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System Simulation: Drive System Example Power

Digital Control Analog Control Automotive and

appliances and other systems consist of a

Each component may influence the behavior of

2 System Simulation: Drive System Example Power Supply Inverter Actuator Mechanic Load Digital Control Analog 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 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

Electromechanical (EM) Components and Systems Component Analysis Look at component

.. Usually by field simulation or analytical models Distributed parameters geometry,

Drives, converters,... composed of motors, coils, resistors, diodes,.

3 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 2010 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary

4 Electrical Machine Technology: Yesterday vs. Today 1980 s DC Machine for Military Aircraft 2004 Toyota Prius IPM Machine Size in Weight lb Rated Power kw Rated Torque Nm Smaller! Lighter! More Powerful! 2010 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

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

5 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 2010 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary

Electrical Machines Design Suite State-of-the-Art Design: RMxprt for analytical machine design or ECE

for thermal and stress analysis Optimetrics or DX for optimization, statistics, sensitivity,.

Tuning Simplorer Multidomain Systems Circuits, Blocks, States, VHDL-AMS Maxwell 2D/3D Electromagnetic Fields

6 Electrical Machines Design Suite 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 Analytical Machine Design Optimetrics/DX Parametrics, Optimization, Sensitivity, Statistical, Tuning Simplorer Multidomain Systems Circuits, Blocks, States, VHDL-AMS Maxwell 2D/3D Electromagnetic Fields Static, Dynamic (t, f), Motion, Circuits MultiPhysics Stresses, Heat, CFD 2010 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary

Electrical Machines RMxprt Overview Analytical

performance, make material and size decisions

hundreds of "what if" analyses in a matter of

7 Electrical Machines 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 2010 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary

8 Electrical Machines 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 2010 ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary

10 Electrical Machines RMxprt Typical Results, Report T(n) I(n) T Cog (j e ) e(j e ) h(n) P(n) Performance curve for varying magnet size Original Optimized Motor Performance curves of a BLDC Optimization of a synchronous generator with damper Customized reports possible ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary

design of electrical machine Quick model

saturation, eddy current effects in system

11 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? 2010 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary

LabelID=IVc1 D34 D36 100ohm LabelID=IVc2 R20 100ohm LabelID=IVc3 R21 LabelID=IVc4 100ohm R22 100ohm LabelID=IVc5 R23 100ohm LabelID=IVc6 R24 100ohm R25 LabelID=VIC

way Complete model setup External circuit created Ready to solve Draw using UDPs Complex machine cores Model Model V Windings with end turns DModel1 SModel1 Draw using CAD

12 LabelID=IVc1 D34 D36 100ohm LabelID=IVc2 R20 100ohm LabelID=IVc3 R21 LabelID=IVc4 100ohm R22 100ohm LabelID=IVc5 R23 100ohm LabelID=IVc6 R24 100ohm R25 LabelID=VIC LabelID=VIB LabelID=VIA D35 D37 D44 D42 D40 V S_50 V S_48 V S_46 D38 D45 D43 D41 V S_51 V S_49 V S_47 D39 Maxwell Motor Model Generation From RMxprt Most powerful way Complete model setup External circuit created Ready to solve Draw using UDPs Complex machine cores Model Model V Windings with end turns DModel1 SModel1 Draw using CAD modeler Full ACIS based 2D/3D CAD 100V LabelID=V e-006H ohm LA RA modeler included e-006H ohm LB RB Easy to use 100V LabelID=V33 Import geometry Share geometry e-006H LC ohm RC LPhaseA LPhaseB LPhaseC + 0V + 0V + 0V + 0V + 0V + 0V 1V 1V 1V 1V 1V 1V LabelID=V14 LabelID=V15 LabelID=V16 LabelID=V17 LabelID=V18 LabelID=V ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary 0 Automatically setup Geometry Motion Boundaries Excitations Materials Mesh Operations Solve Setup

13 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 2010 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary

Windings with end turns Draw using CAD modeler Full ACIS based 2D/3D CAD modeler included Easy

14 Electrical Machines 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 2010 ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary

cores Windings with end turns Draw using CAD

included Easy to use Import geometry Share

15 Electrical Machines 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 2010 ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary

calculation Various loss schemes Windings: Stranded losses Laminated steel: Core losses Solids and magnets: Eddy current losses

