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
ANSYS Magnetics
Mechanical
Thermal/Stress

Field Solution

Model Generation
4 2011 ANSYS, Inc. June 8, 2012
 Simplorer Design Flow System Coupling
ANSYS CFD Simplorer
Icepack/Fluent System Design RMxprt
Motor Design
IA PMSYNC Torque J

A A D2D

IB ICA:
A
PP := 6
IC
A

GAIN

HFSS, Q3D, SIwave

PExprt
Magnetics

ANSYS Maxwell 2-D/3-D

Mechanical Electromagnetic Components
Thermal/Stress
Model order Reduction

Co-simulation

Push-Back Excitation
5 2011 ANSYS, Inc. 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 2011 ANSYS, Inc. 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 2011 ANSYS, Inc. June 8, 2012

 Integrated EMDM Foundations
Auto Setup Maxwell Design from RMxprt

8 2011 ANSYS, Inc. June 8, 2012

 Maxwell/RMxprt V15 Axial Flux Machine
AC or PM Rotor Sample Inputs
Single or Double Side Stator

Sample Outputs
9 2011 ANSYS, Inc. June 8, 2012
 Maxwell/RMxprt V15 Axial Flux Machine
Maxwell 3D auto-setup (Geometry, Motion, Master Slave, Excitations, etc. )

10 2011 ANSYS, Inc. June 8, 2012

 Design Exploration

Maxwell Project

P1 - cond

Workbench Schematic
P2 - parallel

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 Design Exploration

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 Design Exploration Six Sigma

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 Integrated Motor Solution

More Than 30
UDP Machine
Components
for 2D and 3D

14 2011 ANSYS, Inc. June 8, 2012

 RMxprt Dynamic Link to Simplorer

15 2011 ANSYS, Inc. June 8, 2012

 Maxwell
TRW / Ansoft
Position & Current Hysteresis Control Close/Open1
1.40 3.50
Curve Info

Position

1.20 Coil Current

3.00

Diode Current

1.00 2.50

Coil Current [meter]

0.80 2.00

Position [mm]
0.60 1.50

0.40 1.00

0.20 0.50

0.00 0.00
0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00
Time [ms]

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 Automatic Adaptive Meshing

17 2011 ANSYS, Inc. June 8, 2012

 Advanced Capabilities
Coreloss Computation

18 2011 ANSYS, Inc. June 8, 2012

 Lamination Core Loss in Time Domain

Instantaneous hysteresis loss

dB 1 dB
ph (t ) kh Bm cos H irr
dt dt
Instantaneous classic eddy current loss
2
1 dB
pc (t ) 2 c
k
2 dt
Instantaneous excess loss
2
1 dB
pe (t ) kc
Ce dt
where
/2
Ce 2
2
cos1.5d
1.5

21 2011 ANSYS, Inc. June 8, 2012

 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

23 2011 ANSYS, Inc. 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

120
8
100

Loss (W)
Loss (W)

6
80

Three-phase transformer 4
Three-phase motor
60
Core loss
40 2 Input power increase
Input power increase
20 Core loss 0
0 5 10 15 20 25 30 35 40
0
Time (ms)
0 20 40 60 80 100
Time (ms)

25 2011 ANSYS, Inc. June 8, 2012

 Advanced Capabilities
Demagnetization Modeling

26 2011 ANSYS, Inc. June 8, 2012

 Modeling Mechanism

The worst demagnetization point

for each element is dynamically
determined from a full transient B
process Br

Br'
The demagnetization point is
source, position, speed and
K
temperature dependent p Recoil lines

Each element uses its own recoil

Worst demagnetizing point
curve derived at the worst
demagnetization point in Hc 0 H

subsequent transient simulation

27 2011 ANSYS, Inc. June 8, 2012

 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'

p Recoil line

Hc 0 H

The animation shows how the demagnetization

permanently occurs with varying load current
28 2011 ANSYS, Inc. June 8, 2012
 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, element-
based 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) doesnt 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 2011 ANSYS, Inc. June 8, 2012
 Contours of loss density distribution Static temperature distribution (K)

34 2011 ANSYS, Inc. June 8, 2012

 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 2011 ANSYS, Inc. June 8, 2012
 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 H
36 2011 ANSYS, Inc. June 8, 2012
 What is the Difference between Using
Magnetostatic and Transient solver?
B
Magnetostatic case: the
operating point used for computing
magnetization (Br) is from single Br p
source point;

Transient case: the

0 H
operating point used for
B
computing magnetization (Br)
is the maximum operating
point with the largest (B,H) Br
during the entire transient
simulation. p

0 H
37 2011 ANSYS, Inc. June 8, 2012
 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
P(T) input
computation.
Q(T) input

For isotropic magnetization, all three

components have to be set to zero

38 2011 ANSYS, Inc. June 8, 2012

 Field-Circuit
Co-simulation

39 2011 ANSYS, Inc. 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| b c
Gmax

a d
0 Position
WidC+WidB

41 2011 ANSYS, Inc. June 8, 2012

 Case Example for Commutating Circuit

PMDC Motor

Winding currents

Torque
Brush
commutation
circuit

42 2011 ANSYS, Inc. June 8, 2012

 Simplorer:
Power Electronics

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 Simplorer Technology Highlights

44 2011 ANSYS, Inc. 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 SV RS

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. ...

