Electric Machines Considering Power Electronics
Zed (Zhangjun) Tang, Ph.D. Presented at ANSYS Confidence by Design June 5, 2012 1
© 2011 ANSYS, Inc.
June 8, 2012
Outline Machine Design Methodology Introduction RMxprt Maxwell 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 2
© 2011 ANSYS, Inc.
June 8, 2012
Introduction: Machine Design Methodology
3
© 2011 ANSYS, Inc.
June 8, 2012
Maxwell Design Flow – Field Coupling ANSYS CFD
RMxprt
Fluent
Motor Design
Maxwell 2-D/3-D HFSS
Electromagnetic Components
PExprt Magnetics
ANSYS Mechanical Thermal/Stress Field Solution Model Generation 4
© 2011 ANSYS, Inc.
June 8, 2012
Simplorer Design Flow – System Coupling ANSYS CFD Icepack/Fluent
Simplorer System Design
RMxprt Motor Design
PMSYNC
IA A
Torque A
IB A
J D2D
ICA:
IC
PP := 6
A
GAIN
HFSS, Q3D, SIwave PExprt Magnetics
Maxwell 2-D/3-D
ANSYS Mechanical
Electromagnetic Components
Thermal/Stress Model order Reduction Co-simulation Push-Back Excitation 5
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June 8, 2012
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
6
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June 8, 2012
RMxprt - Motor Design Parametric Sweep: Stack_Length Skew/no Skew Stator_ID
AirGap
Monitor: Torque Power Efficiency
Determine the Best Design Create FEA Model Export Circuit Model
7
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June 8, 2012
Integrated EMDM Foundations Auto Setup Maxwell Design from RMxprt
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June 8, 2012
Maxwell/RMxprt V15 – Axial Flux Machine • AC or PM Rotor • Single or Double Side Stator
Sample Outputs 9
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June 8, 2012
Sample Inputs
Maxwell/RMxprt V15 – Axial Flux Machine • Maxwell 3D auto-setup (Geometry, Motion, Master Slave, Excitations, etc. )
10
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June 8, 2012
Design Exploration
Maxwell Project
P1 - cond
Workbench Schematic
P2 - parallel 11
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June 8, 2012
Design Exploration
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June 8, 2012
Design Exploration – Six Sigma
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June 8, 2012
Integrated Motor Solution
More Than 30 UDP Machine Components for 2D and 3D
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June 8, 2012
RMxprt Dynamic Link to Simplorer
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© 2011 ANSYS, Inc.
June 8, 2012
Maxwell TRW / Ansoft
Position & Current Hysteresis Control Close/Open1
1.40
3.50 Curve Info Position
1.20
3.00
Coil Current
1.00
2.50
0.80
2.00
0.60
1.50
0.40
1.00
0.20
0.50
0.00
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June 8, 2012
0.00
2.00
4.00
6.00
8.00
10.00 Time [ms]
12.00
14.00
16.00
18.00
0.00
Coil Current [meter]
Position [mm]
Diode Current
Automatic Adaptive Meshing
17
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June 8, 2012
Advanced Capabilities Coreloss Computation
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June 8, 2012
Lamination Core Loss in Time Domain • Instantaneous hysteresis loss 1
dB dB ph (t ) kh Bm cos H irr dt dt • Instantaneous classic eddy current loss dB pc (t ) k 2 c 2 dt 1
2
• Instantaneous excess loss
1 dB pe (t ) kc Ce dt
2
where Ce 2
1.5
21
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June 8, 2012
2
/2
0
cos1.5d
Core Loss Effects on Field Solutions • Basic concept: the feedback of the core loss is taken into account by introducing an additional component of magnetic field H in core loss regions. This additional component is derived based on the instantaneous core loss in the time domain
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June 8, 2012
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 feedback and 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. 160
12
140
10 8
100
Loss (W)
Loss (W)
120
80
Three-phase transformer
60
Three-phase motor
4
Core loss
40
2
Input power increase
Input power increase
20
Core loss
0 0
0 0
20
40
60 Time (ms)
25
6
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June 8, 2012
80
100
5
10
15
20 Time (ms)
25
30
35
40
Advanced Capabilities Demagnetization Modeling
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June 8, 2012
Modeling Mechanism • The worst demagnetization point for each element is dynamically determined from a full transient process
B Br Br'
• The demagnetization point is source, position, speed and temperature dependent
K p
Recoil lines
• Each element uses its own recoil curve derived at the worst demagnetization point in subsequent transient simulation 27
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June 8, 2012
Worst demagnetizing point Hc
0
H
Irreversible Demagnetization If a demagnetizing point P goes below the knee point K, even after the load is reduced or totally removed, the subsequent working points will no longer along the original BH curve, but along the recoil line.
