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
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2011 ANSYS, Inc.

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Introduction: Machine
Design Methodology

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
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2011 ANSYS, Inc.

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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

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
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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

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

2011 ANSYS, Inc.

June 8, 2012

Integrated EMDM Foundations

Auto Setup Maxwell Design from RMxprt

2011 ANSYS, Inc.

June 8, 2012

Maxwell/RMxprt V15 Axial Flux Machine

AC or PM Rotor
Single or Double Side Stator

Sample Outputs
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2011 ANSYS, Inc.

June 8, 2012

Sample Inputs

Maxwell/RMxprt V15 Axial Flux Machine

Maxwell 3D auto-setup (Geometry, Motion, Master Slave, Excitations, etc. )

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Design Exploration

Maxwell Project

P1 - cond

Workbench Schematic

P2 - parallel
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2011 ANSYS, Inc.

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Design Exploration

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2011 ANSYS, Inc.

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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

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RMxprt Dynamic Link to Simplorer

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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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2011 ANSYS, Inc.

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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

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Advanced Capabilities
Coreloss Computation

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2011 ANSYS, Inc.

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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

Instantaneous excess loss

1
dB
pe (t )
kc
Ce
dt

where
Ce 2

1.5

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/2

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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2011 ANSYS, Inc.

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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

Core loss

40

Input power increase

Input power increase

20

Core loss

0
0

0
0

20

40

60
Time (ms)

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June 8, 2012

80

100

10

15

20
Time (ms)

25

30

35

40

Advanced Capabilities
Demagnetization Modeling

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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
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2011 ANSYS, Inc.

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Worst demagnetizing point

Hc

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

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
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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
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Contours of loss density distribution

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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
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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
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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.

Br

0
B

2011 ANSYS, Inc.

June 8, 2012

Br
p
0

37

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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P(T) input

Q(T) input

Field-Circuit
Co-simulation

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Maxwell Circuit Editor Example

Commutator bar: model position
WidC

WidB
(a)

(b)

(c)

(d)

Commutating model: model parameters

G
LagAngle

Period
|WidC-WidB|

Gmax

a
0

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2011 ANSYS, Inc.

WidC+WidB

June 8, 2012

d
Position

Case Example for Commutating Circuit

PMDC Motor

Winding currents

Torque

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Brush
commutation
circuit

Simplorer:
Power Electronics

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Simplorer Technology Highlights

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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.

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SV

RS

Multi-Domain System Simulator

Analog Simulator
Electrical circuits

Magnetics

Mechanics

Hydraulics, Thermal, ...

J
A 12
B 12

3~

C 12

M( t)

A2
B2

STF

MMF

C2

GND

A 11B 11C 11

JA
R OT1

R OT2

ASMS

F( t)

m
STF

GND

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;

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
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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

I
plunger_control

Solenoid

p1
p2

plunger

em_force

Solenoid

orifice

s0 := 0.0002
m := 0.0066

spring

Future: Multidomain model extraction and

co-simulation

spacer
accumulator

gravity
limit

v alue := 0.0066*9.8

sul := 0.0002
sll_ := 0.0

Mechanical
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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 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
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2011 ANSYS, Inc.

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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
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IGBT Characterization

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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
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2011 ANSYS, Inc.

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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

200.0n

400.0n

618.0n

Device property and

loss consultation
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2011 ANSYS, Inc.

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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

PhaseA1

Rotor1

PhaseA2

Rotor2

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]

Speed

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

50.00m

100.00m

BLDC motor FEA Coupled with Simplorer

Inverter fed three phase BLDC

motor drive
Chopped current control

Output torque
7.80

ICA:

LL:=922u
RA:=2.991
PWM_T:=60
PWM_PER:=180

-14.50

I_TARG:=9

20.00m

30.00m

I_HYST:=0.2

Q3

Q1

RA Ohm

Q5

1500 rpm
sourceA1

Magnet01

sourceA2

Magnet02

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

57.3

EQUBL

EQUBL

8.50

8.50

5.00

5.00

-10.30

20.00m

30.00m

0
0

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20.00m

30.00m

20.00m

30.00m

SRM FEA Coupled with Simplorer

ICA:

LL:=70.6914u

26293 rpm

RA:=203m

140 V

A1

AirRotor1

A2

AirRotor2

B1

100u F

B2
C1
C2
FEA

QA

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

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

100.00m

-10.00

0
0

-17.80
0

62

-30+90

EQUBL

500.00u

2011 ANSYS, Inc.

1.00m

June 8, 2012

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

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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
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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

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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

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Case 2 50 % Eccentricity

Maxwell Couplings

2D/3D Losses

Forced water cooling

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Mapped Losses

Temperature

Forced air cooling

Natural air cooling

Two Way CFD Thermal Analysis, R14

CFD Model

Temperature

Geometry
Losses
Maxwell Model
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Mapped Losses

Power Loss Mapped into FLUENT

Power Loss in windings are not displayed.

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Results Temperature Distribution

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Thank you
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