Motor Actuator LV

ANSYS / Ansoft
Component Design
Motors & Actuators
Leon Voss
ANSYS Inc.
© 2010 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary

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.

Electromechanical (EM)
Components and Systems
• Component Analysis • System Analysis
– Look at component alone • Look at interactions of components
– Motors, actuators, coils, ... • Drives, converters, ... composed of
– Usually by field simulation or motors, coils, resistors, diodes, ...
analytical models • Usually by system/circuit
– Distributed parameters – simulation or analytical models
geometry, materials, • Concentrated parameters –
boundaries, sources behavioral component models

Electrical Machine Technology:
Yesterday vs. Today
1980’s DC Machine for Military Aircraft 2004 Toyota Prius IPM Machine
1980 2004
Size in2 68.75 20.78 Smaller!
Weight lb 70 23 Lighter!
Rated Power kW 13 50 More Powerful!
Rated Torque Nm 100 400

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 and5 more
© 2010 ANSYS, Inc. All rights reserved. ANSYS, Inc. Proprietary
Electrical Machines –
Design Suite
• State-of-the-Art RMxprt
Design: Analytical Machine Design
• RMxprt for analytical Maxwell 2D/3D
machine design or Electromagnetic Fields
ECE Static, Dynamic (t, f), Motion, Circuits
• Maxwell 2D/3D for

static or transient Optimetrics/DX
electromagnetic FEA Parametrics, Optimization,
• Simplorer for circuit Sensitivity, Statistical,
and system analysis
Tuning MultiPhysics
Stresses, Heat, CFD
• ANSYS for thermal Simplorer
and stress analysis Multidomain Systems
• Optimetrics or DX for Circuits, Blocks, States, VHDL-AMS
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
T(n) I(n)
TCog(je) e(je)
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 ...
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
?
Maxwell Motor Model Generation
• From RMxprt Automatically setup

– Geometry
– Most powerful way
– Motion
– Complete model setup
– Boundaries
– External circuit created – Excitations
– Ready to solve – Materials
• Draw using UDPs – Mesh
Operations
– Complex machine cores
– Solve Setup
Model Model
V
– Windings with end turns

D40
D42
D44
DModel1 SModel1
S_46
S_48
S_50
D35
D37
D39
• Draw using CAD modeler

V
LabelID=VIA
– Full ACIS based 2D/3D CAD

+ 100V
LabelID=V32
LabelID=VIB
7.95824e-006H 0.00801603ohm LPhaseA

LA RA
modeler included
LabelID=VIC
0 LPhaseB
7.95824e-006H 0.00801603ohm
LB RB
– Easy to use
+
100V
LabelID=V33 7.95824e-006H 0.00801603ohm LPhaseC
-
LC RC
D41
D43
D45
• Import geometry
100ohm
100ohm
100ohm
100ohm
100ohm
100ohm
S_47
S_49
S_51
D34
D36
D38
R20
R21
R22
R23
R24
R25
LabelID=IVc1
LabelID=IVc2
LabelID=IVc3
LabelID=IVc4
LabelID=IVc5
LabelID=IVc6
V
• Share geometry
+ 0V + 0V + 0V + 0V + 0V + 0V
1V 1V 1V 1V 1V 1V
LabelID=V14 LabelID=V15 LabelID=V16 LabelID=V17 LabelID=V18 LabelID=V19

Maxwell Motor Model Generation
• From RMxprt
– External circuit created
– 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
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
Maxwell – Engineering Approach
Engineer‘s business:
• Geometry
• Materials
• Sources and boundaries slave
• Understand results
master
Maxwell‘s business:
• Numerics B in stator and rotor, J in cage

• Meshing
• Solution
Induced J in cage at t = 8 ms
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
Model Model
V
D 40
D 42
D 44
Loss Types:
DModel1 SModel1
S_46
S_48
S_50
D 35
D 37
D 39
• Steel
V
L a b e lID =V IC L a b e lID =V IB L a b e lID =V IA

• Copper
+ 110V
LabelID=V32
-
0.000921945H 2.99132ohm LPhaseA

LA RA
0
0.000921945H
LB
2.99132ohm
RB
LPhaseB
• Magnet
+
110V
0.000921945H 2.99132ohm LPhaseC
LabelID=V33
-
LC RC
D 41
D 43
D 45
100ohm
100ohm
100ohm
100ohm
100ohm
100ohm
S_47
S_49
S_51
D 34
D 36
D 38
R 20
R 21
R 22
R 23
R 24
R 25
L a b e lID =IV c1
L a b e lID =IV c2
L a b e lID =IV c3
L a b e lID =IV c4
L a b e lID =IV c5
L a b e lID =IV c6
V
+ 0V + 0V + 0V + 0V + 0V + 0V
1V 1V 1V 1V 1V 1V
LabelID=V14 LabelID=V15 LabelID=V16 LabelID=V17 LabelID=V18 LabelID=V19
Ansoft LLC Phase Voltage / Current 4_Partial_Motor_TR_PWM

