SolidWorks + JMAG-Designer + JMAG-Studio + modeFRONTIER

2008 modeFRONTIER® users' meeting 2008 October 14-15, Trieste Italy

  SolidWorks + JMAG-Designer + JMAG-Studio + modeFRONTIER

CD-adapco JAPAN Co., LTD.

Integrated Simulation Technology Dept.

Yasushi Fujishima ([email protected])

P2


  Introduction

  Definition of Optimization Problem for Rotor Design of Interior Permanent Magnet Synchronous Motor

  Analysis model and configuration

  Optimized Results

  Conclusion

P3


  Design optimization of Interior Permanent Magnet Synchronous Motor (IPMSM) was conducted applied for railway traction systems of electric commuter train.

Electric Commuter Train�Stator

Winding Coil

Rotor

IPMSM Configuration �

Permanent Magnet

Electric Commuter Train�

P4


  Difficulties   Rotor shape of IPMSM often becomes complicated structure involving

magnetic saturation and concentration of mechanical stress. Therefore it is not easy to determine optimal rotor shape.

  Plural characteristics must be improved simultaneously under the several constraints.

Magnetic Analysis Structural Analysis Torque Characteristics

Circuit Voltage Characteristics

High Efficiency

Mass Reduction

Reduce Mechanical stress

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N

S

S

N

N

N S

S

Magnetic attraction force

Magnetic repulsion force

Torque Generation

N

S Magnetic Pole

Torque Generation

Stator

Winding Coil

Rotor

IPMSM Configuration �

Permanent Magnet

P6


Torque of IPMSM is divided by magnet torque and reluctance torque.

Without permanent magnet

Reluctance torque is only generated by magnet poles established by the salient shape of rotor core.

Permanent Magnet only.

S

N S

N

N N

S

S

To maximize the total torque, one has to try to maximize both the magnet torque and reluctance torque simultani that are

Magnet torque is only generated by magnet poles established by permanent Magnet.

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  Maximization of Average Torque

  Minimization of open-circuit voltage   To prevent unexpected regenerative brake at maximum speed during no

-load operation

  Minimization of Rotor Mass   To reduce total mass

  Minimization of max value of Von Mises Stress   For at max speed operation

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  What is JMAG ?   Electromagnetic field analysis software based on FEM (or FEM-

BEM) developed by Japan Research I Solutions, Limited.

  Application Field   Motor, Actuator, Transformer, Sensor, Magnetic Recording

Device, Antenna, other electro-magnetic devices and so on.

  Other topics   2D/3D FEM analysis, FEM-BEM combined analysis, static field,

Quasi-Static Field, High frequency field, Frequency domain.   Including electric circuit, thermal, structural analysis solver and

these can be coupled with magnetic field analysis.   Can also be applied for a wide range of system design problems,

including drive circuits by the capability to link the analysis with a power electronics simulator (Matlab, PSIM, etc).

  CAD direct interface (Solidworks, CATIA, Pro/E, and so on)

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  Magnetic Analysis   Analysis-1・・・Load Analysis (Appling Maximum Current Source)

  For evaluating Torque

  Analysis-2・・・No-Load Analysis ( Without appling Current Source)   For evaluating open-circuit induced voltage

  Model Configuration   Analysis Method : 2-dimentional FEM analysis   Analysis Area : Quarter part of model considering periodic boundary condition   Num. of Element: 10000　   Num. of Node : 5000   Magnetic Materials

  Stator/Rotor・・・non-oriented magnetic steel (50H400)   Permanent Magnet ・・・Rare Earth Magnet (39SH)

30°

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  Configuration of Main Electric Circuit

  Power Source : Three-phase symmetric alternating current

  Effective value of current :123.7[A]   Connection : Star

  Num. of Turns : 18 turns per 1 slot

U-Phase

U-Phase

W-Phase

V-Phase

Load Analysis No-Load Analysis

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  Structural Analysis   For evaluating maximum Von Mises Stress Value

  Model configuration   Analysis Method : FEM Analysis

  Analysis Area : 1 / 8 Rotor considering symmetric

and periodic

  Num. of Element : 10000

  Num. of Node : 4000

  Material Value　

Material Young's

modulus[Pa] Poisson’s ratio Density[kg/m3]

Iron Core 2.1*1011 0.3 7850

Perm. Magnet 1.2*1011 0.3 8400

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  The number of design variables :12   11 for rotor shape design variables

  1 for winding current phase [deg]

x4

x10 L1 L2

x11 = L1/L2 * 100 [%]

x1

x2 x3 x5

x9

x6

x7

x8

x1, x2, x3, x5, x6, x7, x8, x9 : [mm] x4, x10, x12: [deg] x11: [%]

Variable unit

Why the winding current phase must be added as design value ? Maximum torque depends on the winding current phase. So it must be optimized simultaneously to obtain maximal torque.

