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1682 IEEE TRANSACTIONS ON MAGNETICS, VOL 33, NO 2, MARCH 1997

lectromechanical System Simulation with Models Generated


from Finite Element Solutions

Thomas E. McDermott, Ping Zhou, and John Gilmore


Ansoft Corporation, Pittsburgh, PA

Zoltan Cendes
Camegie Mellon University, Pittsburgh, PA

Ab~tra~t-This paper shows an effective way of coupling finite We refer to these as “basis fhctions” for the device. To
element analysis to system simulation tools. By creating evaluate these functions analytically, one needs an
equ~valentcircuit models for electromechanical devices, and expression for the stored magnetic coenergy, W’, in terms of
using electrical analogs for mechanical subsystems, it is I and x. Then the force and flux linkages can be calculated
possible to perform accurate parametric design studies. The
from
method is ideally suited to such problems as energy delivery in
a pulse transformer, and transient motion and current
waveforms in an actuator. f =- awf
I. BACKGROUM) ax
Finite element analysis has typically been coupled to (4)
circuit simulators using time-stepped field solutions [ 1,2].
This approach can be very accurate, but it involves long
The force and flux linkage appear in differential equations
simulation times that may discourage parametric studies,
involving the position and coil current, respectively
especially in system-level simulation.
A behavioral model for an electromechanical device can
be extracted from a set of parametric finite element d 2x
f ( I , x ) = m- (5)
solutions. Once the model has been developed, it can be dt2
used in a series of system simulations using SPICE [3] or
Saber [4],varying the electrical circuit and mechanical load
parameters without re-running the field solutions. Typically, dt
the system simulations run much faster than the parametric v = V,,, - rI (7)
or time-stepped field solution, which is the main advantage
of this method. Another advantage is that the models can be These three equations describe the dynamic behavior of
more widely used and distributed, without the need for a the simple system in Figure 1, including the nonlinear
finite element solver and detailed geometry and materials conversion of magnetic and mechanical energy. If the
information. coupling field is electric rather than magnetic, the basis
11. STATE-SPACE
APPROACH
functions become

As an alternative to time-stepped field solutions, the


electromechanical energy conversion may be represented as
a conservative black box, which may be nonlinear [5]. For
the coupling system shown in Figure 1, one can write
expressions for the coil flux linkages and mechanical force
as
f =f ( J , x ) (1)
h =h(I,x) (2)

Manuscript received March 19, 1996;revised August 22,1996


Tom McDemott, e-mail temc@ansoft.com;Ping Zhou, e-mal
ping@ansoft com; John Gilmore, e-mail john@ansoft.cdm;Zoltan Cendes, e-
mail cendes@ece.cmu.edu.
Fig. 1. Magnetic field coupling system.

