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Introduction
Lownoiseregulation
Aimedatreductioninnoisepollution
ComfortCriteria
Noisecausesdiscomfortandfatigue Noisesuppressiondemonstrates technological/marketingedge
ComponentFailure
Sensitivityofstructuretoacousticresonances
TheaboveAppliestomanyIndustrysectors:
Transportation,Power,Environmental,Buildingservices
2 2011ANSYS,Inc. October24,2011
Introduction
Noiseandvibrationinelectricmachinescomefrom manysources. ANSYSprovidesexcellentcapabilitiesforthedesignand analysisofelectricmachines:
Electromagneticperformance ElectricDriveperformance Structuralanalysis Thermalanalysis Acousticsanalysis
ANSYSfieldcouplingtechnologyallowsmappingof
electromagneticforcesforMechanicalanalysis
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MachineTypes
Differentmachinesmayhavedifferentconsiderations dependingontheirarchitectureorcontrolstrategies.
PrimaryForcesareinplane(radialandtangential) SingleandThreePhaseInductionMachines. PMSynchronousMachines(SurfaceMount,IPM). Switchedreluctancemachines PrimaryforceareAxial AxialFluxMachines
2011ANSYS,Inc.
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NoiseSources[1]
Magnetic
Radial
Self Auxiliaries LoadInduced
Mechanical
Aerodynamic
FluidCooling Phenomena
Electronic
Switching Harmonics
Foundation
Dynamic Eccentricity
Audible Frequencies
20Hz
5
60Hz
261.63Hz
October24,2011
4.186kHz
5kHz
20kHz
2011ANSYS,Inc.
[1]P.Vigayraghavan,R.Krishnan,NoiseinElectricMachines:AReview,IEEE,1998
ANSYSMachineModel
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ElectromagneticDesignandAnalysis
ANSYSMachineDesignMethodology
RMxprt:calculateratedperformanceformachine Maxwell:CalculatedetailedmagneticFEAofmachineintime domain Simplorer:Calculatedetaileddrivedesignwithcoupled cosimulation witheitherRMxprtorMaxwell.
SINE1
SINE2
SINE3
TRIANG1
IGBT1 E1
D7
IGBT3
D9
IGBT5
D11
RphaseA PhaseA_in RphaseB PhaseB_in RphaseC PhaseC_in MotionSetup1_in E2 D8 IGBT2 IGBT4 D10 IGBT6 D12 0 PhaseC_out MotionSetup1_out PhaseB_out PhaseA_out
V
VM1
V_ROTB1
2011ANSYS,Inc.
October24,2011
MachineModelinMaxwell Simplorer
2DIPM(InteriorPermanentMagnet)motormodelcreatedfromRMxprtand MaxwellUDP(UserDefinedPrimitive)forrotor
Model
V Model DModel1 D40 D42 D44 SModel1
S_46
V D35
S_48
V D37
S_50
V D39
+ -
LabelID=VIB 0.000512893H*Kle LB
2.00694ohm RB
LPhaseB
+ -
110V LabelID=V33
LabelID=VIC 0.000512893H*Kle LC
2.00694ohm RC
LPhaseC
D41
D43
D45
D34
S_47
D36
S_49
D38
S_51
LabelID=IVc1 LabelID=IVc2 LabelID=IVc3 LabelID=IVc4 LabelID=IVc5 LabelID=IVc6 100ohm 100ohm 100ohm 100ohm 100ohm 100ohm R20 R21 R22 R23 R24 R25
-1 + 1V LabelID=V14
-1 + 1V LabelID=V15
-1 + 1V LabelID=V16
-1 + 1V LabelID=V17
-1 + 1V LabelID=V18
-1 1V LabelID=V19
SINE1
SINE2
SINE3
TRIANG1
IGBT1 E1
D7
IGBT3
D9
IGBT5
D11
PhaseA_out PhaseB_out
Sine Triangle
Basic_Inverter1
Curve Info SINE1.VAL SINE2.VAL SINE3.VAL TRIANG1.VAL
ANSOFT
V
VM1
PhaseC_in MotionSetup1_in
PhaseC_out
TR
0.88
TR TR TR
MotionSetup1_out
V_ROTB1
0.25
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Y1 -0.38 -1.00 -1.10 20.00 22.50 25.00 27.50 30.00 Time [ms] 32.50 35.00 37.50 40.00
MachineModelinMaxwell Simplorer
Torque
Basic_Inverter1
Curve Info
TR FEA1.TORQUE
ANSOFT
Currents
Basic_Inverter1
Curve Info
TR TR RphaseA.I RphaseB.I RphaseC.I
ANSOFT
15.00
12.50
TR
10.00
10.00
5.00
FEA1.TORQUE
7.50
Y1 [A]
20.00 22.50 25.00 27.50 30.00 Time [ms] 32.50 35.00 37.50 40.00
0.00
-5.00
5.00
-10.00
2.50
-15.00
0.00
-20.00 20.00 22.50 25.00 27.50 30.00 Tim e [ms] 32.50 35.00 37.50 40.00
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ForceCalculations
Force calculationusingairgapfluxdensity Maxwell StressTensor
[9]
EdgeForceDensity
DefaultfieldquantityavailableinMaxwell Canbeusedforcreatinglumpedforce
calculationsontoothtips
