pexprt v71 l01 introduction

1 PExprt v7.1 User’s Guide

PExprtPExprtPExprtPExprtDesign Software for Magnetic Components

7.17.17.17.1

User’s Guide


9:00am

Introduction to PExprt (01,02,03,03a)

Example Problem #1

Inductor design with fixed gap

Example Problem #2

Winding Loss Recalculation (Eq,1D,2D)

BREAK

Example Problem #3

Core Loss Modeling

Example Problem #4

PExprt to Maxwell 2D Coupling (flux,J,E,C)

Example Problem #5

Influence of core gap on the winding losses

Lunch 12 noon – 1pm

1:00 pm

PExprt Additional Features (04,05)

Example Problem #6

Influence of the interleaving on the winding losses

Example Problem #7

Integrated Magnetics

BREAK

Example Problem #8

Buck Converter with Simplorer

Example Problem #9

Forward Converter with Simplorer

Example Problem #10

3ph to 6ph transformer with Simplorer

4:00 pm adjourn

Agenda


PExprtIntroduction

PExprtPExprtPExprtPExprtDesign Software for Magnetic Components

7.17.17.17.1

User’s Guide


Quick Overview of PExprt

• Design Software for transformers and inductors

• Includes standard libraries for cores, wires,

bobbins, insulators, and material

• Creates potential designs automatically that can

be analyzed and Modeled

Types

Inductors

Multi-winding transformers

Coupled inductors

Flyback components


Magnetic Design, Modeling & Analysis

C2 Load42

50u 240m

a

p

c

ctr

BUCK_Converter

Diode_Characteristic

SMPS Library

FE

A

Inductor_2

ctrvs

vctrl

vref

C2

R1

vref

R2C1

R3C3

+-

PID_Cont1

ET1

MEAN VALUE

Inductor_Losses


ANSYS offers the most complete solution for power systems design in the industry through its Power System Design Suite of tools

What is the Power System Design Suite of tools?

� Four combinable tools which assist engineers in designing and analyzing power systems, power supplies, and drives

� Integrates electromagnetic, circuit, and system engineering using a common desktop environment

The Power System Design Suite includes:

� PExprt – for transformer and inductor design

� Simplorer – for complete system/circuit analysis

� Maxwell 2D/3D – for finite element analysis

� Q3D Extractor – for parasitic extraction of interconnects, busbars, and cables

Power System Design Suite


Power System Design Suite

ThermalElectromagnetic MechanicalFluidic

Component

Circuit / Subsystem

System

ANSYS:

Multiphysics

Solvers

XPrt

Tools

Simplorer

FEA

Field Solvers


ANSYS SimplorerSystem Design

PP := 6

ICA:

A

A

A

GAIN

A

A

A

GAIN

A

JPMSYNCIA

IB

IC

Torque JPMSYNCIA

IB

IC

Torque

D2D

ANSYS Maxwell2D/3D FEA Analysis

HF/SIHFSS, Q3D, SIWave

RLCG Parasitics

ANSYS

MechanicalThermal/Stress

ANSYS CFDThermal

Model order Reduction

Co-simulation

Field Solution

FE Model Generation

OptimetricsLS-DSO

SCADE SuiteControl Systems

Embedded Design

Push Back Excitations

PExprtMagnetics

RMxprtMachine

Design


Maxwell

Simplorer

ICA:

FML_INIT1

RLoad:=7.2

Engine

engine_ss

n := 3000*1.0 rpm

E1

Ra R := RLoad Ohm

Rb R := RLoad Ohm

Rc R := RLoad Ohm

V

+

V

VMphaseA

V

+

V

VMphaseB

V

+

V

VMphaseC

GeneratorMechanical Source

-180.23

179.07

-100.00

0

100.00

145.00m 150.00m146.00m 148.00m

2DGraphSel1

VMp...

VMp...

VMp...

PWR

Probe

PWR_Probe1DigViewSel1

Name Value

PWR_Probe1.VE [V] 114.18

Total_Power 5.43k

66.5

R1

2.0

EQUFML1

Total_Power := PWR_Probe1.S[0] *3

F1

F2

RMX

A

B

C

N

ROT1

ROT2

RMxprtLink11

0

4.10

2.00

0 250.00m100.00m

2DGraphSel2

E1.I [A]

▲Machines

▲RMxprt - Broad library of machine

topologies (Generators, Motors)

▲ Fully Parameterizable

▲Evaluate Machine Performance

▲Export to Maxwell 3D

▲ Export Circuit Model

▲ Simplorer

RMxprt

FEA Model Extraction


▲Magnetics

▲ PExprt - (Inductors/Transformers)