150.00 1.00
0.80
100.00
0.60
0.40
50.00
-BranchCurrent(VIA) [A]
NodeVoltage(IVa) [kV]
0.20
0.00 0.00
-0.20
-50.00
-0.40
-0.60
-100.00
-0.80
-150.00 -1.00
10.00 15.00
Time [ms]

Design Issues
• Inductance calculation
– Static Ansoft Corporation
3.00
Torque Maxwell2DDesign1
– Transient 2.00
Curve Info
Moving1.Torque
Setup1 : Transient
• Cogging torque 1.00
Moving1.Torque [NewtonMeter]
– Magnetostatic with swept jm, or 0.00
– Transient with wm = 1 deg/s and

-1.00
Rabc = 1 MW
-2.00
-3.00
•
0.00 5.00 10.00 15.00
Back-EMF
Time [s]
– 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)
Design Issues
Ansoft Corporation XY Plot 2 PMSM_CT
1.20
•
Curve Info
Space harmonics
Bradial
Setup1 : Transient
Time='0ns'
1.00
– Evaluate fft( Bn ( Lairgap ) ) 0.80
0.60
• Losses
Bradial
0.40
– Transient with eddy currents enabled 0.20
– Core losses setup for laminated objects

0.00
-0.20
0.00 0.20 0.40 0.60 0.80 1.00
NormalizedDistance
• Field distributions
• Startup, load variations
– Mechanical transients
• Rotor eccentricity

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
200 ms 500 ms 1000 ms

LabelID=IBatt LabelID=ISwitch
Ansoft Corporation XY Plot 1 Maxwell3DDesign3
25.00 50.00
LabelID=VCoil
Curve Info
Current(Winding) 40.00
Setup1 : Transient
12ohm LCoil
InducedVoltage(Winding)
R_Coil Setup1 : Transient
20.00 30.00
NodeVoltage(IVM_SRC)
Setup1 : Transient
20.00
LabelID=I_Pulse
LabelID=VZener
15.00 10.00
Current(Winding) [A]
Y2 [V]
S _ S w itch
0.00
Model
+ V
12.5V
LabelID=VSource
-
SW_Inf o
10.00 -10.00
D _Z ener
Model
1000ohm
R 28
Zener_Inf o -20.00
+ 0V
5V
0 .0 7 7 o h m
R d s_ o n
LabelID=V_Pulse
5.00 -30.00
-40.00
0
0.00 -50.00
0
0.00 0.20 0.40 0.60 0.80 1.00
Time [ms]

Electromagnetic Actuators –
Maxwell
Optimization of Closing Time:
Gap
ArmStepHeight
• Vary geometric parameters

• Transient run
• Detect closing time

Electrical Machines and Actuators –
Simplorer-Maxwell 2D/3D Cosimulation
Mechanics
Electric circuits 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° +
~
V
D1 D3 D5 PhaseB1
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 FEA
PHASE := 0 deg RA:=696.076m
FREQUENCY := 60 Hz
LDUM:=100m
FREQ := 50 Hz
CDC:=10m
AMPL := 500
PHASE := -315 deg
SA LDC:=10m
RDC:=10
Maxwell 2D/3D
VZENER:=650
PHASE := -75 deg SB
Transient+Motion
PHASE := -195 deg
Blocks, states, functions, SC
differential equations
Maxwell 2D/3D
Transient+Motion Mechanics
6.25 Ohm 6.25 Ohm 153 N/m
UPPER_LIM := 0.1 in
PhaseA1 plunger1
D1 Ideal
12 V
F
PhaseA2 plunger2 0.004 kg
RS := 10 Ohm FEA
S0 := 0 in
-0.04 N
10u Ns/m -32.68u m
Electric circuits D3
RS := 10 Ohm

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

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 Deformation ANSYS Multiphysics
Electromagnetic Fields Stresses, Heat, CFD
Static, Dynamic (t, f), Motion, Circuits EM Force
EM Loss
Temperature

ANSYS Workbench R13 Interface
Maxwell Ansys Thermal

B-Field, Losses Temperature
Power
Temperature

Electrical Machine Stresses
• Thermo-mechanical simulation from the thermal solution
• See the (thermo-) deformation of the structure
Stator, rotor
temperature
Deformation due to temperature
Electrical Machine Stresses
• Static coupling Original coil
position
• Electromagnetic force density
– Automatically calculated in Maxwell
– Using the Maxwell’s stress tensor
– Mapped to the ANSYS mesh
– See stator, rotor, coil deformation

