Download - Electric Machines and Power Electronics
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2011 ANSYS, Inc. June 8, 20121
Electric Machines
Considering Power Electronics
Zed (Zhangjun) Tang, Ph.D.
Presented at ANSYS Confidence by Design
June 5, 2012
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Machine Design Methodology Introduction
RMxprtMaxwell
Advance Capabilities
Core Loss
Demagnetization / Magnetization
Field-Circuit Co-Simulation
Maxwell Circuit Editor
Simplorer Capabilities, Switches, IGBT Characterization
Simplorer Examples
Multi-Physics
Force Coupling
Thermal Coupling
Outline
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2011 ANSYS, Inc. June 8, 20123
Introduction: MachineDesign Methodology
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2011 ANSYS, Inc. June 8, 20124
Maxwell 2-D/3-DElectromagnetic Components
Field Solution
Model Generation
HFSS
ANSYS
MechanicalThermal/Stress
ANSYS CFDFluent
PExprtMagnetics
RMxprtMotor Design
Maxwell Design Flow Field Coupling
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2011 ANSYS, Inc. June 8, 20125
SimplorerSystem Design
P P :=6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
JPMSYNCIA
IB
IC
Torque JPMSYNCIA
IB
IC
Torque
D2D
HFSS, Q3D, SIwave
ANSYS CFDIcepack/Fluent
Maxwell 2-D/3-DElectromagnetic Components
ANSYS
MechanicalThermal/Stress
PExprtMagnetics
RMxprtMotor Design
Simplorer Design Flow System Coupling
Model order Reduction
Co-simulation
Push-Back Excitation
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2011 ANSYS, Inc. June 8, 20126
RMxprt - Initial Motor Design
Analytical solution
16 different Motor/Generator types Input data geometry, winding layout saturation, core losses
comprehensive results machine parameters
performance curves
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Parametric Sweep:
Stack_Length
Skew/no Skew
Stator_ID
AirGap
Monitor:
Torque
Power
Efficiency
Determine the Best Design
Create FEA Model
Export Circuit Model
RMxprt - Motor Design
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Maxwell/RMxprt V15 Axial Flux Machine
AC or PM Rotor
Single or Double Side Stator
Sample Inputs
Sample Outputs
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Maxwell/RMxprt V15 Axial Flux Machine
Maxwell 3D auto-setup (Geometry, Motion, Master Slave, Excitations, etc. )
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2011 ANSYS, Inc. June 8, 201211
Design Exploration
P2 - parallel
P1 - cond
Workbench Schematic
Maxwell Project
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2011 ANSYS, Inc. June 8, 201213
Design Exploration Six Sigma
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2011 ANSYS, Inc. June 8, 201214
More Than 30UDP Machine
Components
for 2D and 3D
Integrated Motor Solution
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2011 ANSYS, Inc. June 8, 201215
RMxprt Dynamic Link to Simplorer
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2011 ANSYS, Inc. June 8, 201216
Maxwell
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
1.00
1.20
1.40
Position[mm]
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
CoilCurrent[meter]
TRW/ Ansoft Position & Current Hysteresis Control Close/Open1
CurveInfo
Position
CoilCurrent
DiodeCurrent
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2011 ANSYS, Inc. June 8, 201217
Automatic Adaptive Meshing
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2011 ANSYS, Inc. June 8, 201218
Advanced CapabilitiesCoreloss Computation
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2011 ANSYS, Inc. June 8, 201221
Lamination Core Loss in Time Domain
Instantaneous hysteresis loss
Instantaneous classic eddy current loss
Instantaneous excess loss
where
dt
dBH
dt
dBBkt irrmhh
cos
1)(
2
22
1)(
dt
dBkt cc
dCe 2/
0
5.15.1 cos2
2
21
)( dt
dB
kCt cee
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2011 ANSYS, Inc. June 8, 201223
Core Loss Effects on Field Solutions
Basic concept: the feedback of the core loss istaken into account by introducing an
additional componentof magnetic field Hin
core loss regions. This additional component
is derived based on the instantaneous coreloss in the time domain
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2011 ANSYS, Inc. June 8, 201225
Model Validation by Numerical Experiment
The effectiveness of the model can be validated by the
power balance experiment from two test cases:
considering core loss feedbackand without considering
core loss feedback. The increase of input electric power
and/or input mechanical power between the two cases
should match the computed core loss.
