node to loop
FE Simulator
Lumped fieldparameters
Norton equivalent(conductance matrix
RwETA
UA.VAL
ETBUB.VAL
ETCUC.VAL
TH11 TH12 TH13
TH14 TH15 TH16TH21 TH22 TH23
TH24 TH25 TH26
parameters(inductances, induced
Internal voltages)
(conductance matrix,source currents)
Mww EwJ
STF
M
DCMP STF
J
MasTacho
StfTachoShaft
DcmpMotor
StfMotorShaft
© 2011 ANSYS, Inc. May 10, 201240
MasTachoJ := 0.15m
DcmpMotor
J := 2.1mMasCouplingLeft
J := 0.9m
Circuit Simulator
Maxwell Circuit Editor Example
• Commutator bar: model position
WidB
WidC
• Commutating model: model parameters
(a) (b) (c) (d)
PeriodLagAngle
G
|WidC-WidB|
a
b c
d
Gmax
© 2011 ANSYS, Inc. May 10, 201241
Position0WidC+WidB
Case Example for Commutating Circuit
PMDC Motor
Winding currents
PMDC Motor
Torque Brush commutation
© 2011 ANSYS, Inc. May 10, 201242
circuit
Simplorer:Simplorer:Power ElectronicsPower ElectronicsPower ElectronicsPower Electronics
© 2011 ANSYS, Inc. May 10, 201243
Simplorer Technology Highlights
© 2011 ANSYS, Inc. May 10, 201244
State‐of‐the‐Art Drive System:AMultidomain Challenge
I
A Multidomain Challenge
Drive systems
ANSYS provides a comprehensive toolset for multidomain work:
GAINGAIN LIMIT
GAIN
I
GAIN LIMIT
• Simplorer conservative structures (electrical circuits, mechanics, magnetics, hydraulics, thermal, ...)i l i (bl k• Simplorer non‐conservative systems (blocks, states, digital, nth‐order differential equations.
Drive componentsB11A11 C11
A12 A2B12 B2C12 C2
3~M
ROTJ ROTJ
· = M SV RS
• Maxwell with motion and circuits• RMxprt and PExprt (incl. thermal)• Maxwell with ANSYS Thermal.
ROT2ROT1ASMS
ROT2ROT1ROT2ROT1STF
ROT2ROT1STF
ROT2ROT1
• HFSS, Q3D, SIwave with circuits (Designer/Nexxim), ANSYS Mechanical, ICEPACK, etc. ...
© 2011 ANSYS, Inc. May 10, 201245
Multi‐Domain System Simulator
Magnetics Mechanics Hydraulics, Thermal, ...Electrical circuits
Analog Simulator
+
-
B11A11 C11
A12 A2
B12 B2
C12 C2
ROT2ROT1
ASMS
3~M
J
STF
M(t)
GN
D
mSTF
F(t)
GN
D
JA
MMFL
H
Simplorer Simulation Data Bus / Simulator Coupling Technology
State‐spaceModels
Block Diagram Simulator
State MachineSimulator
Digital/VHDLSimulator
statetransition
(R_LAST.I >= I_OGR)
EIN
SET: TSV1:=1SET: TSV2:=0SET: TSV3:=0SET TSV4 1
PROCESS (CLK,PST,CLR)BEGINIF (PST = '0') THEN
'1'
INV
J Q
QB
CLR
PST
Flip flop
K
© 2011 ANSYS, Inc. May 10, 201246
AUS
SET: TSV1:=0SET: TSV2:=1SET: TSV3:=1SET: TSV4:=0
(R_LAST.I <= I_UGR)
SET: TSV4:=1
CxyBuAxx
state <= '1';ELSIF (CLR = '0') THENstate <= '0';
ENDIF; INV
Electromechanical Design Environment
MatlabRTW UDC MathCAD Matlab
Simulink Maxwell…Simulink
C/C++ Programming Interface (FORTRAN, C, C++ etc.)