▲Design

▲Cores, Materials, Wires …

▲Modeling

▲Toroid, Planar, Integrated,winding

▲Nonlinear core, Skin and proximity

effects, interwinding capacitance,

leakage L …

▲Analysis

▲Gap energy, leakage Inductance, flux

paths, current density, temperature …

▲Circuit Extraction

▲Simplorer



▲Parasitics

▲ Q3D - 2D / 3D Geometry

▲ Circuit Boards, Busbar,

▲ Cables, connectors

▲ Package Parasitics

▲ Creates Z matrix with coupling


▲ Simplorer

▲EMI/EMC analysis

▲CM, DM noise



� 2D and 3D Finite Element Analysis of

� Electrical Machines

� Sensors

� Actuators

� Transformers

� RFID Systems

� Wireless Power Transfer� … and other electromagnetic and electromechanical

components

Modeling with Maxwell 2D, 3D


▲Electo-Mechanical

▲Motors, Generators

▲Actuators …

▲Power Magnetics

▲Inductors, Transformers

▲Electrical Parasitics

▲PCB, Cables, bus bars

▲Thermal

▲IGBT package, CFD

▲Mechanical

▲Example Motor shafts

FEA Model Extraction Into Simplorer


SimplorerSimplorer ®®

ANSYSANSYS ®® IcepakIcepak ®®

Model Model

ANSYSANSYS ®® MechanicalMechanical

ModelModel

SimplorerSimplorer®®

Temperature profile

Current profile

MaxwellMaxwell ® ® /RMxprt/RMxprt ®®

Model Model

Battery3

Battery4

Battery5

Battery0

Battery1

Battery2

Fluid Flow

Region

SimplorerSimplorer ®®

MaxwellMaxwell ®® coupled with ANSYScoupled with ANSYS ®® Mechanical Mechanical

Mapping Electromagnetic ForceMapping Power Loss

Thermal-Structural

ANSYSANSYS ®® Thermal Thermal

Model Model -- CFDCFD

High Power Inverter System


0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]

-125.00

-100.00

-75.00

-50.00

-25.00

0.00

25.00

50.00

75.00

100.00

Y1 [V

]

Ansoft Corporation Basic_Inverter1BackEMFCurve Info

FEA1.EIT1TR

FEA1.EIT2TR

FEA1.EIT3TR

0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]

-200.00

-100.00

0.00

100.00

200.00

300.00

400.00

500.00

FE

A1

.TO

RQ

UE

Ansoft Corporation Basic_Inverter1TorqueCurve Info

FEA1.TORQUETR

Co-Simulation Maxwell


Co-Simulation (3rd parties)

Mathcad

ModelSim® and QuestaSim® - This also allows Simplorer and its VHDL-AMS

capability to now include Verilog digital modeling.

0

22.60

10.00

20.00

0 100.00m50.00m

Motor Current

AM.I ...

Matlab/Simulink


EQU

G(s)

Yt

x:= -4.7306

rating:= 10

a:= (t^(1.0/x)*rating)/(726.3^(1.0/x))

GS1

RTH1

DATAPAIRS1

CTH1

Θ

T1

RTH2therm

rload21

(S1.AC_Sim)? 1k: (S1.DC_Sim)? 1k: rload2_ctrl

TR

Probe

TR_Probe1

R2

EQU

XY

NL

XY1

NL1

I_main

sp

vset

vbus

vbus := VM1.V

D1

CONST

CONST GAIN

I LIMIT

VBUS

VSET

ERR

GAIN1

INTG1 SUM1 LIMIT1

+

V

VM1

I1

GAIN

GAIN2

engine2generator

INREG

OUTREG

GAIN

GAIN3

GAIN

GAIN4

VBUS<VSET

VBUS>=VSET

Circuit, Block, State

C code

VHDL-

AMS

FEA

Spice Import

EQUBLEquation Modeling Block

1k 10*node.V*t*f*L.I

# # i=f(v)pin

Co-Sim

(ie Simulink)

Magnetics

Simplorer’s Integrated Environment


• Standard Format Allows Model Portability (IEEE standard)

– Different engineering groups within same company

– With Sub-Contractors

– Between different simulators

• Multi-level Modeling

– Different levels of abstraction of model behavior

• Multi-domain Modeling

– Electrical, Thermal, Magnetic, Mechanical, etc

• Mixed-signal Modeling

– Supports analog and digital modeling

Power of VHDL-AMS (Compatibility, Capability)


heatout thermalin

rot1

c

b

a

Motor

rot1

c

b

a

m

p

Conv.c

b

aA

A

A

+

V

w

v

u

n

p

PWM Inv.

