ansoft solution motors[1]

Ansoft Solutions for Motor Design

Eun-Sil Han (sr. AE, Ph.D.)Ansoft Korea

2005. 11

Contents

Introduction to the Ansoft EM ToolsThe Process of Electric Motor DesignTutorial Guide for Motor Design

BLDC using RMxprtPMDC using RMxprt + Maxwell EM 2DInduction Motor using RMxprt + Simplorer

Maxwell EM Roadmap

Introduction to the Ansoft EM Tools

Electro-MechanicalElectroElectro--MechanicalMechanical Signal-IntegritySignalSignal--IntegrityIntegrity High-FrequencyHighHigh--FrequencyFrequency

Maxwell2D/3D

Maxwell2D/3D

SimplorerSimplorerSystem System LevelLevel

Circuit Circuit LevelLevel

Component Component LevelLevel

Q3DQ3D

TPATPA

SIwaveSIwave

HFSSHFSS

Ansoft DesignerAnsoft Designer

NexximNexxim

Options

Optimetrics

Full Wave Spice

ePhysics

Multi-processor

AnsoftLink

Options

Optimetrics

Full Wave Spice

ePhysics

Multi-processor

AnsoftLinkRMxprt

PExprt

RMxprt

PExprt

Ansoft Products

모터 해석을 위한 Ansoft EM Tools ?

ElectricalElectrical

Maxwell 2D

Maxwell 3D

RMxprt

Optimetrics

EPhysics

ePhysics

SimplorerMaxwell

MechanicalMechanical

Simplorer

ControlControl

시뮬레이션 수순

RMxprt

설계대상

초기치수설계파라미터영향분석최적설계를통한모델제안

Maxwell 2D/3D설계검증용 / 특성해석용파라미터산출해석기법에의한설계보완해석결과검토에의한국부적형상변경

Simplorer모터및제어알고리즘과연계된정밀시뮬레이션정확한모터모델링제시로제어파라미터분석가능시스템엔지니어링단계

ePhysics전동기의분포적입력파라미터를이용하여열적성능및응력특성을보다정밀해석전동기기계적신뢰성확인

Good quality

Hollow rotor servo MotorHybrid-car Stepping Motor

Claw-pole AlternatorSolenoid Valve

Permanent magnet Coil

Pole piece

Variable Reluctance Sensor

- Powerful Simulation Software for Electromagnetic and Electromechanical Analysis

What’s Maxwell EM 2D/3D ?

Winding Editor

Machine Design

- Software for the Design of Rotating Electric Machines

What’s RMxprt ?

Design Window

Transformer Model

- Magnetic Component Design Software

What’s PExprt ?

ICA:

FML_INIT1

RLoad:=5

A

B

C

N

ROT1

ROT2

F1

F2

RMxprtLink1

Engine

engine_ss

n := 3000*1.0

E1

Ra R := RLoad

Rb R := RLoad

Rc R := RLoad

NX_P3_B

NX_P1_A

NX_P1_BN1_P1_B

N1_P1_A

NX_P2_A

NX_P2_B

N1_P3_B

N1_P3_ANX_P3_A

N1_P2_B

N1_P2_A

NX_P1_A

NX_P1_B

NX_P3_A

NX_P3_B

N2_P3_A

N2_P3_B

N2_P1_A

N2_P1_B

N2_P2_A

N2_P2_B

NX_P2_A

NX_P2_B

NX_P1_A

NX_P1_B

NX_P3_A

NX_P3_B

N2_P3_A

N2_P3_B

N2_P1_A

N2_P1_B

N2_P2_A

N2_P2_B

NX_P2_A

NX_P2_B

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

VM2

Cout3000u

Lina 50u Rina10m

Linb 50u Rinb10m

Linc 50u Rinc10m

M1K := 0

PWM Controller

for DC-DC applicationA B

R_loadsmall

0.288*5

C_Converter

750uV0 := 0

L_Converter

I0 := 0480u*1

D_Converter

BJT_ConverterR3_Converter

500k

R2_Converter

50k

A

B

+ V

R_Load1.2*100m VMout

Louttop5m

Loutbot5m

A A

EQU

EQU

XY

NL

XY

Winding current Amature force

Gap vs. time

D2D

N_1

N_2

N_3

N_4

icoil R1

R := 1500/1.8force

igrav

IS := 0.00545*9.807V1

EMF := 12*1.5

SPRING_TRB1

externalforce:=(-100000)*MASS_TRB1.S*1

externalforce:=(-100000)*MASS_TRB1.S*1.5

XY1

NL1

XY2

D2D1

LIMIT_TRB1

MASS_TRB1

E2

EMSSLink1

icoil.I [A]

t [s]

