ansys / ansoft uk/staticassets/motor... · © 2010 ansys, inc. all rights reserved. 1 ansys, inc....

© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

ANSYS / Ansoft

Component Design

Motors & Actuators

Leon Voss

ANSYS Inc.

© 2010 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

Power Supply Inverter Actuator Mechanic Load

Analog ControlDigital Control

Automotive and railway systems, electric drives, home

appliances and other systems consist of a variety of

components. Each component may influence the behavior

of another component.

System Simulation:

Drive System Example


Electromechanical (EM)

Components and Systems

• Component Analysis

– Look at component alone

– Motors, actuators, coils, ...

– Usually by field simulation or

analytical models

– Distributed parameters –

geometry, materials,

boundaries, sources

• System Analysis

• Look at interactions of components

• Drives, converters, ... composed of

motors, coils, resistors, diodes, ...

• Usually by system/circuit

simulation or analytical models

• Concentrated parameters –

behavioral component models


Electrical Machine Technology:

Yesterday vs. Today

2004 Toyota Prius IPM Machine1980’s DC Machine for Military Aircraft

1980 2004

Size in2 68.75 20.78

Weight lb 70 23

Rated Power kW 13 50

Rated Torque Nm 100 400

Smaller!

Lighter!

More Powerful!


Modern Product Design Issues

To meet todays requirements:

• Include transients

• Previous: Static fields enough

• Latest: Consider eddy and core effects from nonsinusoidal excitations

and motion

• Far more than 50% of all machines produced today are inverter driven

• Include interactions between

• Different physical domains:

• Old: Cool by more steel New: Save steel!

• Different components:

• Old: Leave space between components

• New: Reduce size

• Component and system:

• Old: Leave reserves to account for additional coupling effects

(e.g. Induced Eddy Currents)

• New: Reduce reserves more and more


Optimetrics/DXParametrics, Optimization,

Sensitivity, Statistical,

Tuning

RMxprtAnalytical Machine Design

Electrical Machines –

Design Suite

Maxwell 2D/3DElectromagnetic Fields

Static, Dynamic (t, f), Motion, Circuits

MultiPhysicsStresses, Heat, CFD

SimplorerMultidomain Systems

Circuits, Blocks, States, VHDL-AMS

• State-of-the-Art

Design:

• RMxprt for analytical

machine design or

ECE

• Maxwell 2D/3D for

static or transient

electromagnetic FEA

• Simplorer for circuit

and system analysis

• ANSYS for thermal

and stress analysis

• Optimetrics or DX for

optimization, statistics,

sensitivity, ...



RMxprt Overview

Analytical design of rotating machines

– Calculate machine performance, make material

and size decisions

– Flexible design and optimization process

– Perform hundreds of "what if" analyses in a

matter of seconds



RMxprt Overview

Machine types

• Induction machines

• Three-Phase, Single-Phase

• Wound Rotor (new v13.0)

• Synchronous machines

• Line-Start PM, Adjustable Speed PM

• Salient Pole, Non-Salient Pole

• Brush commutated machines

• DC, Permanent Magnet DC

• Universal, Claw-Pole Alternator

• Electronically commutated

machines

• Brushless PM, Switched Reluctance


RMxprt User Inputs



RMxprt Typical Results, Report

Performance curve for varying magnet size

TCog(je)

T(n)

h(n)

I(n)

P(n)

e(je)

Motor Performance curves of a BLDC

Original Optimized

Optimization of a synchronous generator

with damper

Customized reports possible ...


Electrical Machines – RMxprt

Maxwell and Simplorer Links

• RMxprt:

– Find optimum initial design of electrical machine

– Quick model generation for subsequent finite element analysis

– Easy model parametrization for Simplorer machine

– Typical geometry, saturation, eddy current effects in system model

?