Co‐Simulation
Simulation Data Bus/Simulator Coupling Technology
Maxwell Circuits Block Diagram
State Machine VHDL‐AMS
Model DatabaseElectrical, Blocks, State Machines, Automotive, Hydraulic,
© 2011 ANSYS, Inc. May 10, 201247
Electrical, Blocks, State Machines, Automotive, Hydraulic,Mechanics, Power, Semiconductors…
Analog Circuit Simulator
Multi‐domain simulation example
• Electrical supply bjt1 bjt2Digital ControlC 1 BS >Q
Digital Electrical
ctrl1pp y• Digital control• Mechanical / fluid
Battery- +
TRIG
CTRL2
CTRL1 BS=>Q
BS=>Q
TRIG
75
A
75ctrl2
behavioural models DETECTPLUNGER
I
pp1Solenoid
plunger_control
plungerF
em_force
Solenoidmp2
m := 0.0066 s0 := 0.0002
orifice
limit
springF
accumulatorgravityv alue := 0.0066*9.8
spacer
© 2011 ANSYS, Inc. May 10, 201248
sul := 0.0002sll_ := 0.0
Mechanical Hydraulic
Multi‐Physics Co‐Simulation Transient Electromagnetic
FEM Co‐simulation – Maxwell 2D/3D
bjt1 bjt2Digital ControlC 1 BS >Q
Digital Electrical
ctrl12D/3D
Battery- +
TRIG
CTRL2
CTRL1 BS=>Q
BS=>Q
TRIG
75
A
75ctrl2
DETECTPLUNGER
I
pp1Solenoid
plunger_control
plungerF
em_force
Solenoidmp2
m := 0.0066 s0 := 0.0002
orifice
Future: Multidomain model extraction and co‐simulation
limit
springF
accumulatorgravityv alue := 0.0066*9.8
spacer
© 2011 ANSYS, Inc. May 10, 201249
sul := 0.0002sll_ := 0.0
Mechanical Hydraulic
Semicondutor Modeling In SimplorerIGBT Device model• Semiconductor device model on SimplorerIGBT D i d l A / D i• IGBT Device model : Average / Dynamic
• Capability of IGBTmodel
Thermal management for Inverter• Thermal model in Simplorer’s semiconductor model.• Extract thermal network from ANSYS Icepak• Extract thermal network from ANSYS Icepak• Heat / Power loss coupling with device model
Inverter surge and conduction noise• Extract parasitic LCR from Q3D Extractor• Inverter surge and conduction noise in Simplorer
© 2011 ANSYS, Inc. May 10, 201250
g p
Semiconductor device model in SimplorerIdeal switch model • ON:short, OFF:open
Semiconductor system level• Modeled as nonlinear resistance in consideration of a static characteristic.
Semiconductor device levelSemiconductor device level• Dynamic characteristics, therma and physical characteristics are modeled. – BJT / MOSFET /JFET / IGBT / Diode / Thysistors…
SPICE compatible • spice‐3f5 compatible
© 2011 ANSYS, Inc. May 10, 201251
spice‐3f5 compatible– MOSFET (spice3 Lv.1 ‐ 6, BSIM1 ‐ 4, EKV,JFET)
IGBT model 1. System model
• Nonlinear resistance– verification of operation1) 2)
2. Average model• Static char & average loss• Static char. & average loss.
– Heating & temp. rise
3 Basic Dynamic model3)4)
3. Basic Dynamic model• Dynamic char.& Energy
– Switching loss & heating.
3)
4. Advanced Dynamic model• Detailed dynamic char.
© 2011 ANSYS, Inc. May 10, 201252
y– Inverter surge & noise
IGBT Characterization
• Average model is developed for system i l ti d i i t t d i t th t tisimulation and is integrated into the extraction tool
• Common thermal model is used among the gIGBT family members
© 2011 ANSYS, Inc. May 10, 201253
Average IGBT modelA switching waveform (current and voltage) is systematic.
Calculate a switching loss for every cycle.
DC loss and turn ON/OFF loss pulse is an input to a thermal network.
Losses compute as an averaged rectangle pulse.
A thermal network is calculable in the independent sampling time.
• PON/POFF – switching loss• EON/EOFF – switching energy loss• PDC – conduction loss • TON/TOFF – turn on , turn off time• Vce,sat – collector‐emitter saturation voltage.
© 2011 ANSYS, Inc. May 10, 201254
Dynamic IGBT model
Static characteristic modeled the same as Average model.
Switching energy is derived by the integration of a current cross voltage waveform. g gy y g g
The Dynamic model can obtain an exact switching waveform.
It can applies also to EMI/EMC and a noise simulation.
700.0 00.0
66.7
333.3
500.0
66.7
33.3
00.0
Eoff
Eon
-231.0 618.00 200.0 400.050.0
0
-172.0 750.00 200.0 400.0 600.050.0
0
（VCE=600V、IC=300A、VGE=15V、T=25℃）
© 2011 ANSYS, Inc. May 10, 201255
IGBT device circuit model
RT1 RT2 RT3 RT4Zth_IGBT
IGBT chip bottomIGBT junction
THERMO_T
I l i l i i
Internal thermal network
PT
CT1 CT2 CT3 CT4
RD1
CD1
RD2
CD2
RD3
CD3RDT CDT
RD4
CD4
impedance to ambient
Diode junction
ST
SD
open @ typ_therm>2
switches to GND @ typ_therm +10
Internal equivalent circuit
Current, Voltage, Temp., VgeSlope dependency modeled for each capacitance.