0
20
40
60
80
100
120
140
160
0 20 40 60 80 100
Time (ms)
Los
s(W)
Input power increase
Core loss 0
2
4
6
8
10
12
0 5 10 15 20 25 30 35 40
Time (ms)
L
oss(W)
Core loss
Input power increase
Three-phase transformer Three-phase motor
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2011 ANSYS, Inc. June 8, 201226
Advanced CapabilitiesDemagnetization Modeling
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2011 ANSYS, Inc. June 8, 201227
Modeling Mechanism
The worst demagnetization pointfor each element is dynamically
determined from a full transient
process
The demagnetization point issource, position, speed and
temperature dependent
Each element uses its own recoil
curve derived at the worst
demagnetization point in
subsequent transient simulation
HHc
B
0
Br'
Br
K
p Recoil lines
Worst demagnetizing point
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HHc
B
0
Br'
Br
K
p Recoil line
Irreversible Demagnetization
If a demagnetizing point Pgoes below the knee point K,
even after the load is reduced or totally removed, thesubsequent working points will no longer along the
original BH curve, but along the recoil line.
The animation shows how the demagnetization
permanently occurs with varying load current
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2011 ANSYS, Inc. June 8, 201232
Benchmark Example
8-pole, 48-slot, 50 KW, 245 V, 3000 rpm Toyota Prius IPMmotor with imbedded NdFeB magnet
Two steps in 3D transient FEA:
1. Determine the worst operating point element by elementduring the entire transient process
2. Simulate an actual problem based on the element-basedlinearized 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 analysis
The computed temperature distribution from thermal solveris further feedback to magnetic transient solver to considertemperature impact on the irreversible demagnetization
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2011 ANSYS, Inc. June 8, 201233
Hc'change in one element during a transient process:
The 1stcycle (0 to 5ms) doesnt consider temperature impact. The 2nd
cycle (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
A/m, which is derived from the worst operating condition
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2011 ANSYS, Inc. June 8, 201234
Contours of loss density distribution Static temperature distribution (K)
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2011 ANSYS, Inc. June 8, 201235
Torque profiles showing demagnetization and
temperature dependence:
Torque profiles derived from without considering demagnetization,
considering demagnetization but no temperature impact and
considering demagnetization as well as temperatures dependence
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2011 ANSYS, Inc. June 8, 201236
Magnetization
Compute magnetization basedon the original non-remanent
B-H curve
Find operating pointp from
nonlinear solutions
Construct line bat the operating
pointp, which is parallel to the
line a at saturation point
Br is the intersection of line b
with B-axis Element by element
B
H0
Br Line b
Slope of line a at saturation point
p
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Br
Magnetostatic case: theoperating point used for computing
magnetization (Br) is from single
source point;
What is the Difference between UsingMagnetostatic and Transient solver?
Transient case: the
operating point used for
computing magnetization (Br)
is the maximum operating
point with the largest (B,H)during the entire transient
simulation.
H0
Br p
B
H0
p
B
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2011 ANSYS, Inc. June 8, 201238
Anisotropic magnetization: magnetization direction is determined bythe orientation of the magnet material and the direction is specified by a
user;
Anisotropic or Isotropic Magnetization
P(T) input
Q(T) input
Isotropic magnetization:
magnetization direction isdetermined by the orientation of
the magnetizing field and is
determined during the field
computation.
For isotropic magnetization, all three
components have to be set to zero
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2011 ANSYS, Inc. June 8, 201239
Field-Circuit
Co-simulation
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2011 ANSYS, Inc. June 8, 201241
Maxwell Circuit Editor Example
Commutator bar: model position
Commutating model: model parameters
(a) (b) (c) (d)
WidB
WidC
PeriodLagAngle
Position
G
0WidC+WidB
|WidC-WidB|
a
b c
d
Gmax
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2011 ANSYS, Inc. June 8, 201242
Case Example for Commutating Circuit
Torque
Winding currents
PMDC Motor
Brush
commutation
circuit
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2011 ANSYS, Inc. June 8, 201243
Simplorer:
Power Electronics
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Simplorer Technology Highlights
f h i
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State-of-the-Art Drive System:A MultidomainChallenge
Drive systems
Simplorer conservative structures (electricalcircuits, mechanics, magnetics, hydraulics,
thermal, ...)
Simplorer non-conservative systems (blocks,
states, digital, nth-order differential equations.
Drive components
Maxwell with motion and circuits
RMxprt and PExprt (incl. thermal)
Maxwell with ANSYS Thermal.
HFSS, Q3D, SIwave with circuits(Designer/Nexxim), ANSYS Mechanical,
ICEPACK, etc. ...
