2019 11 06 solving challenges of ev hev nvh simulation … · 2019-11-08 · ev hev nvh simulation...

© 2019 – EOMYS ENGINEERING – www.eomys.com

SOLVING EV HEV NVH SIMULATION CHALLENGES

Application with MANATEE software & e-NVH open-source testbed

� Jean LE BESNERAISCEO of EOMYS

1

Séminaire NAFEMS “La simulation pour la mobilité électrique”Paris, 13 Nov 2019


= ++E-powertrain overall noise

Slot/pole interactionelectromagnetic noise

Pulse Width Modulationelectromagnetic noiseAerodynamic noise

~ball passing frequencies

~gear mesh frequencies

tyre/road noise

~slot/pole passing frequencies ~switching frequencies

e-NVH

What is magnetic noise & vibrations (e-NVH) in EV HEV applications?

Mechanical noise +~blade passing frequencies

wind noise

Case of Renault Zoe e-powertrain - measurement by EOMYS- sound separation by GENESIS & EOMYS

2


ex: Nissan Leaf ex: Renaut Zoe

3

1. variable current source

What is magnetic noise & vibrations (e-NVH) in EV HEV applications?

noise and vibrations coming from variable electromagnetic forces

forces arising from the presence of a variable magnetic field : Maxwell & magnetostriction

3. rotating DC current source2. rotating permanent magnets

I=constant

Always present in e-motors Only present in magnet-based motors Only present in wound rotors

ex: Tesla S

© 2019 – EOMYS ENGINEERING – www.eomys.com 4

What is so special about EV HEV NVH?

• Depends on e-motor topology, load state, fault state and control strategy

• e-NVH problem solving requires skills in both electrical engineering & NVH

• e-NVH transfer path can be complex (structure-borne + air-borne, 3D excitations)

• e-NHV numerical simulation is very challenging (multiphysics + variable speed, high frequency effects)


EV HEV NVH simulation process – drivetrain level

• E-motor mainly affects gear whine through global forces, namely torque ripple & UMP

• Gear mesh frequencies and e-machine excitation frequencies should not overlap (at least of H1)

• Without overlap there is no dynamic coupling so gear whine and motor whine can be analyzed separately

• Strong e-motor to drivetrain couplings can be studied separately, as well as static magnetic forces impact on gearbox (e.g. torque, axial UMF)

[B71]

RPM

Hz

E-machine ordersGear stage 1 ordersGear stage 2 orders


EV HEV NVH simulation process – electric motor level

• Multi-physics models: electrical / electromagnetic / structural mechanics / acoustics

• Strong electrical to magnetic coupling recommended to capture magnetic forces due to induced harmonic voltages (phase-belt harmonics) [R7,E8]

• Strong electro-mechanical coupling in electric motor can be studied separately (e.g. eccentric UMP & CF non linearities)

time domain (ex: Simulink)

or frequency domain (ex: EEC)

Magnet /

current

excitations

ELECTROMAGNETIC MODULE

ELECTRICAL MODULE

STRUCTURAL MODULE

ACOUSTIC MODULE

Dynamic

vibrations Variable

speed NVH

Geometry

and control

parameters

3D force

distribution

time-space domain

or frequency domain (ex: IM)frequency domain

frequency domain

and time domain (sound quality)


EV HEV NVH simulation process – general challenges

• Need of fast calculations in early design phase: electrical engineer choices can lead to +/- 20 dB variations for same electromagnetic performances

• Need of accurate calculations in detailed design phase: iterations with prototype testing ismandatory (e.g. quantification of damping and geometrical/magnetic asymmetries)

• Active research field: magnetic force calculations, mesh to mesh projections

Ex of a traction SCIM

+/-20 dB


• High frequency (e.g. PWM) effects at low speed require high CPU time (small time step) [R14][R38]

• Variable speed application requires large number of speed steps to catch resonances

• Fine airgap mesh necessary for accurate magnetic force calculation

• Transient magnetic simulation may be necessary (for IM magnetoharmonic solver cannot include slotting effects)