45 2011 ANSYS, Inc. June 8, 2012

 Multi-Domain System Simulator
Analog Simulator
Electrical circuits Magnetics Mechanics Hydraulics, Thermal, ...
J
A 11B 11C 11
A 12 A2 M( t)
M

GND
B 12
3~ B2 L
STF
C 12 C2 MMF
JA
+ R OT1 R OT2

ASMS

Q
- F( t)
m H

GND
STF

Simplorer Simulation Data Bus / Simulator Coupling Technology

State-space Block Diagram State Machine Digital/VHDL

Models Simulator Simulator Simulator
CLK
INV

transition
state
CLK

PST
EIN J Q
PROCESS (CLK,PST,CLR) K

BEGIN CLK
Flip flop

SET: TSV1:=1
SET: TSV2:=0
SET: TSV3:=0
(R_LAST.I >= I_OGR) IF (PST = '0') THEN CLR
QB

SET: TSV4:=1

x Ax Bu
state <= '1'; CLK

ELSIF (CLR = '0') THEN

AUS
state <= '0'; CLK
INV

ENDIF;
y Cx
SET: TSV1:=0
SET: TSV2:=1
(R_LAST.I <= I_UGR) SET: TSV3:=1
SET: TSV4:=0

46 2011 ANSYS, Inc. June 8, 2012

 Electromechanical Design Environment

Matlab Matlab
RTW
UDC MathCAD Maxwell
Simulink
Co-Simulation

C/C++ Programming Interface (FORTRAN, C, C++ etc.)

Simulation Data Bus/Simulator Coupling Technology

Block State
Maxwell Circuits VHDL-AMS
Diagram Machine

Model Database
Electrical, Blocks, State Machines, Automotive, Hydraulic,
Mechanics, Power, Semiconductors

47 2011 ANSYS, Inc. June 8, 2012

 Multi-Physics Co-Simulation
Transient Electromagnetic Digital Electrical
FEM Co-simulation Maxwell
Digital Control ctrl1
bjt1 bjt2
2D/3D CTRL1 BS=>Q

CTRL2 BS=>Q
ctrl2 75

TRIG
75
- +
T RIG Battery A
PLUNGER
I
DET ECT

plunger_control

Solenoid p1 p

p2 m
Solenoid

F plunger orifice
s0 := 0.0002
em_force m := 0.0066

spring
Future: Multidomain model extraction and F
spacer
co-simulation gravity
accumulator
v alue := 0.0066*9.8 limit
sul := 0.0002
sll_ := 0.0

Mechanical Hydraulic
49 2011 ANSYS, Inc. June 8, 2012
 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 Simplorers 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 2011 ANSYS, Inc. June 8, 2012

 IGBT model
1. System model
Nonlinear resistance
1) 2) verification of operation

2. Average model
Static char. & average loss.
Heating & temp. rise

4)
3) 3. Basic Dynamic model
Dynamic char.& Energy
Switching loss & heating.

4. Advanced Dynamic model

Detailed dynamic char.
Inverter surge & noise

52 2011 ANSYS, Inc. June 8, 2012

 IGBT Characterization

57 2011 ANSYS, Inc. 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 Line current

1T, 1D SW loss + DC loss

58 2011 ANSYS, Inc. June 8, 2012
 Simplorer + Icepak
= Detailed modeling of thermal system
ANSYS Icepak
Q3D Extractor
CAD Import

Design of the cooling

Parasitism LCR
technique and
extraction
arrangement

700.0

500.0

333.3

Simplorer
166.7

0
-50.0
-231.0n 0 200.0n 400.0n 618.0n
The simulation in consideration of
change of detailed temperature
Device property and environment
loss consultation
59 2011 ANSYS, Inc. June 8, 2012
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
+
PhaseA1 Rotor1
w
3PHAS
A * sin (2 * pi * f * t + PHI + phi_u) B6U g_r1 g_s1 g_t1 PhaseA2 Rotor2
PHI = 0 +
~
D1
V PhaseB1
D3 D5
PHI = -120
~
PhaseB2
PHI = -240 g_r2 g_s2 g_t2
~ D2 D4 D6
PhaseC1

FREQ := 800 Hz
AMPL := 800 ICA: LL:=237.56u PhaseC2
AMPLITUDE := 800 V
PHASE := 0 deg RA:=696.076m FEA
FREQUENCY := 60 Hz
LDUM:=100m
FREQ := 50 Hz
CDC:=10m
AMPL := 500 Name Value

Fed by ac-dc-ac inverter

SA LDC:=10m
PHASE := -315 deg
RDC:=10
SIMPARAM1.RunTime [s] 111.29k
PHASE := -75 deg VZENER:=650
SB
SIMPARAM1.TotalIterations 40.51k