16m

04m

8m

12m

0 0.2350m 0.1 0.15

force.I [A]

t [s]

0

-14

-10

-6

0 0.2350m 0.1 0.15

AN

LPExprtLink1

RMxprtMaxwell 2D/3D

PExprt

Optimetrics

Maxwell 3D

SIMPLORER

Position

Position.V [V]

t [s]

1.2m

-0.2m

0.2m

0.6m

0 0.2325m 75m 0.13 0.18

+ V

VM3

S1CTRL := t>=0

Mechanical Source

N0252.V [V]

t [s]

30

-5

5101520

0 0.2325m 50m 75m 0.1 0.13 0.15 0.18 0.2

Master Load voltage

N0314.V [V]

t [s]

14

-20

2

4

6

8

10

12

0 0.2325m 75m 0.1 0.15

Slave Load voltage

- The complete system simulated by EM Tools

What’s Simplorer ?

What’s Q3D Extractor ?-패키지등신호전송구조의기생회로성분(RLC) Extraction

What is ePhysics ?– Thermal and Stress Analysis

A_phase_pA_phase_m

B_phase_pB_phase_m

C_phase_p

C_phase_m

torque

theta

PMSYNC

E1

E2 RA

RB

RC

TR_5 TR_3 TR_1

TR_6TR_2 TR_4

A

IA

A

IB

A

IC

175

GAIN

GAIN1

theta>90 AND theta<150 theta>150 AND theta<210 theta>210 AND theta<270

theta>270 AND theta<330theta>330 OR theta<30

ctr l 1:=1ctr l 2:=1

ctr l_2:=1ctr l_3:=1

ctr l_4:=1ctr l 3:=1

c tr l_4:=1c tr l 5:=1

ICA:

theta>30 AND theta<90



A

Torque

PP := 6

GAIN

CONST CONST CONST

GAIN GAIN

Torque

T o rq u e .I [A

t [s ]

0 .1 1k

7 3

8 0

9 0

0 .1 k

4 m

4 m

5 m

5 m

4 .5 m

4 .5 m

GAIN

CONST CONST CONST

GAIN GAIN

ctrl_i1

Control Signals

c trl _ i 1 .VAL c trl _ i 1 1 .VALc trl _ i 2 .VAL c trl _ i 2 1 .VALc trl _ i 3 .VAL c trl _ i 3 1 .VAL

t [s ]

2 5

-5

0

1 0

2 0

0

0

1 0 m

1 0 m

5 m

5 m

E3 175

TR_51 TR_31 TR_11

TR_21 TR_61 TR_41

ctrl_i2 ctrl_i3

ctrl_i11 ctrl_i21ctrl_i31

NEG NEG NEG

J

MchRMas1

D2D

Phase Currents

IA. I [A ] IB. I [A ] IC. I [A ]

t [s ]

0 .7 5 k

-0 .5 k

0

0 .5 k

1 .2 m

1 .2 m

1 0 m

1 0 m

2 .5 m

2 .5 m

5 m

5 m

7 .5 m

7 .5 m

PM Synchronous Traction Motor Design

Using Maxwell 2D

Inverter Bridge

Current Sensors for Control

Maxwell Motor Model

Mechanical Load

Drive

Ex. #1 : Traction Motor Simulation

A_phase_pA_phase_m

B_phase_pB_phase_m

C_phase_p

C_phase_m

torque

theta

QuickGraph1

IA.IIB.IIC.I

t

750.00

-500.00

0

500.00

1.20m

1.20m

10.00m

10.00m

2.50m

2.50m

5.00m

5.00m

7.50m

7.50m

A+

A+

A+

GAIN

ICA:

A+

GAIN

CONST CONST CONST

GAIN GAIN

QuickGraph4

Torque.I

t

120.00

0

25.00

50.00

75.00

100.00

1.20m

1.20m

10.00m

10.00m

2.50m

2.50m

5.00m

5.00m

7.50m

7.50m

GAIN

CONST CONST CONST

GAIN GAIN

QuickGraph5

ctrl_i1.VALctrl_i11.VALctrl_i2.VALctrl_i21.VALctrl_i3.VALctrl_i31.VAL

t

25.00

-5.00

0

10.00

20.00

0

0

10.00m

10.00m

5.00m

5.00m

NEG NEG NEG

J

FuelCell C

+-

PMSYNC

E1

IA

IB

IC

GAIN1


ctrl_2:=1ctrl_1:=1 ctrl_2:=1

ctrl_3:=1

theta>150 AND theta<210 theta>210 AND theta<270

ctrl_4:=1ctrl_3:=1


ctrl_4:=1ctrl_5:=1

theta>330 OR theta<30

PP := 6


ctrl_5:=1ctrl_6:=1

ctrl_1:=1ctrl_6:=1

Torque

ctrl_i1 ctrl_i2 ctrl_i3


MchRMas1FUELCELL_C1

D1

C1

C2

P1

FuelCell C

+-

FUELCELL_C2

D2

P2

PIPELevel1

PIPE

Level1

PIPELevel1

PIPE

Level1 CONSTPI

+

-

RHYD1

PI_1

CONSTPI

+

-

RHYD2

Ex. #2 : Fuel Cell in a Traction Motor

L_R

L_S

L_T

ET1

ET2

ET3

CD1m

R_R

R_S

R_T

Yt

LOAD

CONTR_OUT

THRES2 := 2.5

VAL2 := 1

THRES1 := -2.5

VAL1 := -1

-16.66m

DCM.N P_GAIN

KP := 50

I_GAIN

KI := 20

LIMITER

UL := 20LL := 0

10m

GAIN GAIN

I

LIMIT

CONST

N_REF

16.6667

0.3m

M

DCMRA := 1.2

LA := 9.5mKE := 0.544

J := 4m

A

+ AM1D1 D2 D3

D4 D5 D6

D7

TR

CONST

CLOCK

.1m

Wiper System

Ex. #3 : Wiper System- DC Motor Drive System

20.000

T

15.00

0

10.00 10.00

0

0

100.00m

100.00m

50.00m

50.00m

N_REFN

T-10.00 -10.00

0 0

0 100.00m

100.00m

50.00m

50.00m

0

Motor Torque and Load Torque

Motor Speed

The Process ofElectric Motor Design

RMxprt + Simplorer and/or EM 2D + Q3D Extractor

Integrated Motor Solution

RMxprt

Maxwell 2D Maxwell 3D

SIMPLORER

14 types of motors/generators

project design

Equivalent circuits

Co-simulation

RMxprt- Parametrics- Optimization- Export to Simplorer model- Create to Maxwell 2D/3D Project

SIMPLORER- Power Electronics- State Machines- Block Diagrams

Maxwell EM 2D/3D- Fields/Circuits/Motion- Power Electronics- Core Loss- Post Processing- Export to Simplorer model

Ansoft Tools for Electric Motor Design

RMxprt Parametrics

Single Phase Induction Motor

New Setup Panel

RMxprt ParametricsC_run: Nominal 6 uF: Sweep 1 to 12uF in 12 StepsSlot_depth: Nominal 8.2mm: Sweep 6 to 10 mm in 9 Steps

RunRMxprt

RMxprt Parametrics

RMxprt Optimization

Three Phase Synchronous Generator

Select Optimization

RMxprt Optimization

RunRMxprt

RMxprt Optimization

RMxprt Optimization

Optimum Solution

RunRMxprt

RMxprt OptimizationOriginal

Optimized

Objective: sinusoidalair-gap flux density

distribution

RMxprt SIMPLORER

DQ0 model written directly by RMxprt

Transient Parameters

Maxwell EM with Schematic

Brushless DC Motor• Four Pole• Three Phase• Chopped Current Control

Switching Sequence of Phase A vs. Mechanical Degrees

Phase A winding

Switching circuit based on angular position

Current Controlled SwitchesSchematic

Position Dependent Sources

Current Controlled Switches

RunEMpulse

Core Loss

Steel:Loss density = Kh f2B2

max + Kc f B2max + Ke (f Bmax)