[R41]

[Magnet website]

[R42]

EV HEV NVH simulation process – numerical challenges


• Blocked step technique is sometimes used to reduce mesh ripple, resulting in a match between space and time discretization

• For a fixed airgap mesh maximum frequency increases with speed and high frequency low speed NVH is missed

Flux, [R40]Ansys, [R67]


missing part of vibration and noise spectrum



• Full FEA-based simulation of variable speed e-NVH including skewing, strong electromagneticcoupling and PWM or asymmetries (e.g. eccentricities) can take several days of simulations

• Need of several modelling levels & model hybridation to address e-NVH issues during whole V-cycle e-motor development process

• Need of analytic & semi-analytic techniques to avoid parasitic numerical noise or filter FEA-basedcalculations


MANATEE software solutions - overview

• MANATEE is the only simulation environment dedicated to electric motor e-NVH simulation, analysis and reduction at all design stages

Third-party sound quality tools

Third-party electromagnetic design tools

Third-party structural design tools

Third-party acoustic design tools

Standalone e-motor NVH solution (electromagnetics

+vibro-acoustics)

© Actran

© Oros

© Jmag

© Ansys

Third-party NVH data acquisition tools

© Oros

optional

v1.08 coupling

v1.09 coupling


MANATEE software solutions – early design magnetic solutions

• Use of Permeance / MagnetoMotive force models or SubDomain Models for fast airgap Maxwell stress calculations in early design phase

• Hybridation of PMMF and SDM with non-linear magnetostatic FEA to extend these models to all main radial flux topologies

Subdomain model on SPMSM:Permeance/mmf model on SCIM:


MANATEE software solutions – early design magnetic solutions

time

Flux: ~1 hour MANATEE: ~1 sec

Ex: comparison of MANATEE SDM and Flux FEA airgap flux distribution on a loaded SPMSM including non-linearity:

time

airgap angle airgap angle


MANATEE software solutions – early design vibro-acoustic solutions

• Use of semi-analytical equivalent cylindrical shell vibro-acoustic models

Acoustic meshat 590Hz

Acoustic meshat 2116Hz

Ex: comparison of MANATEE semi-analytic model and Actran/Nastran FEA on EV HEVe-motor under variable frequency Maxwell stress harmonic of wavenumber r=2

Actran: ~20 mnMANATEE: ~1 sec


MANATEE software solutions – detailed design solutions• Electromagnetic Vibration Synthesis or Electromagnetic Noise Synthesis algorithms

airgap flux distribution

HARMONIC FORCE PROJECTION

r=1 r=2

MAGNETIC MODEL

r=0

STRUCTURAL MODEL

Unit rotating loads identified with

MANATEE (r=0, ±1, ±2 …)radial + tangential + moments

applied to stator + rotor

STRUCTURAL FREQUENCY RESPONSE FUNCTIONS

ELECTROMAGNETIC VIBRATION SYNTHESIS

2D or 3D external FEA software MANATEE built-in magnetic models

3D external FEA software MANATEE built-in structural models

Vibration & noise per load case (numerical TPA)Air-borne Vs structure-borne noise

Rotor Vs stator noise due torque / radial ripple & UMP

CALC

ULA

TION O

F

OPERATIONAL LO

ADS

STRUCTU

RAL

CHARACTE

RIZATION

vibration velocity field


MANATEE software solutions – EV HEV NVH demo on Prius• Early design stage application: 100 speeds up to 8,4 kHz in 5 sec

project tuto_IPMSM_03


MANATEE software solutions – EV HEV NVH demo on Prius• Detailed design stage application (coupling with Ansys): 100 speeds up to 8,4 kHz in 10 mn

project tuto_IPMSM_20


EV HEV NVH open-source testbed

• Allow reproducible research works around e-NVH phenomena (e.g. saturation, slot modulation, magnetomechanical coupling)

• Perform benchmarking of simulation software & algorithms (e.g. accuracy Vs computing time)