ANSYS provides a comprehensive toolset for multidomain work:
=M SV RS
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+
-
B11A11 C11
A12 A2
B 12 B 2
C12 C2
ROT2ROT1
ASMS
3~M
J
STF
M(t)
GND
m
STF
F(t)
GND
Magnetics
JA
MMF
Mechanics
L
HQ
Hydraulics, Thermal, ...
Simplorer Simulation Data Bus / Simulator Coupling Technology
State-space
Models
statetransition
AUS
SET: TSV1:=0SET: TSV2:=1SET: TSV3:=1SET: TSV4:=0
(R_LAST.I = I_OGR)
EIN
SET: TSV1:=1SET: TSV2:=0SET: TSV3:=0SET: TSV4:=1
Cxy
BuAx
Electrical circuits
Multi-Domain System Simulator
Analog Simulator
Block DiagramSimulator
State MachineSimulator
Digital/VHDLSimulator
PROCESS (CLK,PST,CLR)
BEGIN
IF (PST = '0') THEN
state
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Electromechanical Design Environment
Simulation Data Bus/Simulator Coupling Technology
Model Database
Electrical, Blocks, State Machines, Automotive, Hydraulic,
Mechanics, Power, Semiconductors
Maxwell CircuitsBlock
Diagram
State
Machine VHDL-AMS
MatlabRTW
UDC MathCAD MatlabSimulink
Maxwell
C/C++ Programming Interface (FORTRAN, C, C++ etc.)
Co-Simulation
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2011 ANSYS, Inc. June 8, 201249
Transient Electromagnetic
FEM Co-simulationMaxwell2D/3D
Future: 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 := 0.0066s0 := 0.0002
gravity
value := 0.0066*9.8
spacer
sul := 0.0002sll_ := 0.0
Digital Electrical
Mechanical Hydraulic
Solenoid
A
orifice
75
ctrl1
ctrl2
plunger_control
Multi-Physics Co-Simulation
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Semicondutor Modeling In Simplorer
IGBT Device model
Semiconductor device model on Simplorer IGBT Device model : Average / Dynamic Capability of IGBTmodel
Thermal management for Inverter Thermal model in Simplorers semiconductor model. 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
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2011 ANSYS, Inc. June 8, 201252
IGBT model1. System model
Nonlinear resistance verification of operation
2. Average model
Static char. & average loss.
Heating & temp. rise
3. Basic Dynamic model
Dynamic char.& Energy Switching loss & heating.
4. Advanced Dynamic model
Detailed dynamic char. Inverter surge & noise
1) 2)
3)4)
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2011 ANSYS, Inc. June 8, 201257
IGBT Characterization
G i d i
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2011 ANSYS, Inc. June 8, 201258
IGBT inverter designCircuit design (loss) + thermal model
Line current
1T, 1D SW loss + DC loss
1T, 1D
junction
temperature
Package
temperature
Examination of
temperature cycle
1T 1D
Ambient temperature = 20 cel
Si l I k
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2011 ANSYS, Inc. June 8, 201259
-231.0n 618.0n0 200.0n 400.0n
-50.0
700.0
0
166.7
333.3
500.0
Simplorer + Icepak= Detailed modeling of thermal system
Simplorer
ANSYS Icepak
Q3D Extractor
Parasitism LCR
extraction
Device property and
loss consultation
CAD Import
Design of the coolingtechnique and
arrangement
Design of substrate radiating route
The simulation in consideration of
change of detailed temperature
environment
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2011 ANSYS, Inc. June 8, 201260
Induction Motor FEA Coupled with Simplorer
FEA
PhaseA1
PhaseA2
PhaseB1
PhaseB2
PhaseC1
PhaseC2
Rotor1
Rotor2
w+
ICA:
1400 rpm
LL:=237.56u
RA:=696.076m
B6U
D1 D3 D5
D2 D4 D6
2L3_GTOS
g_r1
g_r2
g_s1
g_s2
g_t1
g_t2
~
3PHAS
~
~
A * sin (2 * pi * f * t + PHI + phi_u)
PHI = 0
PHI = -120
PHI = -240
LDUM:=100m
CDC:=10m
LDC:=10m
RDC:=10
VZENER:=650
AMPLITUDE := 800 V
FREQUENCY := 60 Hz
-297.50
300.00
-200.00
0
200.00