0

0

LPhaseA

LPhaseB

LPhaseC

0.00801603ohm

RA

0.00801603ohm

RB

0.00801603ohm

RC

7.95824e-006H

LA

7.95824e-006H

LB

7.95824e-006H

LC

La

be

lID

=V

IAL

ab

elI

D=

VIB

La

be

lID

=V

IC

+ 0V

1VLabelID=V14

+ 0V

1VLabelID=V15

+ 0V

1VLabelID=V16

+ 0V

1VLabelID=V17

+ 0V

1VLabelID=V18

+ 0V

1VLabelID=V19

10

0o

hm

R2

0

10

0o

hm

R2

1

10

0o

hm

R2

2

10

0o

hm

R2

3

10

0o

hm

R2

4

10

0o

hm

R2

5

La

be

lID

=IV

c1

La

be

lID

=IV

c2

La

be

lID

=IV

c3

La

be

lID

=IV

c4

La

be

lID

=IV

c5

La

be

lID

=IV

c6

-

+ 100V

LabelID=V32

-

+100VLabelID=V33

D3

4

D3

5

D3

6

D3

7

D3

8

D3

9

D4

0

D4

1

D4

2

D4

3

D4

4

D4

5

V

S_

46

V

S_

47

V

S_

48

V

S_

49

V

S_

50

V

S_

51

Model

DModel1

ModelV

SModel1

Maxwell Motor Model Generation

• From RMxprt

– Most powerful way

– Complete model setup

– External circuit created

– Ready to solve

• Draw using UDPs

– Complex machine cores

– Windings with end turns

• Draw using CAD modeler

– Full ACIS based 2D/3D CAD

modeler included

– Easy to use

• Import geometry

• Share geometry

Automatically setup

– Geometry

– Motion

– Boundaries

– Excitations

– Materials

– Mesh

Operations

– Solve Setup


Maxwell Motor Model Generation

• From RMxprt




– Ready to solve

• Draw using UDPs





modeler included

– Easy to use

• Import geometry

• Share geometry


Electrical Machines – Maxwell

Motor Model Generation

• From RMxprt




– Ready to solve

• Draw using UDPs





modeler included

– Easy to use

• Import geometry

• Share geometry


Maxwell – Transient 2D/3D FEA

with Large Motion

• Easy to use, autoadaptive meshing

• Functional or PE-switched excitation

(circuits)

• dB/dt transients – fully integrated solution

• Large motion induced dB/dt transients

• Virtual Force and Stress Tensor-based

Force calculation

• Various loss schemes

• Windings: Stranded losses

• Laminated steel: Core losses

• Solids and magnets: Eddy current losses

• Linear and nonlinear, isotropic and

anisotropic, and laminated materials


Induced J in cage at t = 8 ms

B in stator and rotor, J in cage

Maxwell – Engineering Approach

master

slave

Engineer‘s business:

• Geometry

• Materials

• Sources and boundaries

• Understand results

Maxwell‘s business:

• Numerics

• Meshing

• Solution


Maxwell –

2D/3D Transient Large Motion

• Transient motion along/about one dimension

• Rotation – cylindrical, disk type, limited (tilting) – full

cylindrical or ring type, rotor eccentricity

• Translation

• Inertia, mechanical damping, load torque/force


Maxwell 2D/3D: Transient Motion

with External Circuits

0

0

LPhaseA

LPhaseB

LPhaseC

2.99132ohm

RA

2.99132ohm

RB

2.99132ohm

RC

0.000921945H

LA

0.000921945H

LB

0.000921945H

LC

La

be

lID

=V

IAL

ab

elID

=V

IBL

ab

elID

=V

IC

+ 0V

1V

LabelID=V14

+ 0V

1V

LabelID=V15

+ 0V

1V

LabelID=V16

+ 0V

1V

LabelID=V17

+ 0V

1V

LabelID=V18

+ 0V

1V

LabelID=V19

10

0o

hm

R2

0

10

0o

hm

R2

1

10

0o

hm

R2

2

10

0o

hm

R2

3

10

0o

hm

R2

4

10

0o

hm

R2

5

La

be

lID

=IV

c1

La

be

lID

=IV

c2

La

be

lID

=IV

c3

La

be

lID

=IV

c4

La

be

lID

=IV

c5

La

be

lID

=IV

c6

-

+ 110V

LabelID=V32

-

+110V

LabelID=V33

D3

4

D3

5

D3

6

D3

7

D3

8

D3

9

D4

0

D4

1

D4

2

D4

3

D4

4

D4

5

V

S_

46

V

S_

47

V

S_

48

V

S_

49

V

S_

50

V

S_

51

Model

DModel1

ModelV

SModel1

10.00 15.00Time [ms]

-1.00

-0.80

-0.60

-0.40

-0.20

0.00

0.20

0.40

0.60

0.80

1.00N

od

eV

olta

ge

(IV

a)

[kV

]

-150.00

-100.00

-50.00

0.00

50.00

100.00

150.00

-Bra

nch

Cu

rre

nt(

VIA

) [A

]

Ansoft LLC 4_Partial_Motor_TR_PWMPhase Voltage / Current

Loss Types: • Steel

• Copper

• Magnet



Design Issues

• Inductance calculation

– Static

– Transient

• Cogging torque

– Magnetostatic with swept jm, or

– Transient with wm = 1 deg/s and

Rabc = 1 MW

• Back-EMF

– Transient, some constant wm and

iabc = 0

• Conditions at operating points

(idle, rated, peak, startup, ...)