• Perform benchmarking of testing hardware & algorithms (e.g. EMA, acoustic imaging, TPA methods)

• Use the tesbench for education & training, illustrating all e-NVH control techniques on a single testbench (skewing, notching, RPWM, passive insulation, etc)

Objectives



• Geometry & weights

• Voltage, current

• Magnetization, airgap flux density

• Vibration, noise (SWL in semi anechoic chamber)

• EMA / ODS / OT / spectrogram / spatiogram

Multiphysic test plan

Acc. [m/s²]

Frequency [Hz]

(2,0)720 Hz

(1,0)850 Hz

(1,1)1150 Hz

2fs

4fs

Rotation sped

[RPM

]

10f

s

• Variation of slot number, tooth thickness, slot opening

• Variation of step-skew pattern

• Inner / outer rotor

Magnetic design variations



• Open-data available at https://eomys.com/recherche/article/e-nvh-benchmark

• Collaboration with simulation software providers, NVH systems suppliers, sensor suppliers and with laboratories is welcome


Thank you for your attention

� [email protected]

� www.eomys.com


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Espanet, “Natural Frequencies Analytical Modeling of Small Industrial Radial Flux Permanent Magnet Motors”, 18th International Conference on Electrical Machines and Systems (ICEMS), 2015. [R12] J.L. Coulomb, “A methodology for the determination of global electromechanical quantities from a finite element analysis and its application to the evaluation of magnetic forces, torques and stiffness”, IEEE Transactions on Magnetics, 1983.[R13] F. Henrotte and K. Hameyer, “Computation of electromagnetic force densities: Maxwell stress tensor vs. virtual work principle”. JCAM, 2004,[R14] M. Boesing, « Noise and Vibration Synthesis based on Force Response Superposition », PhD Thesis, RWTH Aachen, 2013.[R15] F. Zidat, H. Ennassiri, «Webinar: Vibro‐acoustics Analysis for noise reduction of electric machines Example: Synchronous Machine – Flux 2D Coupling to ANSYS”, © FLUX CEDRAT, 2015.[R16] C. McCulloch, M. Tournour, and P. Guisset, « Modal Acoustic Transfer Vectors Make Acoustic Radiation Models Practical for Engines and Rotating Machinery », LMS International, 2002.[R17] M. Régniez, Q. Souron, P. Bonneel and J. Le Besnerais, “Numerical simulation of structural-borne vibrations due to electromagnetic forces in electric machines - coupling between Altair Optistruct and Manatee software”, 2016[R18] F. Marion, “Magneto-vibroacoustic analysis: a new dedicated context inside Flux ®11.2” , Cedrat News, 2013[R19] K. Vansant, “From Tesla to Pascal, a magneto-vibroacoustic analysis linking Flux® to LMS Virtual. Lab”, Cedrat News, 2014[R20] G. Kumar, “Noise prediction for electric motors by coupling electromagnetic and vibroacoustic simulation tools”, Proceedings of NAFEMS conference, 2014[R21] M. Solveson, C. Rathod, M. Hebbes, G. Verma, T. Sambharam, “Electromagnetic Force Coupling in Electric Machines”, ANSYS Inc, http://resource.ansys.com, 2011[R22] J. Hallal, “Études des vibrations d'origine électromagnétique d'une machine électrique : conception optimisée et variabilité du comportement vibratoire”, PhD thesis (in French), 2014[R23] P. Pellerey, V. Lanfranchi, G. Friedrich, "Coupled Numerical Simulation between Electromagnetic and Structural Models. Influence of the Supply Harmonics for Synchronous Machine Vibrations," in IEEE TMag, 2012,[R24] V. Wilow, “Electromagnetical model of an induction motor in COMSOL Multiphysics”, Master’s thesis, KTH University, Sweden, 2014[R25] M. K. Nguyen, “Predicting Electromagnetic Noise in Induction Motors”, Master’s thesis, KTH University, Sweden, 2014[R26] M. K. Nguyen, R. Haettel and A. Daneryd, “Prediction of Noise Generated by Electromagnetic Forces in Induction Motors” [R27] T. Hattori, “Starting With Vibration Noise Analyses” JMAG Newsletter January, 2014. [R28] F. Chauvicourt, C. Faria, A. Dziechciarz and C. Martis, "Infuence of rotor geometry on NVH behavior of synchronous reluctance machine," 2015 Tenth International Conference on Ecological Vehicles and Renewable Energies (EVER), Monte Carlo, 2015, pp. 1-6.[R29] H. Ennassiri, “Magneto-Vibro-Acoustic Analysis Linking Flux® to ANSYS® Mechanical”, 2016[R30] M. Senousy, P. Larsen, and P. Ding, "Electromagnetics, Structural Harmonics and Acoustics Coupled Simulation on the Stator of an Electric Motor," SAE Int. J. Passeng. Cars - Mech. Syst, 2014.