16 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 2010 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary

17 Maxwell Engineering Approach Engineer s business: Geometry Materials Sources and boundaries Understand results slave Maxwell s business: Numerics Meshing Solution B in stator and rotor, J in cage master Induced J in cage at t = 8 ms 2010 ANSYS, Inc. All rights reserved. 17 ANSYS, Inc. Proprietary

18 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 2010 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary

-BranchCurrent(VIA) [A] Maxwell 2D/3D: Transient Motion with External Circuits D 40 S_46 V D 34 D 41 S_47 V D 35 D 42 S_48 V D 36 D 43 S_49 V D 37 D 44 S_50 V D 38 D 45 S_51 V LabelID =IVc1 D 39

25 0 + - 110V LabelID=V32 Model DModel1 V Model SModel1 0.000921945H LA 0.000921945H LB 2.99132ohm RA 2.99132ohm RB LPhaseA LPhaseB Loss Types: Steel Copper Magnet + 110V 0.000921945H 2.

19 -BranchCurrent(VIA) [A] Maxwell 2D/3D: Transient Motion with External Circuits D 40 S_46 V D 34 D 41 S_47 V D 35 D 42 S_48 V D 36 D 43 S_49 V D 37 D 44 S_50 V D 38 D 45 S_51 V LabelID =IVc1 D ohm LabelID =IVc2 R ohm LabelID =IVc3 R 21 LabelID =VIA LabelID =VIB LabelID =VIC 100ohm LabelID =IVc4 R ohm LabelID =IVc5 R ohm LabelID =IVc6 R 24 NodeVoltage(IVa) [kv] 100ohm R V LabelID=V32 Model DModel1 V Model SModel H LA H LB ohm RA ohm RB LPhaseA LPhaseB Loss Types: Steel Copper Magnet + 110V H ohm LPhaseC LabelID=V33 - LC RC + 0V + 0V + 0V + 0V + 0V + 0V 1V 1V 1V 1V 1V 1V LabelID=V14 LabelID=V15 LabelID=V16 LabelID=V17 LabelID=V18 LabelID=V19 0 Ansoft LLC Phase Voltage / Current 4_Partial_Motor_TR_PWM Time [ms] 2010 ANSYS, Inc. All rights reserved. 19 ANSYS, Inc. Proprietary

20 Electrical Machines Design Issues Moving1.Torque [NewtonMeter] Inductance calculation Static Transient Cogging torque Magnetostatic with swept j m, or Transient with w m = 1 deg/s and R abc = 1 MW Back-EMF Transient, some constant w m and i abc = 0 Conditions at operating points (idle, rated, peak, startup,...) Transient with w m = w m OP and some v abc (t) or i abc (t) Ansoft Corporation Torque Maxwell2DDesign Curve Info Moving1.Torque Setup1 : Transient Time [s] 2010 ANSYS, Inc. All rights reserved. 20 ANSYS, Inc. Proprietary

Electrical Machines Design Issues Bradial Space harmonics

currents enabled Core losses setup for laminated objects Field

Rotor eccentricity Ansoft Corporation XY Plot 2 PMSM_CT 1.

80 0.60 0.40 0.20 0.00-0.20 0.00 0.20 0.40 0.60 0.80 1.

21 Electrical Machines Design Issues Bradial Space harmonics Evaluate fft( B n ( L airgap ) ) Losses Transient with eddy currents enabled Core losses setup for laminated objects Field distributions Startup, load variations Mechanical transients Rotor eccentricity Ansoft Corporation XY Plot 2 PMSM_CT 1.20 Curve Info Bradial Setup1 : Transient Time='0ns' NormalizedDistance 2010 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary

Electromagnetic Actuators Maxwell db/dt motion and time induced

Coupled FEA with external circuit and motion Includes time-induced

magnetic fields Motion-induced eddy effects Nonlinear material effects

22 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 2010 ANSYS, Inc. All rights reserved. 22 ANSYS, Inc. Proprietary

0.077ohm R ds_on 1000ohm R 28 D _Z ener S_Sw itch V Current(Winding) [A] Y2 [V] Actuators 200 ms 500 ms 1000 ms LabelID=IBatt LabelID=ISwitch Ansoft Corporation 25.00 XY Plot 1 Maxwell3DDesign3 50.