Vibration Analysis
Torque 02_DC-6step_IPM ANSOFT

8.00
Curve Inf o avg pk2pk
Moving1.Torque 4.7552 5.7332
7.00
6.00
Moving1.Torque [NewtonMeter]
5.00
4.00
3.00
2.00
1.00
0.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
Tim e [m s ]

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
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)
-25.00
-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)
-200.00
-250.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
Time [ms]

Geometry in WB
• Pattern Geometry in DM to create complete geometry

from 1/4th sector

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

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
Full model Model without water
• Maxwell2D Transient Model with solid only

– 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 Experimentation
parameters
• Experiment with x to make y
Ansoft
outputs as desired
Optimetrics
• Experimentation Analyses:
– Parametrization ANSYS
– Optimization DesignExplorer DX
– Sensitivity (calls Optimetrics)
– Statistical
External tools via
scripting
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.
Slot Width
Slot Height
Magnet Width
Magnet Height
TorquePerMagArea Bavg Tooth #5 Torque Magnet Area
Sensitivity chart (computed instantaneously from response surface)

Torque T
Pareto fronts shown, the best

to worst go from blue to red
respectively
Bavg Tooth #5
Probability density of output torque

Flux density at
optimum design
parameters

Modern Product Design Issues
Component & System simulation are key elements

in achieving modern requirements !
• Higher • Lower
– Functionality – Cost
– Performance – Time to Market
– Usability / automation – Material Consumption
– Precision – Size
– Reliability – Energy Consumption
– Lifetime – …
– …

Questions ?

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ANSYS / Ansoft

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

Digital Control Analog Control

 Automotive and railway systems, electric drives, home

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

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

© 2010 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

To meet todays requirements:

• Maxwell 2D/3D for

© 2010 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary

© 2010 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary

© 2010 ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary

© 2010 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary

Motor Performance curves of a BLDC

Optimization of a synchronous generator

• From RMxprt Automatically setup

– Windings with end turns

• Draw using CAD modeler

– Full ACIS based 2D/3D CAD

7.95824e-006H 0.00801603ohm LPhaseA

© 2010 ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary

• Numerics B in stator and rotor, J in cage

• Transient motion along/about one dimension

L a b e lID =V IC L a b e lID =V IB L a b e lID =V IA

0.000921945H 2.99132ohm LPhaseA

Ansoft LLC Phase Voltage / Current 4_Partial_Motor_TR_PWM

© 2010 ANSYS, Inc. All rights reserved. 19 ANSYS, Inc. Proprietary

• Cogging torque 1.00

– Transient with wm = 1 deg/s and

– Transient, some constant wm and

– Evaluate fft( Bn ( Lairgap ) ) 0.80

– Transient with eddy currents enabled 0.20

– Core losses setup for laminated objects

© 2010 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary

– Fully Coupled FEA with external circuit and motion

– Includes time-induced effects such as:

– Motion-induced eddy effects

• Nonlinear material effects

200 ms 500 ms 1000 ms

© 2010 ANSYS, Inc. All rights reserved. 23 ANSYS, Inc. Proprietary

• Vary geometric parameters

© 2010 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary

© 2010 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary

© 2010 ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary

• Maxwell – ANSYS Workbench:

© 2010 ANSYS, Inc. All rights reserved. 27 ANSYS, Inc. Proprietary

Maxwell Ansys Thermal

© 2010 ANSYS, Inc. All rights reserved. 28 ANSYS, Inc. Proprietary

© 2010 ANSYS, Inc. All rights reserved. 30 ANSYS, Inc. Proprietary

Torque 02_DC-6step_IPM ANSOFT

© 2010 ANSYS, Inc. All rights reserved. 31 ANSYS, Inc. Proprietary

• Fields Calculator to create

Tangential Force on Tooth Tips 02_DC-6step_IPM ANSOFT

Radial Force on Tooth Tips 02_DC-6step_IPM ANSOFT

© 2010 ANSYS, Inc. All rights reserved. 33 ANSYS, Inc. Proprietary

• Pattern Geometry in DM to create complete geometry

© 2010 ANSYS, Inc. All rights reserved. 34 ANSYS, Inc. Proprietary

• Plane Strain 2D Analysis of the Stator

© 2010 ANSYS, Inc. All rights reserved. 35 ANSYS, Inc. Proprietary

Radial and Tangential forces in Mechanical

© 2010 ANSYS, Inc. All rights reserved. 37 ANSYS, Inc. Proprietary

• Radial and Tangential Directional Deformation

© 2010 ANSYS, Inc. All rights reserved. 38 ANSYS, Inc. Proprietary

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