B Br Br'
K p
Hc
28
The animation shows how the demagnetization permanently occurs with varying load current © 2011 ANSYS, Inc.
June 8, 2012
Recoil line
0
H
Benchmark Example • 8-pole, 48-slot, 50 KW, 245 V, 3000 rpm Toyota Prius IPM motor with imbedded NdFeB magnet • Two steps in 3D transient FEA: 1. Determine the worst operating point element by element during the entire transient process 2. Simulate an actual problem based on the element-based linearized model derived from the step 1 • To further consider the impact of temperature, elementbased average loss density over one electrical cycle is used as the thermal load in subsequent thermal analysis • The computed temperature distribution from thermal solver is further feedback to magnetic transient solver to consider temperature impact on the irreversible demagnetization 32
© 2011 ANSYS, Inc.
June 8, 2012
Hc' change in one element during a transient process:
The 1st cycle (0 to 5ms) doesn’t 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 33
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June 8, 2012
Contours of loss density distribution
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June 8, 2012
Static temperature distribution (K)
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 35
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Magnetization • Compute magnetization based on the original non-remanent B-H curve • Find operating point p from nonlinear solutions • Construct line b at the operating point p, which is parallel to the B Slope of line a at saturation point line a at saturation point • Br is the intersection of line b with B-axis p Br Line b • Element by element
0 36
© 2011 ANSYS, Inc.
June 8, 2012
H
What is the Difference between Using Magnetostatic and Transient solver? • Magnetostatic case: the operating point used for computing magnetization (Br) is from single source point;
• 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.
B
Br
0 B
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June 8, 2012
H
Br p 0
37
p
H
Anisotropic or Isotropic Magnetization • Anisotropic magnetization: magnetization direction is determined by the orientation of the magnet material and the direction is specified by a user;
• Isotropic magnetization: magnetization direction is determined 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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June 8, 2012
P(T) input
Q(T) input
Field-Circuit Co-simulation
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June 8, 2012
Maxwell Circuit Editor Example • Commutator bar: model position WidC
WidB (a)
(b)
(c)
(d)
• Commutating model: model parameters G LagAngle
Period |WidC-WidB|
Gmax
b
a 0
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WidC+WidB
June 8, 2012
c
d Position
Case Example for Commutating Circuit
PMDC Motor
Winding currents
Torque
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June 8, 2012
Brush commutation circuit
Simplorer: Power Electronics
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June 8, 2012
Simplorer Technology Highlights
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June 8, 2012
State-of-the-Art Drive System: A Multidomain Challenge ANSYS provides a comprehensive toolset for multidomain work: Drive systems
• Simplorer conservative structures (electrical •
circuits, mechanics, magnetics, hydraulics, thermal, ...) Simplorer non-conservative systems (blocks, states, digital, nth-order differential equations. M
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. ...
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© 2011 ANSYS, Inc.
June 8, 2012
·
SV
=
RS
Multi-Domain System Simulator Analog Simulator Electrical circuits
Magnetics
Mechanics
Hydraulics, Thermal, ...
J A 12 B 12
M
3~
C 12
M( t)
A2 B2
STF
MMF
C2
GND
A 11B 11C 11
L
JA R OT1
R OT2
ASMS
-
F( t)
m STF
Q
GND
+
H
Simplorer Simulation Data Bus / Simulator Coupling Technology
State-space Models
Block Diagram Simulator
State Machine Simulator
Digital/VHDL Simulator CLK INV
state
© 2011 ANSYS, Inc.
(R_LAST.I >= I_OGR)
AUS
(R_LAST.I <= I_UGR)
June 8, 2012
CLK PST
SET: TSV1:=1 SET: TSV2:=0 SET: TSV3:=0 SET: TSV4:=1
x Ax Bu y Cx 46
transition EIN
SET: TSV1:=0 SET: TSV2:=1 SET: TSV3:=1 SET: TSV4:=0
PROCESS (CLK,PST,CLR) BEGIN IF (PST = '0') THEN state <= '1'; ELSIF (CLR = '0') THEN state <= '0'; ENDIF;
J
Q
K CLK
Flip flop QB CLR
CLK
CLK INV
Electromechanical Design Environment Matlab RTW
UDC
MathCAD
Matlab Simulink
…
Maxwell
Co-Simulation C/C++ Programming Interface (FORTRAN, C, C++ etc.)
Simulation Data Bus/Simulator Coupling Technology
Maxwell
Circuits
Block Diagram
State Machine
Model Database Electrical, Blocks, State Machines, Automotive, Hydraulic, Mechanics, Power, Semiconductors… 47
© 2011 ANSYS, Inc.