0018-9464/97$10,00 0 1997 IEEE


1683

resulting from 1 amp in coil ,j. When i=j, a self inductance is


calculated, otherwise a mutual inductance is calculated. The
And the sys,temdifferential equations are matrix of inductance values will be symmetric about the
diagonal.
If there are permanent magnets in the device, another
d'x linear field solution is performed with the same localized
f ( v , x )= m-
dt2 permeabilities, but all the coil currents set to zero. The
permanent magnet flux linking each coil is evaluated from
weighted integrals of the magnetic vector potential over the
coil conductor cross sections.
Note that apparent stored energy is used to calculate the
inductances, so that we: can write
Losses can be modeled with external damping elements in
Figure 1, and magnetic diffusion or charge relaxation can N
also he approximated with external circuit elements. The hi= L,,I, + C L ,+A,
~I~ (15)
state-space technique is very powerful. Unfortunately, it is j=l
difficult to dierive the necessary expressions for the stored dh,
coenergy, except by making simplifying assumptions. v. =-
I dt
I1 I. APPLICATION
OFFINITEELEMENT SOLUTIONS
where N is the number of coils and represents coil flux
Instead of evaluating the basis functions from an linkages created by permanent magnets, if there are any.
analytical expression of the stored coenergy, finite element This procedure varies from many other circuit models of
analysis may be used to evaluate the force, torque, flux nonlinear inductance, which use incremental inductance
linkage, or charge from field solutions. This procedure
(dudi) linearized around the operating point. Reference [6]
produces a taible of force and flux linkage output values, for
explores the difference between using apparent and
example, versus current and position input values. The
incremental inductanoes in circuit simulation.
advantage of the finite element approach is that complicated
Using a spreadsheet interface, a series of field solutions is
geometries and nonlinear material properties can be included
performed to characterize the device behavior for system-
more easily than in the analytical approach.
level simulations. Each coil is an electrical port, with amp-
In the fiinite element method, force and torque are
turns as input and apparent inductance as output. Each
calculated using the method of virtual work. For example,
moving assembly is a mechanical port, with position or
the force on an object is calculated from the derivative of
angle as the input, and force or torque as the output. The
stored coenergy
resulting finite element solutions provide piecewise linear
basis functions for an equivalent circuit model. Motion is
accounted for by referencing the derived lumped parameters
to their corresponding coils, conductors, and masses; the
electromagnetic field solution does not include any velocity
terms.
Inductances in a nonlinear system are evaluated with
localized permeabilities obtained from a field solution at the Iv. INTERFACE TO SYSTEM SIMULATIONSOFTWARE
specified operating point. Then the material properties are
frozen in each element, and a linear field solution is To use the equivalent circuit models in SPICE, a
performed for each coil to be included in the inductance piecewise linear dependent source component was added to
matrix, with one amp flowing in that coil and all other Berkeley SPICE version 3F5. This component evaluates the
sources turnled off. The B and H solutions are saved, and all lookup table produced by the finite element solutions. For
the self and mutual inductances are calculated from example, given position and current, it would return flux and
force.
Mechanical subsystems can be represented using their
(14) electrical analogs in ,SPICE, summarized in Table I. In this
1
V
analog, force or torque corresponds to current, and velocity
corresponds to voltiig. A mass or rotating inertia is
where W,, is the apparent energy created by current I represented with a capacitor, a shaft or spring with an
(which is set to 1 amp), Bi is the magnetic flux density inductor, and viscou!; damping with a resistor. Mechanical
resulting from 1 amp in coil i, and Hj is the magnetic field hardstops can be simulated with controlled switches.
Rotating mechanical loads can be represented with a
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nonlinear resistor, using a V-I characteristic to match the Saber offers some advantages over SPICE for this
speed-torque curve. application:
The new "B source" component in Berkeley SPICE 3F5
provides considerable modeling flexibility for nonlinear Saber uses piecewise linear soluti
electrical and mechanical loads. Unlike previous versions of SPICE uses the continuous Newton Raphson algorithm.
SPICE that provided only polynomial nonlinear dependent Saber includes an extensive library of mechanical
sources, the B source can include more general expressions. components.
However, it is not a replacement for the multi-dimensional The differentiating circuits in Figures 2 and 3 are not
piecewise linear component developed here, because of the required because Saber can solve the coupling equations
various hazards in fitting analytical expressions to numerical directly.
values.
V. EXAMPLES
TABLEI
MECHANICAL
ANALOGS The first example is a linear actuat
axisymmetric with a stroke of 0.0127 m, 12500 turns, and
Rotational Translational Electrical SS430 material in the armature and stop. Parameters of
z [N-in] F [NI 1 [AI interest are the time to closure, and the waveshape of the coil
o [rads] w [&SI v [VI current, which may be used for electronic sensing. Fig
J [kg-m2] m [kg1 C[Fl shows the laboratory test current waveshape, along
K [N-&rad] K [N/m] 1K r1m simulation results using the finite-element derived model,
D [N-m-s/rad] D [N-s/ml 11R [1/a] and a simpler electromagnet model based on magnetic
Power = zo Power = Fw Power = IV circuit analysis. The simpler model provides a reasonable
e=lo+oa x = Iw+xo v, = i v + vno estimate of the time to closure, but is not as good at
simulating the total coil current waveshape. The finite-
Using the electrical analogs, a force output from the element derived model required 121 separate field solutions,
piecewise linear source can be applied as a current to a varying the core position and coil current as parameters.
capacitance representing the device mass. To provide the The second example is a pulse transformer, which is
position input, it is necessary to integrate the voltage across required to deliver a specified energy to a nonlinear load.
the capacitor, which may be done with SPICE components. This transformer has a C core, 0.023 m thick, with a turns
Given the coil flux linkages, a back emf is generated by ratio of 12700/140. A circuit model in the form of Figure 5
differentiating the flux. Figure 2 shows the necessary SPICE was derived from finite element solutions. T
components for a linear actuator corresponding to Figure 1. the magnetizing inductance, L,forty-one separate field
If the device is based on the electric rather than the magnetic solutions were performed, varying the primary coil current
field, Figure 3 shows the necessary SPICE components. as a parameter with the secondary current set to zero. This
Examples in the following section were run in both our simulates the laboratory open-circuit test.
modified SPICE, and the commercial Saber simulator. While the parametric field solutions for
for the leakage inductances, it is much