+

V

Θ

vf_full

ICA:

PWM signal

dead time

u_phase.i

w_phase.i

DC_link.v

fan

u_phase

w_phase

ctrl_5

ctrl_3

ctrl_6

ctrl_2

ctrl_1

ctrl_4

DC_link

c_freq:=650

c_rpm:=60*c_freq

mw

mu

mvst3

st6

st2

st5

st1

st4

EQU

Vmn

Vwu_mn := PI/(2.0*sqrt(2.0))*1.0/20.0m*INTEG(ABS(Vwu.V))

Vuv_mn := PI/(2.0*sqrt(2.0))*1.0/20.0m*INTEG(ABS(Vuv.V))

Vmn := (Vuv_mn + Vvw_mn + Vwu_mn)/3.0

Vvw_mn := PI/(2.0*sqrt(2.0))*1.0/20.0m*INTEG(ABS(Vvw.V))

DSP Program Model FPGA Program Model

PWM inverter Model PM Motor Model

TMS320C6701

Simplorer

RMxprt/Maxwell

VHDL-AMS

C code

Q

3

D

Motor Drive Example


F1

F2

RMX

A

B

C

N

ROT 1

ROT 2

RMxprtLink1

Engine

engine_ss

n := 3000*1.0 rpm

E1

A

B

C

A

B

C

C

B

ATFR3P11

TFR3P22

+

V

VMphaseA

+

V

VMphaseB

+

V

VMphaseC

+

V

+

V

D1 D2 D3

D6D5D4

D7 D8 D9

D12D11D10

VM1

VM2Cout

3000u F

Lina 50u H Rina10m Ohm

Linb 50u H Rinb10m Ohm

Linc 50u H Rinc10m Ohm

M1

K := 0

+

VR_Load

1.4*100m

VMout

Louttop

5m H

Loutbot5m H

Generator

DC/DC Converter

Mechanical Actuator

AC/DC Conversion

+ V

TR

Probe

Am

plif

ier

Inp

ut,

Ou

tpu

t

VM

4.V

[V

]

4.00

6.00

5.00

195.00m 200.00m198.00m

Timet

Amplif ier Input, Output vs. Time

VM4....

Am

plif

ier

Inp

ut

Vo

ltag

e

E3

.V [

V]

-50.00m

50.00m

-25.00m

0

25.00m

195.00m 200.00m

Timet

Amplif ier Input Voltage vs. Time

E3.V [V]

RC

R := 1k Ohm

RE

R := 375 Ohm

Vcc

EMF := 12 V

R5

R := 365 Ohm

R2R := 140 Ohm

C2

C := 500u F

E3

AMPL := 10m V

FREQ := 1k Hz

TPERIO := Tend+1 s

C3

C := 1u F

C1C := 10n F

R3

R := 4k Ohm

R4

R := 13.7E+006 Ohm

VM4

TR_Probe1

BJT1

Electrical Loads

PW R

Probe

PWR_Probe1

0

5.50k

2.00k

4.00k

0 200.00m100.00m

2DGraphSel4

PWR_...

TFR3P21

0

28.00

10.00

20.00

0 200.00m100.00m

2DGraphSel6

VMou...

-200.00

200.00

0

158.41m 163.83m160.00m 162.00m

2DGraphSel7

VMph...

VMph... VMph...

A A

Winding current Amature force

Gap vs. time

D2D

ECE

N_1

N_2

N_3

N_4

icoil1 R6

R := 1500/1.8 Ohmforce1

igrav1

IS := 0.00545*9.807 A

D2D2LIMIT_TRB2MASS_TRB2

E4

S2

CTRL := t>=0.15

ECELink2

-5.00u

1.00m

500.00u

142.23m 196.50m

Probe4

N034...

0

16.00m

10.00m

0 200.00m100.00m

Probe5

icoil1...

-14.00

0

-5.00

0 200.00m100.00m

Probe6

force...

12v Bus

28v Bus

W

+ +

V

+

V

+

-

buck_vhdlams_dxn_ng

v gp

v gm

d1p d1m v mode

eoutm

eoutp

v loadm

v loadp

WM2

R1 VM3

rload

7.5

r487k

r1

166k

vref

4

r2

50k

c2

1479p

r3

7.45k

E5

AC_MAG 0

EMF 2.0 V

C42.5u

vopamp

E2

AC_MAG 0.0

(1/2.5)*vopamp.V

OPV54

AD := 50k V/V

F_TR := 5meg Hz

VOMIN -10

VOMAX 10

RO := 0 OhmE6

AC_MAG 1 0c1

440p

fs 200k

dutymax 1.0

l 0.53m

dutymin 0.01

R7

100meg

0

28.00

10.00

20.00

0 200.00m

Probe1

N025...