REFERENCES[R31] X. Ge, “Simulation of Vibrations in Electrical Machines for Hybrid-electric Vehicles”, 2014[R32] P. Lombard, “Webinar: Summary of Vibro-acoustic Coupling”, © FLUX CEDRAT, 2017.[R33] D. Meeker, “Finite Element Method Magnetics” FEMM User Manual, 2015.[R34] D. Twyman, “Webinar: ANSYS Maxwell Coupling”, 2016. [R35] F. Lin, S. Zuo, W. Deng and S. Wu, "Modeling and Analysis of Electromagnetic Force, Vibration, and Noise in Permanent-Magnet Synchronous Motor Considering Current Harmonics," in IEEE Trans. Ind. Elec, 2016. [R37] Z.Q Zhu and D. Howe,“Electromagnetic noise radiated by brushless permanent magnet DC drives. 6th International Conference on Electrical Machines and Drives, 1993.[R38] J. Le Besnerais, “Fast Prediction of Variable-Speed Acoustic Noise and Vibrations due to Magnetic Forces in Electrical Machines”, ICEM 2016,[R39] S. Zuo, F. Lin and X. Wu, "Noise Analysis, Calculation, and Reduction of External Rotor Permanent-Magnet Synchronous Motor," in IEEE Trans. Indus. Elec, 2015.[R40] P. Pellerey, “Etude et Optimisation du Comportement Vibro-Acoustique des Machines Electriques, Application au Domaine Automobile”, PhD thesis, Univ. Tech. Compiègne, 2012[R41] J. Le Besnerais, "Fast prediction of variable-speed acoustic noise due to magnetic forces in electrical machines," ICEM, 2016.[R42] S. Peters and F. Hetemi, « Airborne Sound of Electrical Machines using Symmetric Matrices in ANSYS 14”, ANSYS Conference[R43] M. Van der Giet et al, “Comparison of acoustic single-value parameters for the design process of electrical machines”, Internoise 2010.[R44] G. Verez, “Contribution à l’étude des émissions vibro-acoustiques des machines électriques. Cas des machines synchrones à aimants dans un contexte automobile », PhD thesis, University of Le Havre, 2014.[R45] K. Balachandran, “Electric Motor Noise and Vibration simulation using Actran software”, MSC software, Nov 2016 [ppt][R46] D. Reeves, “From Electromagnetic Forces To Acoustics - Full Chain Analysis for Vibro-Acoustic Studies with Electromagnetic Excitations”, MSC software, 2015 [ppt][R47] J. Chen, Y. Ma, and R. HE, “SMFF Computation for Probe of Online Magnetic Flux Leakage Detection System with combination of ANSYS and Virtual Work Method”, In International Symposium on Mechanical Engineering and Material Science, 2016.[R48] L. Kostetzer, F. Hetemi, and D. Gerling, "Scalable system simulation for electric drives," in Electric Drives Production Conference (EDPC), 2011.[R49] P. Dular and C. Geuzaine, “GetDP reference manual: The documentation for GetDP, a general environment for the treatment of discrete problems”[R50] ME2D User Guide, Cobham Technical Services, Opera, Oxford, U.K. [Online] Available: https://operafea.com/[R51] FLUX3D User Guide, Version 10.3.3. [Online]. Available: https://altairhyperworks.com/product/flux[R52] J. Otto, “Simulation of Electric Machines with ANSYS”, © CADFEM (2017). [ppt][R53] M, Michon, “Workshop: Romax electrical machine NVH analysis”, © ROMAX Technology (Oct. 2016). [ppt][R54] K. Kouumdjieff and M. Popescu, “Webinar: Solving Electric Vehicle Powertrain problems using RomaxDESIGNER and Motor-CAD”, (2017). [ppt][R55] A. McCloskey, X. Arrasate, G. Almandoz, X. Hernandez, and O. Salgado, “Vibro-acoustic finite element analysis of a Permanent Magnet Synchronous Machine”. EURODYN, 2014.[R56] Owen Harris, April 2019 webinar, https://www.smartmt.com/video/webinar-nvh/[R57] A. Anderson “Electric Machine Control for Energy Efficient Electric Drive Systems”, PhD Thesis, Chalmers University, 2019[R58] R. Pile et al, “Application Limits of the Airgap Maxwell Tensor”, CEFC 2019[R59] Numerical Prediction of Motor Noise in a Continuous Speed Range, J. Wobbler, M. Hanke, TAE symposium Elektromagnetismus 2019, 8-9 March 2019*[R60] D. Torregrossa, B. Fahimi, F. Peyraut and A. Miraoui, "Fast Computation of Electromagnetic Vibrations in Electrical Machines via Field Reconstruction Method and Knowledge of Mechanical Impulse Response," in IEEE Transactions on Industrial Electronics, vol. 59, no. 2, pp. 839-847, Feb. 2012.[R61] Pile, R., Devillers, E., & Le Besnerais, J. (2019). Comparison of Main Magnetic Force Computation Methods for Noise and Vibration Assessment in Electrical Machines. IEEE Transactions on Magnetics, 54(7), 1–13. [R62] Parent, G., Dular, P., Ducreux, J.-P. P., & Piriou, F. (2008). Using a galerkin projection method for coupled problems. IEEE Transactions on Magnetics, 44(6), 830–833.[R63] Farrel, P. E. Galerkin projection of discrete fields via supermesh construction. 2009. Thèse de doctorat. Imperial College London.[R64] Liang, W. (2017). The investigation of electromagnetic radial force and associated vibration in permanent magnet synchronous machines. Cranfield University.[R65] P. Millithaler, “Dynamic behaviou of electric machine stators – modelling guidelines for efficient finite-element simulations and design specifications for noise reduction”, 2013, PhD thesis, UFC