– Transient with wm = wm OP and

some vabc(t) or iabc(t)

0.00 5.00 10.00 15.00Time [s]

-3.00

-2.00

-1.00

0.00

1.00

2.00

3.00

Mo

vin

g1

.To

rqu

e [N

ew

ton

Me

ter]

Ansoft Corporation Maxwell2DDesign1Torque

Curve Info

Moving1.Torque

Setup1 : Transient



Design Issues

• Space harmonics

– Evaluate fft( Bn ( Lairgap ) )

• Losses

– Transient with eddy currents enabled

– Core losses setup for laminated objects

• Field distributions

• Startup, load variations

– Mechanical transients

• Rotor eccentricity

0.00 0.20 0.40 0.60 0.80 1.00NormalizedDistance

-0.20

0.00

0.20

0.40

0.60

0.80

1.00

1.20

Bra

dia

l

Ansoft Corporation PMSM_CTXY Plot 2

Curve Info

Bradial

Setup1 : Transient

Time='0ns'


Electromagnetic Actuators –

Maxwell

• dB/dt – motion and time induced effects

– Transient solver solves time-varying magnetic fields

– Fully Coupled FEA with external circuit and motion

– Includes time-induced effects such as:

• Eddy effects

• Proximity effects

• Time diffusion of magnetic fields

– Motion-induced eddy effects

• Nonlinear material effects

• Power electronic switching


Actuators

0

0

LCoil

Model

V

SW_Inf o

V

S_

Sw

itch

0.0

77

oh

m

Rd

s_

on

12ohm

R_Coil

-

+12.5V

LabelID=VSource

LabelID=I_Pulse

+ 0V

5V

LabelID=V_Pulse

10

00

oh

m

R2

8

Model

Zener_Inf o

D_

Ze

ne

r

LabelID=IBatt LabelID=ISwitch

LabelID=VCoil

LabelID=VZener

200 ms 500 ms 1000 ms

0.00 0.20 0.40 0.60 0.80 1.00Time [ms]

0.00

5.00

10.00

15.00

20.00

25.00

Cu

rre

nt(

Win

din

g)

[A]

-50.00

-40.00

-30.00

-20.00

-10.00

0.00

10.00

20.00

30.00

40.00

50.00

Y2

[V

]

Ansoft Corporation Maxwell3DDesign3XY Plot 1

Curve Info

Current(Winding)

Setup1 : Transient

InducedVoltage(Winding)

Setup1 : Transient

NodeVoltage(IVM_SRC)

Setup1 : Transient


Electromagnetic Actuators –

Maxwell

Optimization of Closing Time:

ArmStepHeight

Gap

• Vary geometric parameters

• Transient run

• Detect closing time


FEA

PhaseA1

PhaseA2

PhaseB1

PhaseB2

PhaseC1

PhaseC2

Rotor1

Rotor2

w+

ICA: 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

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

+

V

FEA

PhaseA1

PhaseA2

plunger1

plunger2

Ideal

F

UPPER_LIM := 0.1 in

S0 := 0 in

0.004 kg

10u Ns/m-0.04 N

-32.68u m

153 N/m6.25 Ohm

D3

RS := 10 Ohm

6.25 Ohm

12 VD1

RS := 10 Ohm

Blocks, states, functions,

differential equations

Electric circuits

Electric circuits

Mechanics

Mechanics

Maxwell 2D/3D

Transient+Motion

Maxwell 2D/3D

Transient+Motion

Electrical Machines and Actuators –

Simplorer-Maxwell 2D/3D Cosimulation


SimplorerMultidomain Systems

Circuits, Blocks, States, VHDL-AMS

Maxwell 2D/3DElectromagnetic FieldsDynamic (t, f), Motion, Circuits

Electrical Machines and Actuators –

Simplorer-Maxwell 2D/3D Cosimulation


Maxwell – Multiphysics Integration

Thermal/Mechanical Load Transfer

• Maxwell – ANSYS Workbench:

– One-way thermal coupling

– Two-way thermal coupling

– One-Way Mechanical Coupling

– Two-Way Mechanical Coupling (planned for 2012)

EM Force

Temperature

EM Loss

MaxwellElectromagnetic Fields

Static, Dynamic (t, f), Motion, Circuits

ANSYS MultiphysicsStresses, Heat, CFD

Deformation


ANSYS Workbench R13 Interface

Power

Temperature

Maxwell

B-Field, Losses

Ansys Thermal

Temperature



Electrical Machine Stresses

• Thermo-mechanical simulation from the thermal solution

• See the (thermo-) deformation of the structure

Stator, rotor

temperatureDeformation due to temperature



Electrical Machine Stresses

• Static coupling

• Electromagnetic force density

– Automatically calculated in Maxwell

– Using the Maxwell’s stress tensor

– Mapped to the ANSYS mesh

– See stator, rotor, coil deformation

Original coil

position


Vibration Analysis

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00Time [ms]