-68.00u

13.00

5.00

10.00

0 200.00m

Probe2

vout.V

PE

X

PExprtLink1

SSPC

PExprt

Simplorer

Simplorer

RMxprt

Maxwell

VHDL-AMS

Maxwell

VHDL-AMS

Power

of

ANSYS

Q3D


Flyback Example

Q3DPExprt

Simplorer

Simplorer

Simplorer


� PExprt® is an interactive, performance based design tool that produces

initial designs of magnetic components, such as transformers and

inductors.

� Designs can then be Modeled and Analyzed with the highest level of fidelity using FEA tools.

� Design Models can then be evaluated in the circuit using Simplorer

� Standard libraries of magnetic cores, bobbins, insulators, and conductors

allow you to define the model to your exact specifications.

� Using PExprt, you can design: inductors, multi-winding transformers, coupled inductors, and flyback components.

� Optimize constructive parameters, such as core size, core material, number of turns, air gap length, wire gauge, and winding stratagy.

PExprt - Introduction


� Calculate performance parameters, such as

winding losses, core losses, flux density, DC and

AC resistance, Irms currents, magnetizing

inductance, leakage inductance, and temperature

rise.

� Consider complex effects, such as skin and

proximity effects, fringing flux near the air-gap for

energy calculations

� Calculate winding losses based on FEA field

solution and core losses.

� PExprt also includes the PEmag modeling module,

a powerful magnetic analysis module based on

finite element analysis. This module conducts a

detailed analysis of geometry, frequency, and

material

� Generate model netlists for SIMPLORER®,

electrical simulator to perform a complete system simulation of the entire device.

PExprt - Introduction


▲Solves 2D and 3D electromagnetic

field problems using FEA

▲Five Solution Types: Electrostatic,

Magnetostatic, Eddy Current,

Transient Electric, Transient Magnetic

▲Determines R,L,C, forces, torques,

losses, saturation, time-induced

effects

▲Parameter extraction for:

▲Power Magnetics: Inductors,

Transformers

▲Machines: Motors, Generators,

Actuators

▲Electrical Parasitic: Cables,

vias, bus bars

Maxwell - Introduction


▲Electrical Parasitic Extraction

▲ 2D / 3D Geometry

▲ Circuit Boards, Busbars

▲ Cables, Connectors

▲Interfaces with popular layout tools

▲Cadence

▲Mentor


▲ Numerical Analysis (MoM)

Q3D Extractor - Introduction


▲ Multi-domain, system simulator for designing

high performance systems

▲Three Basic Simulation Engines: Circuits,

Block Diagrams, State Machines

▲Mixed Signal – Mixed Mode Modeling

▲Digital / Analog

▲Magnetic, Mechanical, Thermal …

▲Integrated analysis with electromagnetic

simulation tools (Maxwell, PExprt, RMxprt, Q3D)

▲Analysis Types: AC, DC, Transient

▲Co-simulation with Maxwell and Simulink

▲Statistical Analysis and Optimization

▲VHDL-AMS Capability

SUM2_6

CONST

id_ref

G(s)

GS2

I

I_PART_id

GAIN

idLIMIT

yd

UL := 9

LL := -9

GAIN

P_PART_id

KP := 0.76

12

R1 R2 R3 R450

1k 1k50

C1 C2

3.3u

3.3u

V0 := 5 V0 := 0

N0005

N0003N0004

N0002

IMP = 0

IMP = 1IMP = 0

IMP = 1

IMP = 0 and RLine.I <= ILOW

IMP = 1 and RLine.I >= IUP

IMP = 0 and RLine.I >= IUP

IMP = 1 and RLine.I <= ILOW

SET: CS1:=-1SET: CS2:=-1SET: CS3:=-1SET: CS4:=-1

SET: CS1:=-1SET: CS2:=1SET: CS3:=-1SET: CS4:=-1

SET: CS1:=1SET: CS2:=-1SET: CS3:=-1SET: CS4:=-1

SET: CS1:=-1SET: CS2:=-1SET: CS3:=-1SET: CS4:=-1

Circuits

Block Diagrams

State Machines

Simplorer - Introduction

pexprt v71 l01 introduction

Documents

pexprt v7

power systems design

magnetic design

simplorerexample problem

dbreakexample problem

cexample problem

aexample problem

winding lossesexample