© 2011 ANSYS, Inc. May 10, 201256
Zth_diode
PDSD
Diode chip bottomTHERMO_D
Independent tail current source.
RC snubber are implemented.
IGBT Characterization
© 2011 ANSYS, Inc. May 10, 201257
IGBT inverter designCircuit design (loss) + thermal model
Ambient temperature = 20 cel
Package temperature
1T 1D
1T, 1Djunction temperature
1T 1D
temperature
Examination of l
© 2011 ANSYS, Inc. May 10, 201258
Line current
1T, 1D SW loss + DC loss
temperature cycle
Simplorer + Icepak= Detailed modeling of thermal system
ANSYS IcepakANSYS IcepakQ3D ExtractorQ3D Extractor
CAD Import
Parasitism LCR extraction
Design of the cooling technique and arrangement
00.0
00.0
g
-231.0 618.00 200.0 400.050.0
0
66.7
33.3 SimplorerSimplorer
The simulation in consideration of change of detailed temperature
© 2011 ANSYS, Inc. May 10, 201259
Device property and loss consultation
Design of substrate radiating route
change of detailed temperature environment
Induction Motor FEA Coupled with Simplorer
PhaseA1
PhaseA2
PhaseB1
Rotor1
Rotor2
+
1400 rpm
B6U
D1 D3
2L3_GTOS
g_r1 g_s1 g_t1
~
3PHASA * sin (2 * pi * f * t + PHI + phi_u)
PHI = 0°
G_R1 := SA.VAL
G_R2 := -SA.VAL
G_S1 := SB.VAL
G_S2 := -SB.VAL
G_T1 := SC.VAL
G_T2 := -SC.VAL
+ V
Frequency controlled speed
FEA
PhaseB1
PhaseB2
PhaseC1
PhaseC2ICA: LL:=237.56uRA:=696.076m
D1 D3 D5
D2 D4 D6g_r2 g_s2 g_t2
~
~
PHI = -120°
PHI = -240°
LDUM:=100mCDC:=10m
AMPLITUDE := 800 VFREQUENCY := 60 Hz
FREQ := 800 HzAMPL := 800PHASE := 0 deg
FREQ := 50 HzCDC: 10mLDC:=10mRDC:=10VZENER:=650
AMPL := 500PHASE := -315 deg
PHASE := -195 deg
PHASE := -75 deg
SA
SB
SC
Name Value
SIMPARAM1.RunTime [s] 111.29k
SIMPARAM1.TotalIterations 40.51k
SIMPARAM1.TotalSteps 10.00k
FEA1.FEA_STEPS
Fed by ac-dc-ac inverter
300.00
0
200.00
LA.I [A]
LB.I [A]
LC.I [A]
1.50k
1.00k 100.00 * LD.I [A]
VDC.V [V]
425.00
0
Current Torque
Speed
-297.50
-200.00
0 100.00m50.00m
-500.00
0
0 100.00m50.00m
-715.00
-500.00
0 100.00m50.00m
p
© 2011 ANSYS, Inc. May 10, 201260
BLDC motor FEA Coupled with SimplorerOutput torque
ICA: LL:=922uRA:=2.991
PWM_T:=60
PWM PER 180-14.50
7.80
0
Output torque
Inverter fed three phase BLDC motor drive
Chopped current control
sourceA1
sourceA2
sourceB1
Magnet01
Magnet02
+
1500 rpm
I_TARG:=9
I_HYST:=0.2
Q1 Q3 Q5 RA Ohm LL H
PWM_PER:=180
0 30.00m20.00m
FEA
sourceB2
sourceC1
sourceC2
+GAIN ANGRAD
QS1VAL[0] := mod( INPUT[0] ,INPUT[1] )
Q2Q4 Q6
400 V
THRES := PWM_TINPUT[1] := PWM_PER
CONST
CONST
EQUBL
EQUBL
EQUBL
57.3
-60+PWM_PER
-30+PWM_PER
QS2
QS3
CONST
QS4-90+PWM_PER
LB.I
-LC.I
LA.I
h d EQUBL
EQUBL
CONST
QS5-120+PWM_PER
EQUBL
CONST
QS6
-150+PWM_PERINPUT := -LB.I
LC.I
-LA.I
THRES1 := I_TARG - I_HYST
8.50
10.00
0
Chopped currents
8.50
© 2011 ANSYS, Inc. May 10, 201261
0
5.00
0 20.00m 30.00m
-10.30
0 30.00m20.00m 0
5.00
0 30.00m20.00m
SRM FEA Coupled with Simplorer
A1
A2
AirRotor1
AirRotor2
+
26293 rpmICA: LL:=70.6914u
RA:=203m
A2
B1
B2
C1
C2