AutomaticForcemappingfromMaxwellto
ANSYSMechanical.(2D2D,2D3D,3D3D)
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EdgeForceDensityinMaxwell
Tangential Force on Tooth Tips
10.00
02_DC-6step_IPM
ANSOFT
5.00
0.00
Force (Newtons)
-5.00
-10.00
-15.00
Curve Info ExprCache(ToothTipTangent_Full1)
-20.00
-25.00
-30.00 0.00 5.00 10.00 15.00 20.00 Time [ms] 25.00 30.00 35.00 40.00
02_DC-6step_IPM
ANSOFT
-0.00
-100.00
-150.00
-200.00
-250.00 0.00 5.00 10.00 15.00 20.00 Time [ms] 25.00 30.00 35.00 40.00
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EccentricityModel
LeftSide Tooth
RightSide Tooth
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EdgeForceDensity,50%Eccentricity
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50%Eccentricity:RadialandTangential ForceonRightSideandLeftSideTooth
0.00
ANSOFT
15.00
ANSOFT
-100.00
0.00
-150.00
-200.00
-250.00
Curve Info Radial Force Small Gap Radial Force Large Gap
Force (N)
Force (N)
-5.00
-10.00
-15.00
-20.00
Curve Info Tangential Force Small Gap Tangential Force Large Gap
-25.00
-300.00 20.00
22.50
25.00
27.50
32.50
35.00
37.50
40.00
-30.00 20.00
22.50
25.00
27.50
32.50
35.00
37.50
40.00
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ANSYSForceMapping
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TwoApproaches
DirectForceMapping
ElectromagneticforcesfromMaxwellto Mechanicalbylinkingsystemsin Workbench Maps2DEdgeForce,and 3DSurfaceforce TransientAnalysisforStressprediction
LumpedForceMapping
ToothTipobjectscreatedformapping calculatedlumpedforceusing EdgeForceDensityinMaxwell. Applytheselumpedforcesmanually orthroughAPDLMacro FurtherharmonicandNoiseAnalysis
17 2011ANSYS,Inc. October24,2011
Approach1 DirectForceMapping
Scenario:StudytheeffectofRotorEccentricity Case1:0%Eccentricity
Nomisalignment
Case2:50%Eccentricity
Eccentricityamountissetto 50%ofgapwidth Createsunbalanced electromagneticforces
PeakEdgeForceDensity1.5e6N/m2
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PeakEdgeForceDensity1.9e6N/m2
DirectionalDeformationRadial
This image cannot currently be display ed.
MaxDeformationvs time
Case10%Eccentricity
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Case250%Eccentricity
VonMissesStress
MaxStressesvs time
Case10%Eccentricity
This image cannot currently be display ed. This image cannot currently be display ed.
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Case250%Eccentricity
Results:Comparison
Highertheamountofeccentricity,higheristhevariationof electromagneticforces,causingdeformationofstator, vibrationandnoise
TotalDeformation
Deformationhigherforeccentric model
PeakStresses
Stressesattime=12ms
StatorStressesarenonsymmetricandhigherforeccentricmodelwheretheair gapisminimum
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Approach2LumpedForceMapping
ElectromagneticForces Exportforces ANSYS Maxwell LumpedForcesinTimeDomain PerformFFTinMaxwell Real/ImaginaryForces InFrequencyDomain APDLinWorkbench ANSYS Mechanical HarmonicResponse APDLinWorkbench ANSYS Acoustics
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ExtractAcousticPressures
ANSYSHarmonicAnalysis
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ModalAnalysis:GetResonantFrequencies
Mode#1,8502Hz
Mode#2,8708Hz
Mode#3,8708Hz
FirstfourNaturalFrequencyand correspondingmodeshapes
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Mode#4,9080Hz
WhyHarmonicAnalysis
Tomakesurethatagivendesigncanwithstandsinusoidalloadsat differentfrequencies Todetectresonantresponseandavoiditifnecessary(e.g.using mechanicaldampers,changingPWMfrequency,etc.) TodetermineAcousticresponse
BoundaryConditions
InputForces
Applingharmonicforcesfrom MaxwellintoANSYSMechanical
25 2011ANSYS,Inc. October24,2011
HarmonicResponse Bodeplot
Frequencyresponseataselectednodelocationofthemodel.