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

Mov

ing1

.Tor

que

[New

tonM

eter

]

02_DC-6step_IPMTorque ANSOFT

Curve Info avg pk2pk

Moving1.Torque 4.7552 5.7332


Machine Model in Maxwell

• Fields Calculator to create

Radial and Tangential Force

Expressions from

EdgeForceDensity

• Calculates Radial and

Tangential Force on Tooth Tips

• Allows only force on edge that

neighbors non ferrous objects


Machine Model in Maxwell

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00Time [ms]

-250.00

-200.00

-150.00

-100.00

-50.00

-0.00

50.00

Fo

rce

(N

ew

ton

s)

02_DC-6step_IPMRadial Force on Tooth Tips ANSOFT

Curve Info

ExprCache(ToothTipRadial_Full1)

ExprCache(ToothTipRadial_2)





0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00Time [ms]

-30.00

-25.00

-20.00

-15.00

-10.00

-5.00

0.00

5.00

10.00

Fo

rce

(N

ew

ton

s)

02_DC-6step_IPMTangential Force on Tooth Tips ANSOFT

Curve Info

ExprCache(ToothTipTangent_Full1)

ExprCache(ToothTipTangent_2)






Geometry in WB

• Pattern Geometry in DM to create complete geometry

from 1/4th sector


• Plane Strain 2D Analysis of the Stator

• Generate Mesh

• Fixed support at the four bolted edges

• Apply the time varying forces obtained from Maxwell

on stator tooth tip

Workbench Setup


Workbench Setup

Radial and Tangential forces in Mechanical


Results - Equivalent stress


Results - Deformation

• Radial and Tangential Directional Deformation


Electrical Machine Cooling –

Maxwell-CFD: Heat-Up Analysis

• Maxwell solve

• Maxwell loss to CFD

• CFX solver used

• CFD temperature back to Maxwell

• Iterate as necessary

EM Loss

Temperature


Electrical Machine Cooling –

Maxwell-CFD: Heat-Up Analysis

Model without water

Model with solid only

Full model

• Maxwell2D Transient

– Losses averaged

– Expanded to 3D, mapped to ...

• ANSYS CFD (Fluent) solver

– Steady state analysis

– Water cooled

– Airgap


Experimentation

with Maxwell, Simplorer, ...

Experimentation

• Have a model with x input

parameters

• Experiment with x to make y

outputs as desired

• Experimentation Analyses:

– Parametrization

– Optimization

– Sensitivity

– Statistical

Experimentation

External tools via

scripting

Ansoft

Optimetrics

ANSYS

DesignExplorer DX

(calls Optimetrics)


DX – IPM Torque Optimization

• Multiobjective optimization

– Maximize torque with fixed current

– Minimize magnet volume

– Maximize torque/volume ratio

– Obtain a maximum stator tooth flux

density of 1.9 T

• Vary parameters

– 20 < tN < 36 (Slot Height)

– 3 < bN < 11 (Slot Width)

– 5 < hM < 16 (Magnet Height)

– 25 < wM < 44 (Magnet Width)



Maxwell runs a parametric solution given

x from DOE setup.

DX creates n-dimensional response

surface from this DOE table.



• Response Surface Technique

– ANSYS DesignExplorer (DX)

– Various experimentations can be

applied (optimization, sensitivity, ...)

– Very fast (analytical) results

– Response Surfaces precalculated

from Design of Experiments (DoE)

– Reduces drastically the amount of

FEA calculations

[1]: Germishuizen, J. J.; Hädrich, O.; Stanton, S.; Tharp, J.: Torque Optimization for

Interior Permanent Magnet Machines (IPM). Proc. ACUM, Leipzig, 2009.



TorquePerMagArea Bavg Tooth #5 Torque Magnet Area

Slot Width

Slot Height

Magnet Width

Magnet Height

Sensitivity chart (computed instantaneously from response surface)


DX – IPM Torque OptimizationTorq

ue T

Bavg Tooth #5

Pareto fronts shown, the best

to worst go from blue to red

respectively



Probability density of output torque



Flux density at

optimum design

parameters


Modern Product Design Issues

• Higher

– Functionality

– Performance

– Usability / automation

– Precision

– Reliability

– Lifetime

– …

Component & System simulation are key elements

in achieving modern requirements !

• Lower

– Cost

– Time to Market

– Material Consumption

– Size

– Energy Consumption

– …


Questions ?

ansys / ansoft uk/staticassets/motor... · © 2010 ansys, inc. all rights reserved. 1 ansys, inc....

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