23 0.077ohm R ds_on 1000ohm R 28 D _Z ener S_Sw itch V Current(Winding) [A] Y2 [V] Actuators 200 ms 500 ms 1000 ms LabelID=IBatt LabelID=ISwitch Ansoft Corporation XY Plot 1 Maxwell3DDesign LabelID=VCoil Curve Info Current(Winding) ohm R_Coil LCoil Setup1 : Transient InducedVoltage(Winding) Setup1 : Transient NodeVoltage(IVM_SRC) Setup1 : Transient LabelID=I_Pulse LabelID=VZener V V Model LabelID=VSource SW_Inf o Model Zener_Inf o + 0V V LabelID=V_Pulse Time [ms] 2010 ANSYS, Inc. All rights reserved. 23 ANSYS, Inc. Proprietary

parameters Transient run Detect closing time 2010

24 Electromagnetic Actuators Maxwell Optimization of Closing Time: Gap ArmStepHeight Vary geometric parameters Transient run Detect closing time 2010 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary

25 Electrical Machines and Actuators Simplorer-Maxwell 2D/3D Cosimulation 3PHAS A * sin (2 * pi * f * t + PHI + phi_u) ~ ~ ~ PHI = 0 PHI = -120 PHI = -240 AMPLITUDE := 800 V FREQUENCY := 60 Hz Electric circuits B6U D1 D3 D5 D2 D4 D6 Blocks, states, functions, differential equations FREQ := 800 Hz AMPL := 800 PHASE := 0 deg FREQ := 50 Hz AMPL := 500 PHASE := -315 deg PHASE := -75 deg PHASE := -195 deg + V 2L3_GTOS g_r1 g_r2 SA g_s1 g_s2 SB g_t1 g_t2 SC ICA: LL:=237.56u RA:= m LDUM:=100m CDC:=10m LDC:=10m RDC:=10 VZENER:=650 PhaseA1 PhaseA2 PhaseB1 PhaseB2 PhaseC1 PhaseC2 Mechanics Rotor1 Rotor2 Maxwell 2D/3D Transient+Motion FEA + w 6.25 Ohm 6.25 Ohm Maxwell 2D/3D Transient+Motion UPPER_LIM := 0.1 in Mechanics 153 N/m PhaseA1 plunger1 12 V D1 Electric circuits RS := 10 Ohm D3 RS := 10 Ohm PhaseA2 plunger2 FEA Ideal kg S0 := 0 in 10u Ns/m F N u m 2010 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary

26 Electrical Machines and Actuators Simplorer-Maxwell 2D/3D Cosimulation Simplorer Multidomain Systems Circuits, Blocks, States, VHDL-AMS Maxwell 2D/3D Electromagnetic Fields Dynamic (t, f), Motion, Circuits 2010 ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary

Maxwell Multiphysics Integration Thermal/Mechanical Load Transfer

coupling One-Way Mechanical Coupling Two-Way Mechanical Coupling

f), Motion, Circuits Deformation EM Force ANSYS Multiphysics Stresses,

27 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) Maxwell Electromagnetic Fields Static, Dynamic (t, f), Motion, Circuits Deformation EM Force ANSYS Multiphysics Stresses, Heat, CFD EM Loss Temperature 2010 ANSYS, Inc. All rights reserved. 27 ANSYS, Inc. Proprietary

29 Maxwell Multiphysics Integration Electrical Machine Stresses Thermo-mechanical simulation from the thermal solution See the (thermo-) deformation of the structure Stator, rotor temperature Deformation due to temperature 2010 ANSYS, Inc. All rights reserved. 29 ANSYS, Inc. Proprietary

Automatically calculated in Maxwell Using the Maxwell

rotor, coil deformation Original coil position 2010

30 Maxwell Multiphysics Integration 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 2010 ANSYS, Inc. All rights reserved. 30 ANSYS, Inc. Proprietary

Moving1.Torque [NewtonMeter] Vibration Analysis 8.00 7.

7332 Torque 02_DC-6step_IPM ANSOFT 6.00 5.00 4.00 3.00 2.00 1.00 0.00 0.00 5.00 10.

Tangential Force on Tooth Tips Allows only force on edge that neighbors

32 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 2010 ANSYS, Inc. All rights reserved. 32 ANSYS, Inc. Proprietary

Force (Newtons) Force (Newtons) Machine Model in Maxwell 10.