0 100.00m 50.00m
LA.I [A]
LB.I [A]
LC.I [A]
FREQ := 800 Hz
AMPL := 800
PHASE := 0 deg
AMPL := 500
PHASE := -315 deg
FREQ := 50 Hz
PHASE := -195 deg
PHASE := -75 deg
SA
SB
SC
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
Name Value
SIMPARAM1.RunTime [s] 111.29k
SIMPARAM1.TotalIterations 40.51k
SIMPARAM1.TotalSteps 10.00k
FEA1.FEA_STEPS
-500.00
1.50k
0
1.00k
0 100.00m 50.00m
100.00 * LD.I [A]
VDC.V [V]
-715.00
425.00
-500.00
0
0 100.00m 50.00m
Current Torque
Speed
Fed by ac-dc-ac inverter
Frequency controlled speed
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2011 ANSYS, Inc. June 8, 201261
BLDC motor FEA Coupled with Simplorer
FEA
sourceA1
sourceA2
sourceB1
sourceB2
sourceC1
sourceC2
Magnet01
Magnet02
w+
ICA:
+
FGAIN
CONST
CONST
EQUBL
EQUBL
EQUBL
1500 rpm
LL:=922u
RA:=2.991
ANGRAD
57.3
-60+PWM_PER
-30+PWM_PER
QS1
QS2
QS3
VAL[0] := mod( INPUT[0] ,INPUT[1] )
PWM_T:=60
I_TARG:=9
I_HYST:=0.2
Q1
Q2
Q3 Q5
Q4 Q6
400 V
THRES := PWM_T
EQUBL
CONST
QS4
-90+PWM_PER
EQUBL
CONST
QS5
-120+PWM_PER
EQUBL
CONST
QS6
-150+PWM_PER
RA Ohm LL H
PWM_PER:=180
INPUT[1] := PWM_PER
INPUT := -LB.I
LC.I
-LA.I
LB.I
-LC.I
LA.I
THRES1 := I_TARG - I_HYST
0
8.50
5.00
0 20.00m 30.00m
-14.50
7.80
0
0 30.00m20.00m
-10.30
10.00
0
0 30.00m20.00m
Output torque
Chopped currents
Inverter fed three phase BLDC
motor drive
Chopped current control
0
8.50
5.00
0 30.00m20.00m
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FEA
A1
A2
B1
B2
C1
C2
AirRotor1
AirRotor2
w
+
26293 rpmICA: LL:=70.6914u
RA:=203m
140 V
100u F
+
F ANGRADGAIN
57.3
CONST -30+90
CONST -60+90
EQUBL
VAL[0] := mod( INPUT[0] ,90 )QA
QB
QC
EQUBL
EQUBL
Name Value
FEA1.FEA_STEPS 1.00k
SIMPARAM1.RunTime [s] 6.90k
SIMPARAM1.TotalIterations 4.05k
SIMPARAM1.TotalSteps 1.00k
0
100.00
50.00
0 1.00m500.00u
10.00 * QA.VAL
10.00 * QB.VAL + 30.00
10.00 * QC.VAL + 60.00
ROTA.VAL[0]ROTB.VAL[0]
ROTC.VAL[0]
-54.00m
264.00m
0
100.00m
200.00m
0 1.00m500.00u
10.00u * FEA1.OMEGA
V_ROTB1.TORQUE [Nm]
mechanical
-17.80
18.00
-10.00
0
10.00
0 1.00m500.00u
L1.I [A]
L2.I [A]
L3.I [A]
E1.I [A]
current control variable
SRM FEA Coupled with Simplorer
Electric Machine Design:
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2011 ANSYS, Inc. June 8, 201263
Electric Machine Design:Maxwell Simplorer Co-Simulation
3-ph Windings
Permanent Magnets
Stator & Rotor
Flux Linkages
3ph Line Currents
Co-simulation
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Multi-physics
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2011 ANSYS, Inc. June 8, 201265
Multiphysics Coupling through WB
Maxwell 3D provide volume/surface forces to ANSYS Structural
Solver improvements Surface forces are supported
Deformation of the stator Deformation of coils
The electromagnetic force density from
Maxwell is used as load in Structural
Thermal-Stress with Electromagnetic Force load
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Maxwell Couplings
Forced water cooling Forced air cooling Natural air cooling
Mapped Losses2D/3D Losses Temperature
T W CFD Th l A l i R14
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2011 ANSYS, Inc. June 8, 201269
Two Way CFD Thermal Analysis, R14
Geometry
Losses
Maxwell Model
CFD Model
Mapped Losses
Temperature
P L M d i FLUENT
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2011 ANSYS, Inc. June 8, 201270
Power Loss in windings are not displayed.
Power Loss Mapped into FLUENT
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2011 ANSYS, Inc. June 8, 201271
ResultsTemperature Distribution
http://localhost/var/www/apps/conversion/tmp/scratch_9/TemperatureRendering.cvf -
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Thank you