REFERENCES[R66] Michael Shwarzer, « Structural Dynamic Modeling and Simulation of Acoustic Sound Emissions of Electric Traction Motors”, PhD thesis, 2017[R67] https://www.youtube.com/watch?v=FlJ3thJ3I9Y[R68] “Simcenter Acoustics Electric Motor Noise”, presentation, 2016[R71] F.V. Bombardi et al, « Effects of unbalancedmagnetic pull on NVH performance of an electric drivetrain », SAE 2018[R72] M. Michon, « Electromechanical interactions in the design of integrated EV drivetrains », Romax presentation, Oct 2016


BACK UP SLIDES

25


How is xEV NVH applications?

(pole)

26


How xEV NVH is generated?

• Magnetic forces excite both stator and rotor, resulting in air-borne and structure-borne noise

• Resonance occurs when magnetic forces frequency + shapematch with a natural frequency + modal shape

+ RESONANCE=

magnetic excitation of wavenumber r=2 at fnat

modal shape (2,0) at fnat

27


How xEV NVH is generated?

• It is therefore important to identify magnetic force wavenumbers r and frequency f as well as to identifymodal shapes, and vibro-acoustic transfer path

= + + +

+r=0

“tangential ripple”

“torque ripple”

pulsating+…

28

2019 11 06 solving challenges of ev hev nvh simulation … · 2019-11-08 · ev hev nvh simulation...

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