00 Curve Info ExprCache(ToothTipTangent_Full1) ExprCache(ToothTipTangent_2)

ExprCache(ToothTipTangent_6) -30.00 0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 Time [ms] 50.

00 Curve Info ExprCache(ToothTipRadial_Full1) ExprCache(ToothTipRadial_2) ExprCache(ToothTipRadial_3)

33 Force (Newtons) Force (Newtons) Machine Model in Maxwell Tangential Force on Tooth Tips 02_DC-6step_IPM ANSOFT Curve Info ExprCache(ToothTipTangent_Full1) ExprCache(ToothTipTangent_2) ExprCache(ToothTipTangent_3) ExprCache(ToothTipTangent_4) ExprCache(ToothTipTangent_5) ExprCache(ToothTipTangent_6) Time [ms] Radial Force on Tooth Tips 02_DC-6step_IPM ANSOFT Curve Info ExprCache(ToothTipRadial_Full1) ExprCache(ToothTipRadial_2) ExprCache(ToothTipRadial_3) ExprCache(ToothTipRadial_4) ExprCache(ToothTipRadial_5) ExprCache(ToothTipRadial_6) Time [ms] 2010 ANSYS, Inc. All rights reserved. 33 ANSYS, Inc. Proprietary

35 Workbench Setup 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 2010 ANSYS, Inc. All rights reserved. 35 ANSYS, Inc. Proprietary

Workbench Setup Radial and Tangential forces in Mechanical

Results - Equivalent stress 2010 ANSYS, Inc.

temperature back to Maxwell Iterate as necessary EM Loss

39 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 2010 ANSYS, Inc. All rights reserved. 39 ANSYS, Inc. Proprietary

.. ANSYS CFD (Fluent) solver Steady state analysis Water cooled Airgap Model

40 Electrical Machine Cooling Maxwell-CFD: Heat-Up Analysis Full model Model without water Maxwell2D Transient Losses averaged Expanded to 3D, mapped to... ANSYS CFD (Fluent) solver Steady state analysis Water cooled Airgap Model with solid only 2010 ANSYS, Inc. All rights reserved. 40 ANSYS, Inc. Proprietary

41 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 Ansoft Optimetrics ANSYS DesignExplorer DX (calls Optimetrics) External tools via scripting 2010 ANSYS, Inc. All rights reserved. 41 ANSYS, Inc. Proprietary

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.

42 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) 2010 ANSYS, Inc. All rights reserved. 42 ANSYS, Inc. Proprietary

43 DX IPM Torque Optimization Maxwell runs a parametric solution given x from DOE setup. DX creates n-dimensional response surface from this DOE table ANSYS, Inc. All rights reserved. 43 ANSYS, Inc. Proprietary

DX IPM Torque Optimization Response Surface Technique ANSYS DesignExplorer (DX) Various experimentations can be applied (optimization, sensitivity,.

44 DX IPM Torque Optimization 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, ANSYS, Inc. All rights reserved. 44 ANSYS, Inc. Proprietary

45 DX IPM Torque Optimization Slot Width Slot Height Magnet Width Magnet Height TorquePerMagArea B avg Tooth #5 Torque Magnet Area Sensitivity chart (computed instantaneously from response surface) 2010 ANSYS, Inc. All rights reserved. 45 ANSYS, Inc. Proprietary

Torque T DX IPM Torque Optimization Pareto

to red respectively B avg Tooth #5 2010 ANSYS,

DX IPM Torque Optimization Probability density of output torque

49 Modern Product Design Issues Component & System simulation are key elements in achieving modern requirements! Higher Functionality Performance Usability / automation Precision Reliability Lifetime Lower Cost Time to Market Material Consumption Size Energy Consumption 2010 ANSYS, Inc. All rights reserved. 49 ANSYS, Inc. Proprietary

Electromagnetic Force Coupling in Electric Machines Mark Solveson, Cheta Rathod, Mike Hebbes, Gunjan Verma, Tushar Sambharam ANSYS, Inc.

Electromagnetic Force Coupling in Electric Machines Mark Solveson, Cheta Rathod, Mike Hebbes, Gunjan Verma, Tushar Sambharam ANSYS, Inc. 1 ANSYS, Inc. September 29, Introduction Low noise regulation Aimed