3/2

Loss will be a function of Lamination Thickness

Power Ferrite: Loss density= Cm fx Bmaxy

May be expressed in Watts/m3 or Watts/Kg

Core Loss

Select Object to for which Core Loss is to be Calculated

RunMaxwell EM

Core Loss

Maxwell EM Post Processing

EMI in the Motor Drive System

ECU

Battery+ -

ConductiveRadiative

Normal Mode Current

Common Mode Current

Normal mode current flows --- LoopCommon mode current flows --- Open

Common Mode Current Analysis

All components are representedby “Multi-Domain” Simulation model

- Battery- Inverter/Converter- Bus bar- Motor- DSP/FPGA

Simulation Model Ⅰ(ECE)

ICA:

A_phase_p

A_phase_m

B_phase_p

B_phase_m

C_phase_p

C_phase_m

torque

theta

PMSYNC

Phase Current

IA.I [A] IB.I [A] IC.I [A]

t [s]

600.00

-600.00

0

-500.00

-250.00

250.00

500.00

1.20m

1.20m

10.00m

10.00m

2.50m

2.50m

5.00m

5.00m

7.50m

7.50m

A

IA

A

IB

A

IC GA

IN

theta>90 AND theta<150 theta>150 AND theta<210 theta>210 AND theta<270

theta>270 AND theta<330theta>330 OR theta<30

ctrl 1:=1ctrl_2:=1

ctrl 2:=1ctrl_3:=1

ctrl_4:=1ctrl 3:=1

ctrl_4:=1ctrl_5:=1


ctrl_5:=1ctrl_6:=1

ctrl_1:=1ctrl 6:=1

GAIN

CONST CONST CONST

GAIN GAIN

Torque

Rotor.M1

t [s]

104.40

75.40

80.00

85.00

90.00

95.00

100.00

4.12m

4.12m

4.85m

4.85m

4.25m

4.25m

4.50m

4.50m

4.75m

4.75m

GAIN

CONST CONST CONST

GAIN GAIN

ctrl_i1

Control Signals

ctrl_i1.VAL ctrl_i11.VA...ctrl_i2.VAL ...ctrl_i21.VA...ctrl_i3.VAL ...ctrl_i31.VA...

t [s]

25.00

-5.00

0

10.00

20.00

0

0

10.00m

10.00m

5.00m

5.00m

ctrl_i2 ctrl_i3


NEG NEG NEG

J

Rotor

D2D

C1

C2

FuelCell

+-

FuelCell

+ -

R1

A

AM1

S1 EQU

FML1

Common Mode Current

Terminal Currents

f = 1/0.00076 = 1.3kHz

FFT of Common Mode Current

AM1.I = f(...

-1.07k

-1.07k

15.99k

15.99k

0

0

3.33k

3.33k

6.67k

6.67k

10.00k

10.00k

13.33k

13.33k

0 0

25.00u

5.00u 5.00u

0.00u 10.00u

5.00u 15.00u

20.00u 20.00u

f1=1.3kHz f3=3.9kHz

Simulation Model Ⅱ(Tr-Tr Link)

FEA

sourceA1

sourceA2

sourceB1

sourceB2

sourceC1

sourceC2

Magnet01

Magnet02

Name ValueFEA1.FEA STEPS

SIMPARAM1.RunTime [s] 0SIMPARAM1.TotalIterations 0

SIMPARAM1.TotalSteps 2.64k

ω+

ICA:

+ΦGAIN

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

LDUM:=10m

LDUM H

0

8.50

5.00

0 13.30m5.00m 10.00m

Q1.C... Q2.C... Q3.C... Q4.C... Q5.C... Q6.C...

-9.30

9.30

-5.00

0

5.00

0 13.30m5.00m 10.00m

LA.I [A] LB.I [A] LC.I [A] 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

THRES2 := I_TARG + I_HYSTVAL1 := 1VAL2 := 0Y0 := 1

-14.60

5.00m

-10.00

-5.00

0 13.30m5.00m 10.00m

Torque Output

-430.00

1.51k

0

1.00k

0 13.30m5.00m

FEA Outputs

FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1...

0

8.50

5.00

0 13.30m5.00m 10.00m

QS1.... QS2.... QS3.... QS4.... QS5.... QS6....

A

AM1

2DGraphSel6 LA.I [A] LB.I [A] LC.I [A]

R4

probe model(Q3D)

FFT of Common Mode Current

AM1.I ...