HarmonicResponse Contourplot
Amplitudedistributionofthedisplacementsataspecificfrequency,
Deformationplotat8710Hz
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ANSYSAcoustics
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AcousticsCapabilitiesinANSYS
Acousticsisthestudyofthegeneration,propagation,absorption,
andreflectionofsoundpressurewavesinanacousticmedium.
Acousticproblemscanbeidentifiedas
VibroAcoustics:Soundgeneratedstructurally(ANSYSMechanical) AeroAcoustics :Soundgeneratedaerodynamically(ANSYSCFD)
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2011ANSYS,Inc.
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ModelingAeroAcoustics(ANSYSCFD)
FreeSpaceProblemwithnosolidsurfaces:
soundgeneratedfromturbulence,jetnoise
FreeSpaceProblemwithsolidsurfaces:
Fannoise,airframenoise,rotornoise,boundarylayernoise, cavitynoise
Interiorproblem:
Ductnoise,mufflers,ductedfannoise
Soundpressurefluctuations
30 2011ANSYS,Inc. October24,2011
VibroAcoustics(ANSYSMechanical)
Computingtheacousticfieldradiatedbyavibratingstructure StructuremodeledinANSYSMechanicalwherevibration patternsarecalculated(Modal,HarmonicAnalysis).Applied loadsareobtainedfromMaxwell. Vibrationpatternsusedasboundaryconditionstocompute acousticfieldradiatedbystructure(ANSYSMAPDL,ANSYS AcousticStructures)
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AcousticAnalysis PressurePlot
This image cannot currently be display ed.
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AcousticAnalysis PressurePlot
0.5m
Pres_1
Pres_2
Pres_3
Pressurevs Freq
Pressure(Pa)
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Freq(Hz)
Summary
Investigateddifferentnoisesourcesforelectricmachines DemonstratedanintegratedapproachfromElectromagnetics
toStructuraltoAcoustics. Showedtheeffectsofstaticeccentricityonstatortoothforces, deformationandstresses. Performedmodalanalysistofindtheacousticresonances
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References
[1] P.Vijayraghavan,R.Krishnan,Noiseinelectricmachines:AReview,IEEE,1998 [2] K.Shiohata,R.Kusama,S.Ohtsu,T.Iwatsubo,TheStudyonElectromagneticForceInducedVibrationandNoisefroma NormalandEccentricUniversalMotors,PIERSProceedings,2011. [3] S.Fink,S.Peters,AnsoftNoisePredictionforElectricalMotors,CADFEM/ANSYSPresentation,2011. [4] WeiWang,QuanfengLi,ZhihuanSong,ShenboYu,JianChen,RenyuanTang,ThreeDimensionalFieldCalculationand AnalysisofElectromagneticVibrationandNoiseforDiskPermanentMagnetSynchronousMachines,ShenyangUniversityof Technology,China. [5] R.Belmans,D.Verdyck,W.Geysen,R.Findlay,ElectroMechanicalAnalysisoftheAudibleNoiseofanInverterFedSquirrel CageInductionMotor,IEEE,2008. [6] M.Anwar,I.Husain,DesignPerspectivesofaLowAcousticNoiseSwitchedReluctanceMachine,IEEE,2000. [7] S.Huang,M.Aydin,T.A.Lipo,ElectronmagneticVibrationandNoiseAssessmentforSurfaceMountedPMMachines,IEEE, 2001. [8] RakibIslam,IqbalHussain,AnalyticalModelforPredictingNoiseandVibrationinPermanentMagnetSynchronousMotors, IEEE2009. [9] PragasenPillay,William(Wei)Cai,AnInvestigationintoVibrationinSwitchedReluctanceMotors,IEEETransactionson IndustryApplications,Vol.35,NO.3,May/June,1999.
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ThankYou
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ANSYSAcousticsStructure
ANSYSAcoustics Structurescomputes noiseradiatedby vibratingstructures. FromHarmonic Vibrations toNoise Estimates. ANSYSAcoustics Structuresintegrateswith yourcurrentsimulation tools.
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TitleandAbstract
ElectromagneticForceCouplinginElectricMachines IncludingStress,Deformation,andAcousticAnalysis. Understandingtheimpactofelectromagneticforceson noisegenerationforelectricmachinescanincludemany factors. Thispresentationwillreviewtheseissuesand illustrateelectromagneticforces,stress,deformation,and acousticcouplinginANSYSWorkbench. Anexample showingautomaticmappingofmagnetictimedomain forces,andacomparisonofstressesfordifferentrotor eccentricitieswillbeshown.