AirRotor2
140 V
100u F
FEA
+ ANGRADGAIN
57.3
CONST -60+90
EQUBL
VAL[0] := mod( INPUT[0] ,90 ) QA
QBName Value
FEA1.FEA_STEPS 1.00kSIMPARAM1.RunTime [s] 6.90k
SIMPARAM1 TotalIterations 4 05k
CONST -30+90QC
EQUBL
EQUBL
SIMPARAM1.TotalIterations 4.05kSIMPARAM1.TotalSteps 1.00k
100.00 10.00 * QA.VAL10.00 * QB.VAL + 30.0010.00 * QC.VAL + 60.00ROTA VAL[0]
264.00m
200 00
mechanical18.00 L1.I [A]
L2.I [A]L3.I [A]
current control variable
50.00
ROTA.VAL[0]ROTB.VAL[0]ROTC.VAL[0]
0
100.00m
200.00m 10.00u * FEA1.OMEGA
V_ROTB1.TORQUE [Nm]
-10.00
0
10.00 E1.I [A]
© 2011 ANSYS, Inc. May 10, 201262
0
0 1.00m500.00u-54.00m
0 1.00m500.00u
-17.80
0 1.00m500.00u
Electric Machine Design: Maxwell – Simplorer Co‐Simulation
3‐ph Windings
Stator & RotorStator & Rotor
Permanent Magnets
Co‐simulation
Permanent Magnets
© 2011 ANSYS, Inc. May 10, 201263Flux Linkages
3ph Line Currents
MultiMulti‐‐physicsphysics
© 2011 ANSYS, Inc. May 10, 201264
Multiphysics Coupling through WB
•• Maxwell 3D provide volume/surface forces to ANSYS Structural• Solver improvements
S f f t d– Surface forces are supported
Thermal‐Stress with Electromagnetic Force load
© 2011 ANSYS, Inc. May 10, 201265Deformation of the stator Deformation of coils
The electromagnetic force density from Maxwell is used as load in Structural
Force Coupling – Maxwell to Mechanical
0.00
5.00
10.0002_DC-6step_IPMTangential Force on Tooth Tips ANSOFT
-20.00
-15.00
-10.00
-5.00
Forc
e (N
ewto
ns)
Curve InfoExprCache(ToothTipTangent_Full1)ExprCache(ToothTipTangent_2)ExprCache(ToothTipTangent 3)
50.0002_DC-6step_IPMRadial Force on Tooth Tips ANSOFT
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00Time [ms]
-30.00
-25.00
ExprCache(ToothTipTangent_3)ExprCache(ToothTipTangent_4)ExprCache(ToothTipTangent_5)ExprCache(ToothTipTangent_6)
150 00
-100.00
-50.00
-0.00
Forc
e (N
ewto
ns)
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00Time [ms]
-250.00
-200.00
-150.00Curve Info
ExprCache(ToothTipRadial_Full1)ExprCache(ToothTipRadial_2)ExprCache(ToothTipRadial_3)ExprCache(ToothTipRadial_4)ExprCache(ToothTipRadial_5)ExprCache(ToothTipRadial_6)
© 2011 ANSYS, Inc. May 10, 201266
Force Coupling – Maxwell to Mechanical
Max Deformation vs timeMax Deformation vs time
• Case 1 0% Eccentricity
© 2011 ANSYS, Inc. May 10, 201267 • Case 2 50 % Eccentricity
Maxwell Couplings
Mapped Losses2D/3D Losses Temperature
© 2011 ANSYS, Inc. May 10, 201268
Forced water cooling Forced air cooling Natural air cooling
Two Way CFD Thermal Analysis, R14
CFD Model Temperature
Geometry
© 2011 ANSYS, Inc. May 10, 201269
Losses
Maxwell Model Mapped Losses
Power Loss Mapped into FLUENT
Power Loss in windings are not displayed.Power Loss in windings are not displayed.
© 2011 ANSYS, Inc. May 10, 201270
Results – Temperature Distribution
© 2011 ANSYS, Inc. May 10, 201271
Thank youThank you© 2011 ANSYS, Inc. May 10, 201272
Thank youThank you