PHASE := -195 deg SC SIMPARAM1.TotalSteps 10.00k

FEA1.FEA_STEPS

300.00
LA.I [A]

200.00
Current LB.I [A] Torque 1.50k

LC.I [A] 425.00

1.00k 100.00 * LD.I [A]

VDC.V [V]

0
0 Speed
0

-500.00
-200.00 -500.00
-715.00

-297.50 0 50.00m 100.00m

0 50.00m 100.00m
0 50.00m 100.00m

60 2011 ANSYS, Inc. June 8, 2012

 BLDC motor FEA Coupled with Simplorer
Output torque
Inverter fed three phase BLDC
7.80

motor drive ICA: LL:=922u

Chopped current control RA:=2.991

PWM_T:=60
PWM_PER:=180
-14.50

I_TARG:=9 0 20.00m 30.00m

I_HYST:=0.2 1500 rpm

+
sourceA1 Magnet01 w
Q1 Q3 Q5 RA Ohm LL H
sourceA2 Magnet02

sourceB1

sourceB2
400 V
sourceC1

Q4 Q6 Q2 sourceC2
FEA

THRES := PWM_T VAL[0] := mod( INPUT[0] ,INPUT[1] )

QS1 INPUT[1] := PWM_PER +
ANGRAD
GAIN
F
LA.I EQUBL 57.3
QS2
CONST
-30+PWM_PER

-LC.I EQUBL
QS3
CONST
-60+PWM_PER

LB.I EQUBL
QS4
CONST
-90+PWM_PER

Chopped currents -LA.I

QS5
EQUBL

10.00 CONST
-120+PWM_PER

LC.I QS6 EQUBL

CONST
-150+PWM_PER
INPUT := -LB.I
THRES1 := I_TARG - I_HYST EQUBL

0
8.50 8.50

5.00 5.00

-10.30

0
0 20.00m 30.00m 0
0 20.00m 30.00m
0 20.00m 30.00m

61 2011 ANSYS, Inc. June 8, 2012

 SRM FEA Coupled with Simplorer
ICA: LL:=70.6914u
26293 rpm
RA:=203m
+
A1 AirRotor1
w

A2 AirRotor2

140 V
B1

100u F
B2

C1

C2
FEA

VAL[0] := mod( INPUT[0] ,90 )

QA +
ANGRAD
GAIN
F
Name Value EQUBL
57.3
FEA1.FEA_STEPS 1.00k QB
SIMPARAM1.RunTime [s] 6.90k CONST -60+90
SIMPARAM1.TotalIterations 4.05k
SIMPARAM1.TotalSteps 1.00k EQUBL

QC
CONST -30+90
EQUBL

current control variable mechanical

100.00 10.00 * QA.VAL
18.00 L1.I [A] 264.00m
10.00 * QB.VAL + 30.00
L2.I [A]
10.00 * QC.VAL + 60.00
L3.I [A] ROTA.VAL[0]
10.00 200.00m 10.00u * FEA1.OMEGA
E1.I [A]
ROTB.VAL[0]
V_ROTB1.TORQUE [Nm]
ROTC.VAL[0]

50.00
0 100.00m

-10.00
0
0
-17.80 -54.00m
0 500.00u 1.00m
0 500.00u 1.00m 0 500.00u 1.00m

62 2011 ANSYS, Inc. June 8, 2012

 Electric Machine Design:
Maxwell Simplorer Co-Simulation

3-ph Windings

Stator & Rotor

Co-simulation

Permanent Magnets

3ph Line Currents

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Flux Linkages
 Multi-physics

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 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 Deformation of the stator Deformation of coils
65 2011 ANSYS, Inc. June 8, 2012
 Force Coupling Maxwell to Mechanical
Tangential Force on Tooth Tips 02_DC-6step_IPM ANSOFT
10.00

5.00

0.00

-5.00

Force (Newtons)
-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 25.00 30.00 35.00 40.00
Time [ms]

Radial Force on Tooth Tips 02_DC-6step_IPM ANSOFT

50.00

-0.00

-50.00

Force (Newtons)
-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
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
Time [ms]

66 2011 ANSYS, Inc. June 8, 2012

 Force Coupling Maxwell to Mechanical

Max Deformation vs time

Case 1 0% Eccentricity

67 2011 ANSYS, Inc. June 8, 2012 Case 2 50 % Eccentricity

 Maxwell Couplings

2D/3D Losses Mapped Losses Temperature

Forced water cooling Forced air cooling Natural air cooling

68 2011 ANSYS, Inc. June 8, 2012
 Two Way CFD Thermal Analysis, R14

CFD Model
Temperature

Geometry

Losses
Maxwell Model Mapped Losses
69 2011 ANSYS, Inc. June 8, 2012
 Power Loss Mapped into FLUENT

Power Loss in windings are not displayed.

70 2011 ANSYS, Inc. June 8, 2012

 Results Temperature Distribution

71 2011 ANSYS, Inc. June 8, 2012

 Thank you
72 2011 ANSYS, Inc. June 8, 2012