I I

integrator mechanica I ana I og integrator mechanical analog

Fig. 2. SPICE components for a magnetic field device. Fig. 3. SPICE components for an electric field device
1685

mm capacitances will typiically be shorted out by ground


connections. In three-phase transformers with delta
windings or ungrounded neutrals, some of the Figure 5
capacitances will be paralleled with other winding terminal
capacitances.
Both the leakage inductances and the capacitances were
assumed to be linear, so their calculation required only a few
more field solutions. Table I1 shows simulated and
measured energy delivery for two different core materials,
using both finite-element derived models, and a simpler
t model based on magnetic circuit analysis.
TABLEI1
PULSE TRANSFORMER LOADENERGY
DELIVERED

Fig. 4. Coil currents in a linear actuator. Model MI9 Core Composite Core
Magnetic Circuit 60.2 mJ 42.4 mJ
obtain leakage inductances from a simulated bucking test E A Model 53.9 mJ 34.5 mT
[7]. Equal and opposite amp-turns are applied to each Measurement -50.0 mJ (production req.) 32.4 mJ

winding (pair-wise if there are more than two windings). In


this case all of the stored field energy is due to leakage flux, In both examples, all of the finite element solutions were
and the leakage branch inductance for each winding is completed in less than three hours on a Pentium 90 class
calculated from machine. Subsequent isystem simulations were completed in
a matter of seconds using either SPICE or Saber. Once the
equivalent circuit model has been derived from the field
Li= j A - J d v (17) solutions, there is no significant difference in system
vi simulation time between the finite-element based model and
The capacitance elements in Figure 5 are derived from the magnetic circuit model.
electrostatic field solutions using a 3D model. The
capacitance matrix is set up with the core and the case or REFERENCES
tank grounded, and each coil specified as a single conductor.
From the capacitance matrix values C, C2, and C,, the Shen, G. L. Meunier, and J. L. Coulomb, “Solution of magnetic fields and
electrical circuits combined problems”, IEEE Transactions on Magnetics,
equivalent circuit parameters are found from vol. 21, no. 6, pp. 2288-2291, 1985.
J. R. Brauer and J. J. Ruehl, “Coupled nonlinear electromagnetic and
structural finite element analsyis of an actuator excited by an electric
l = Cl + C”‘
CO circuit”, EEE Transactions on Magnetics, vol. 31, no. 3, pp. 1861-1864,
c,, = c, + c, 1995.
L. W. Nagel, “SPICE2: a computer program to simulate semiconductor
c,, = -cm circuits”, Memo UCB,BRL M530, Electronics Research Laboratory,
University of Califomia, Berkeley, CA, 1975.
H A. Mantooth and M. Vlach, “Beyond SPICE with Saber and MAST”,
The total capacitance is usually split equally between each Analogy white paper M[P-0161, Beaverton, Oregon.
winding terminal as shown in Figure 5; some of these H. H. Woodson and J. IR. Melcher, Electromechanical Dvnamics, reprint,
vol. 1. Malabar, Florida: Robert E. Krieger, 1990, pp. 60-79.
T. W. Nehl and N. Demerdash, “Finite element state space modeling
environments for electric motor drives”, IEEE Tutorid on Adjustable
Speed Drives,92 EH0 362-4-PWR, 1992, pp. 109-126.
D. A. Lowther and P. P. Silvester, Comuuter-Aided Design in Magnetics,
Berlin: Springer-Verlag, 1986, pp 163-176.

TO.~*CIO
-
-
I \
0.5*C12
0.5*C20rp‘
-
-

Fig. 5 . Transfonner equivalent circuit model.

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