June 8, 2012
VHDL-AMS
Multi-Physics Co-Simulation Transient Electromagnetic FEM Co-simulation – Maxwell 2D/3D
Digital
Electrical
Digital Control
CTRL1
BS=>Q
CTRL2
BS=>Q
TRIG
bjt2
75
ctrl2
-
75
+
Battery
T RIG PLUNGER DET ECT
bjt1
ctrl1
A
I plunger_control
Solenoid
p1 p2
plunger
F
em_force
p
Solenoid
m
orifice
s0 := 0.0002 m := 0.0066
spring
Future: Multidomain model extraction and co-simulation
F
spacer accumulator
gravity limit
v alue := 0.0066*9.8
sul := 0.0002 sll_ := 0.0
Mechanical 49
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June 8, 2012
Hydraulic
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 Simplorer’s 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 50
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June 8, 2012
IGBT model 1. System model • Nonlinear resistance – verification of operation
2)
1)
2. Average model • Static char. & average loss. – Heating & temp. rise 4)
3. Basic Dynamic model • Dynamic char.& Energy
3)
– Switching loss & heating.
4. Advanced Dynamic model • Detailed dynamic char. – Inverter surge & noise 52
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June 8, 2012
IGBT Characterization
57
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June 8, 2012
IGBT inverter design Circuit design (loss) + thermal model Ambient temperature = 20 cel Package temperature 1T
1D
1T, 1D junction temperature
Examination of temperature cycle 1T, 1D SW loss + DC loss 58
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June 8, 2012
Line current
Simplorer + Icepak = Detailed modeling of thermal system Q3D Extractor
ANSYS Icepak CAD Import
Design of the cooling technique and arrangement
Parasitism LCR extraction
700.0
500.0
333.3
Simplorer
166.7
0 -50.0
-231.0n
0
200.0n
400.0n
618.0n
Device property and loss consultation 59
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June 8, 2012
The simulation in consideration of change of detailed temperature environment Design of substrate radiating route
Induction Motor FEA Coupled with Simplorer Frequency controlled speed
G_R1 := SA.VAL
G_S1 := SB.VAL
G_T1 := SC.VAL
G_R2 := -SA.VAL
G_S2 := -SB.VAL
G_T2 := -SC.VAL
1400 rpm
2L3_GTOS 3PHAS
B6U
A * sin (2 * pi * f * t + PHI + phi_u)
~
PHI = 0°
~
PHI = -120°
~
PHI = -240°
g_r1
g_s1
g_t1
+ D1
D3
D5
D2
D4
D6
V
PhaseA1
Rotor1
PhaseA2
Rotor2
+
w
PhaseB1
PhaseB2 g_r2
g_s2
g_t2 PhaseC1
FREQ := 800 Hz AMPL := 800 PHASE := 0 deg
AMPLITUDE := 800 V FREQUENCY := 60 Hz
Fed by ac-dc-ac inverter
ICA:
LL:=237.56u
PhaseC2 FEA
RA:=696.076m LDUM:=100m
FREQ := 50 Hz AMPL := 500 PHASE := -315 deg PHASE := -75 deg
CDC:=10m
SA
Name
LDC:=10m RDC:=10 VZENER:=650
SB
PHASE := -195 deg
SIMPARAM1.RunTime [s]
111.29k
SIMPARAM1.TotalIterations
40.51k
SIMPARAM1.TotalSteps
SC
Value
10.00k
FEA1.FEA_STEPS
300.00
Current
200.00
LA.I [A] 425.00
LC.I [A]
1.50k
Torque
LB.I [A]
1.00k
100.00 * LD.I [A] VDC.V [V]
0
Speed
0
0 -500.00 -200.00 -297.50
0 0
60
-500.00
-715.00
© 2011 ANSYS, Inc.