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  Max. Von Mises Stress・・・Less than 200[MPa]

  Torque・・・More than 600[Nm]   Can realize Rotor Configuration (Avoid unfeasible shape

design)

The bridge part is broken due to unfeasible set of design parameters.

Cannot generate FEM meshes for field analysis ! Must be avoided to Compute.

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SolidWorks has API so that user can control it from outside.

SolidWorks has VBA macro recorder then user can be somewhat easy to make VBA macros.

Change CAD parameters and detect geometry error by ExcelVBA.

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Magnetic Analysis

VBScript

JMAG-Script

Torque/Voltage data.csv

SolidWorks

DOS batch

JMAG-Designer

JMAG-Studio

JythonScript CAD Parameter

JMAG-studio output file(.plot)

CAD data

Return Output Variables

Detection of geometry error before executing SolidWorks.

Change of parametric shape design detection of geometry error .

CAD data

Return Output Variables Structural Analysis

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Objectives / Constraints

JMAG-Designer JMAG-Studio

Output Variables

SolidWorks Detection of Geometry Error

Subsytem (includes Determination of Geometry Error)

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 Step 1   Optimization Algorithm : MOGA ( Multi-Objective GA)   Primal individuals : Created Rondomly   Num. of individuals : 24   Num. of generations: 20

 Step 2   Optimization Algorithm : Fast-MOGA (Using Adaptive Response Surface)   Primal individuals: Copied a part of Pereto-Frontier obtained from Step 1   Num. of individuals : 24   Num. of generations: 20   Probability of using Adaptive Response Surface : 50 %

 Step 3   Optimization Algorithm : Fast-MOGA (Using Adaptive Response Surface)   Primal individuals: Copied a part of Pereto-Frontier obtained from Step 2   Num. of individuals : 24   Num. of generations: 20   Probability of using Adaptive Response Surface : 50 %

 Total Num. of Calculation : 747 case  Total CPU-time : 60 hours (5min per 1 case) (Pentium-4 3.2GHz)

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  Pareto-Frontier

Average Torque [Nm]

Ope

n C

ircui

t Vol

tage

[V]

Maximize

Minimize Average Torque [Nm]

Rot

or M

ass

[Kg]

Trade-Off relationship between the Open Circuit Voltage and Average Torque

Need to degrade Open Circuit Voltage to inclease Average Torque beyond 600 [Nm]

Trade-Off relationship betweeen the Average Torque and Rotor Mass

Need to degrade Rotor Mass to inclease Average Torque beyond 600 [Nm]

Minimize

Maximize

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  Rotor design on Pareto-Frontier (Average Torque vs Open Circuit Voltage)

Hierarchical Clustering (using Shape Design Parameters)

Rotor shape design among the Torque v.s. Voltage Pareto-Frontier were very similar ! �

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Average Torque [Nm]

Ope

n C

ircui

t Vol

tage

[V]

  Rotor design on Pareto-Frontier (Average Torque vs Open Circuit Voltage)

Design of Rotor iron core is almost the same except the permanent magnet size.

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  Investigation of Pareto-Frontier (Torque v.s. Voltage) from the viewpint of Magnet Torque and Reluctance Torque on

Magnet Torque Reluctance Torque

Magnet Torque Value is incleased along the Pareto-Frontier, while Reluctance Torque Value is kept almost maximum value at the Pareto-Frontier.

Torque = Magnet Torque + Reluctance Torque

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  In this study, multidisciplinary optimization of IPMSM rotor shape applied for railway traction system was conducted by modeFRONTIER.

  Automating the optimization process, design engineers can be assigned to more creative project.

  The following Trade-off relation was found:   Maximizing Torque v.s. Minimizing Open Circuit Voltage   Maximizing Torque v.s. Minimizing Rotor Mass

  Analyzing obtained Pareto-Optimal deeply by the multivariate analysis (such as Clustering Analysis), underlying design principles could be revealed.   Rotor iron core designs were very similar on the Torque v.s. Voltage Pareto-Frontier. And

the reluctance torque of those designs was almost maximized.

SolidWorks + JMAG-Designer + JMAG-Studio + modeFRONTIER

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