38 2011ANSYS,Inc. October24,2011
PresentationOutline(Goal30totalSlides)
1. 2. Introduction Literaturereview whatarethenoisecomonents forelectricmachines
a. b. NoiseSources,examples AcousticDefinition,examples RMxprttoMaxwell,Simplorer Forcecalculations EccentricityModel
3.
EMMotorMethodology
a. b. c.
4.
MechanicalAnalysis
a. 2D(3D?)transientforcemappingresults b. DiscussionofFFTapproaches(byinspectionor3rd partytools/scripts) c. 2D(3D?)harmonicAnalysis
5.
Acousticanalysis
a. Generalcapabilities(acousticelements,Actran coupling?) b. Resultsforstatorlamination
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NoiseSources
Magnetic
Theinteractionofmagneticfieldsandcurrentsinthemachinecause electromagnetictorque andthusrotationoftherotor. Evaluationoftheradialandtangentialforcesonthetoothtipsareimportant. Thiscanbeaccomplishedthroughevaluationoftheairgapfluxdensity,orusing ForceDensityfieldcalculationsavailablewithinMaxwell. Ifoneoftheradialforcefrequenciescoincideswiththenaturalfrequency ofthe machine,resonanceoccursleadingtoacousticnoise. Mixedproductofstatorandrotorwindingspaceharmonics. SlotHarmonics RotorEccentricity:improperrotoralignmentcausingunbalancedmagnetic forcesonthestator. Laminationvibrationduetomagnetorestrictiveforces(worstwhennotstacked properly)
Electronic
40
Switchingnoise InverterPWMfrequenciescanbeinaudiblerange. ANSYS,Inc. October 24,2011 2011 Current through the winding Lorentzforces
NoiseSources
Mechanical
Selfresonance naturalresonancefrequencies Closedformequations FEA Loadinduced Couplingofmachinetoload,andmounting. Auxiliaries BearingVibration Brushcommutators Chattering Intralamination FunctionofBoltforce Involves3DMechanicaltransientvibrationanalysis Manufacturingasymmetriesoftherotorandstator nonuniformairgap Statorwindingwhicharenotinstalledproperly
AeroDynamics
41 2011ANSYS,Inc. October24,2011 ANSYSCFD
MachineModelinMaxwell
VBscriptFieldsCalculatortocreateRadialand TangentialForceExpressionsfrom EdgeForceDensity VBscriptCalculatesRadialandTangential ForceonToothTips Allowsonlyforceonedgethatneighborsnon ferrousobjects Halfteethforcecomponentsaddedtogether AddtoExpressionCache
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HarmonicAnalysisOverview
Atechniquetodeterminethesteadystateresponseofastructureto sinusoidal(harmonic)loadsofknownfrequency. Input: Harmonicloads(forces,pressures,andimposeddisplacements)ofknown magnitudeandfrequency. (ObtainedfromMaxwell) Maybemultipleloadsallatthesamefrequency. Output: HarmonicdisplacementsateachDOF,usuallyoutofphasewiththeapplied loads. Otherderivedquantities,suchasstressesandstrains.
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ANSYSAcoustics
Structuralbornenoise(onewayVibroAcoustics)
ANSYSAcousticsStructures(FFTsACTRANSolver)
VibroAcoustics
ANSYSMechanical(APDLSolver)
AeroAcoustics
ANSYSCFD
Nonlinearfluidstructureinteraction
ANSYSCFD+ANSYSMechanical
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AeroAcousticsANSYSCFDApproaches
Directcalculation:
ResolvetheacousticpressurefluctuationsaspartoftheCFD solution CoupleCFDwithspecializedacousticscodes,Boundary ElementMethods(BEM),Hybridzonalmethods AcousticwavesarenottrackedwithCDFsolution Calculatewavepropagationusingspecializedcodes(ACTRAN, SYSNOISE)
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2011ANSYS,Inc.
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AeroAcousticsimulationofAutomotive FrontEndModulecoolingfans
byusingFLUENTsAcousticmodule
CourtesyofHyundaiMOBIS,Korea
Computationaldomain GeometryofCoolingFans
PressureContours
46 2011ANSYS,Inc. October24,2011
SubwooferExample(ANSYSCFD) (nonlinearfluidwithstructure)
FluidStructureInteractionSolution
TransientPressures
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ScatteredAcoustic Radiation
AnimationofAcoustic Pressure(Pa)
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