50.00m
100.00m
June 8, 2012
50.00m
100.00m
0
50.00m
100.00m
BLDC motor FEA Coupled with Simplorer
Inverter fed three phase BLDC motor drive Chopped current control
Output torque 7.80
0
ICA:
LL:=922u RA:=2.991 PWM_T:=60 PWM_PER:=180
-14.50
I_TARG:=9
0
20.00m
30.00m
I_HYST:=0.2
Q3
Q1
RA Ohm
Q5
1500 rpm sourceA1
Magnet01
sourceA2
Magnet02
+
w
LL H
sourceB1 sourceB2
400 V
sourceC1
Q4
Q2
Q6
sourceC2 FEA
THRES := PWM_T
VAL[0] := mod( INPUT[0] ,INPUT[1] )
QS1
INPUT[1] := PWM_PER
+ GAIN
LA.I
QS2
-LC.I
Chopped currents
QS5
CONST
-60+PWM_PER
CONST
-90+PWM_PER
CONST
-120+PWM_PER
CONST
-150+PWM_PER
EQUBL
QS6
INPUT := -LB.I THRES1 := I_TARG - I_HYST 0
-30+PWM_PER
EQUBL
10.00
LC.I
CONST
EQUBL
QS4
-LA.I
ANGRAD
EQUBL
QS3
LB.I
F
57.3
EQUBL
EQUBL
8.50
8.50
5.00
5.00
-10.30
0
20.00m
30.00m
0
0 0
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June 8, 2012
20.00m
30.00m
0
20.00m
30.00m
SRM FEA Coupled with Simplorer ICA:
LL:=70.6914u
26293 rpm
RA:=203m
140 V
A1
AirRotor1
A2
AirRotor2
+
w
B1
100u F
B2 C1 C2 FEA
QA
VAL[0] := mod( INPUT[0] ,90 )
+
F
GAIN
Name
Value
FEA1.FEA_STEPS
EQUBL
1.00k
SIMPARAM1.RunTime [s]
6.90k
SIMPARAM1.TotalIterations
4.05k
SIMPARAM1.TotalSteps
1.00k
ANGRAD
57.3
QB
CONST
-60+90
EQUBL
QC CONST
control variable
current L1.I [A]
18.00
10.00 * QB.VAL + 30.00
L2.I [A]
264.00m
10.00 * QC.VAL + 60.00
L3.I [A] 10.00
mechanical
10.00 * QA.VAL
100.00
ROTA.VAL[0]
E1.I [A]
200.00m
ROTB.VAL[0]
10.00u * FEA1.OMEGA V_ROTB1.TORQUE [Nm]
ROTC.VAL[0] 50.00
0
100.00m
-10.00
0 0
-17.80 0
62
-30+90
EQUBL
500.00u
© 2011 ANSYS, Inc.
1.00m
June 8, 2012
0
500.00u
1.00m
-54.00m 0
500.00u
1.00m
Electric Machine Design: Maxwell – Simplorer Co-Simulation 3-ph Windings Stator & Rotor
Co-simulation
Permanent Magnets
3ph Line Currents 63
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June 8, 2012
Flux Linkages
Multi-physics
64
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June 8, 2012
Multiphysics Coupling through WB • Maxwell 3D provide volume/surface forces to ANSYS Structural • Solver improvements – Surface forces are supported Thermal-Stress with Electromagnetic Force load
The electromagnetic force density from Maxwell is used as load in Structural 65
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June 8, 2012
Deformation of the stator
Deformation of coils
Force Coupling – Maxwell to Mechanical Tangential Force on Tooth Tips
10.00
02_DC-6step_IPM
ANSOFT
5.00
Force (Newtons)
0.00
-5.00
-10.00
-15.00 Curve Info ExprCache(ToothTipTangent_Full1)
-20.00
ExprCache(ToothTipTangent_2) ExprCache(ToothTipTangent_3) ExprCache(ToothTipTangent_4)
-25.00
ExprCache(ToothTipTangent_5) ExprCache(ToothTipTangent_6)
-30.00
0.00
5.00
10.00
15.00
20.00 Time [ms]
25.00
30.00
Radial Force on Tooth Tips
50.00
35.00
02_DC-6step_IPM
40.00
ANSOFT
-0.00
Force (Newtons)
-50.00
-100.00
-150.00
Curve Info ExprCache(ToothTipRadial_Full1) ExprCache(ToothTipRadial_2) ExprCache(ToothTipRadial_3)
-200.00
ExprCache(ToothTipRadial_4) ExprCache(ToothTipRadial_5) ExprCache(ToothTipRadial_6)
-250.00
66
© 2011 ANSYS, Inc.
June 8, 2012
0.00
5.00
10.00
15.00
20.00 Time [ms]
25.00
30.00
35.00
40.00
Force Coupling – Maxwell to Mechanical
Max Deformation vs time
• Case 1 0% Eccentricity
67
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June 8, 2012
• Case 2 50 % Eccentricity
Maxwell Couplings
2D/3D Losses
Forced water cooling 68
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June 8, 2012
Mapped Losses
Temperature
Forced air cooling
Natural air cooling
Two Way CFD Thermal Analysis, R14
CFD Model
Temperature
Geometry Losses Maxwell Model 69
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June 8, 2012
Mapped Losses
Power Loss Mapped into FLUENT Power Loss in windings are not displayed.
70
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June 8, 2012
Results – Temperature Distribution
71
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June 8, 2012
Thank you 72
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June 8, 2012