0

0

126k

126k

25k

25k

50k

50k

75k

75k

100k

100k

0 0

39.09m

5.00m 5.00m

0.00m 10.00m

5.00m 15.00m

20.00m 20.00m

25.00m 25.00m

30.00m 30.00m

35.00m 35.00m

AM...

0

0

7.840m

7.840m

1.667m

1.667m

3.333m

3.333m

5.000m

5.000m

6.667m

6.667m

10.6m -10.6m

343.9m

50.0m 50.0m

00.0m 100.0m

50.0m 150.0m

200.0m 200.0m

250.0m 250.0m

300.0m 300.0m

Time

Freq.

FFT

Maxwell EM Roadmap

Non-cylindrical rotationNextGenAnsoft

Desktop

Nonlinear anisotropyand nonlinear lamination

New electric solver

Dynamic demagnetization

Non-Cartesian localCS for easy setup

Designer schematic forexternal circuit coupling

ECE with distributed analysis

RMxprt integrated

What’s New in Maxwell 11

Maxwell 3D Desktop

What’s New in Maxwell 11More motion types in 3D transient

Non-cylindrical rotation for relay, DC contactor, circuit breaker applications

Allows general moving bands with different radii for rotational motion

Relay

Sensor

Dynamic Demagnetization Results

Source H fieldin the PM

Target H fieldin the PM

B Field in rotorand stator

Y

X

r

Example: Reluctance Motor

The rotor local coordinate system is attached to the moving rotor

Rotor lamination is defined along r direction in the local

cylindrical coord system

Flux density plot

Torque with different load angle

Create Maxwell 3D Transient Circuit

Use .sph extension for exported files

NextGenAnsoft

Desktop

Dynamic geometrydisplay with data input

Consistent materiallibrary with Maxwell FEA

Maxwell 3Dgeometry model creation

Any load type for all machines(constant speed, constant power,constant torque, linear torque orfan load)

Winding editor for arbitrary winding configration

Integrated in the samedesktop with Maxwell

What’s New in RMxprt 11

Complete geometry creationOne-click FEA design

Option for periodic or full models

Automatic update with project variables

Complete geometry creationOne-click FEA design

Option for periodic or full models

Automatic update with project variables

Geometry component creationGeneral and dedicated machine parts

Arbitrary combination –create new machine types

Dimension variables supported

Geometry component creationGeneral and dedicated machine parts

Arbitrary combination –create new machine types

Dimension variables supported

3D Geometry Creation

Periodic or Whole Model Option

Geometry model with a minimum period

Geometry model with a minimum period

One-Click Insert of Maxwell Design

Geometry Variables Sharing with RMxprt

Maxwell geometry automatic update

with variables changed in RMxprt

Maxwell geometry automatic update

with variables changed in RMxprt

Convenient for geometry parametric sweep and

optimization

Convenient for geometry parametric sweep and

optimization

Arbitrary Winding Configurations

Single-layer lap winding

Double-layer lap winding

DC winding

Lap winding with coil pitch=1

Concentric winding

Common Slot Type Support

Inner/outer AC/DC armature cores

Inner/outer AC/DC armature cores

Single/double squirrel-cage cores

Single/double squirrel-cage cores

Geometry Component Creation in Maxwell

General and dedicated machine parts

Integrated in Maxwell 3D Modeler

Arbitrary combination, possible for a new

machine type

Machine Parts Integrated in 3D Modeler

General Machine Parts

Components

for most

machines

Dedicated Machine Parts

Components

for specific

machines

Easy Swap between Outer and Inner Cores

Inner core: DiaYoke < DiaGap

Inner core: DiaYoke < DiaGap

Outer core: DiaGap < DiaYoke

Outer core: DiaGap < DiaYoke

Easy Swap between 3D and 2D Models

2D core: Length = 0 2D core: Length = 0

3D core: Length > 0

Arbitrary Combination of Machine Parts, Possible for

a New Machine Type

A three-phase claw-pole rotor A cylindrical rotor of synchronous machines

Tips to Mesh Success

Use straight coils:• add a half span length to EndExt;• set SpanExt = 0

Use straight coils:• add a half span length to EndExt;• set SpanExt = 0

Add axial sheetsAdd axial sheets

ansoft solution motors[1]

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