Ansoft Solution Motors[1]

Ansoft Solutions for Motor Design

Eun-Sil Han (sr. AE, Ph.D.) Ansoft Korea 2005. 11

Contents

Introduction to the Ansoft EM Tools The Process of Electric Motor Design Tutorial Guide for Motor Design

BLDC using RMxprt PMDC using RMxprt + Maxwell EM 2D Induction Motor using RMxprt + Simplorer

Maxwell EM Roadmap

Introduction to the Ansoft EM Tools

Ansoft Products System Level

Simplorer Simplorer Ansoft Ansoft Designer Designer

Options Options Optimetrics Optimetrics

Nexxim Nexxim

Circuit Level

ePhysics ePhysics

SIwave SIwave RMxprt RMxprt

Component Level

Full Full Wave Wave Spice Spice

PExprt PExprt

Maxwell

TPA TPA

Multi-processor Multi-processor AnsoftLink AnsoftLink

HFSS

Q3D

2D/3D 2D/3D

-Integrity High -Frequency Electro -Mechanical Signal Signal-Integrity High-Frequency Electro-Mechanical

모터 해석을 위한 Ansoft EM Tools ? Maxwell 2D

Control Simplorer

Maxwell 3D Electrical RMxprt

ePhysics

Mechanical Optimetrics Simplorer Maxwell EPhysics

시뮬레이션 수순 설계 대상

RMxprt 초기 치수 설계 파라미터 영향 분석 최적 설계를 통한 모델제안

Good quality

ePhysics 전동기의 분포적 입력파라미터를 이용하여 열적 성능 및 응력 특성을 보다 정밀 해석 전동기 기계적 신뢰성 확인

Maxwell 2D/3D 설계 검증용 / 특성 해석용 파라미터 산출 해석 기법에 의한 설계 보완 해석 결과 검토에 의한 국부적 형상 변경

Simplorer 모터 및 제어 알고리즘과 연계된 정밀 시뮬레이션 정확한 모터 모델링 제시로 제어 파라미터 분석 가능 시스템 엔지니어링 단계

What’s Maxwell EM 2D/3D ? - Powerful Simulation Software for Electromagnetic and Electromechanical Analysis

Hybrid-car Stepping Motor

Hollow rotor servo Motor

Variable Reluctance Sensor

Pole piece

Permanent magnet

Coil

Claw-pole Alternator Solenoid Valve

What’s RMxprt ? - Software for the Design of Rotating Electric Machines

Winding Editor

Machine Design

What’s PExprt ? - Magnetic Component Design Software

Transformer Model

Design Window

What’s Simplorer ? - The complete system simulated by EM Tools ANL

PExprtLink1

14

N0314.V [V]

12 10 8

RMxprt Maxwell 2D/3D

PExprt

6 4 2 0 -2 0 25m

75m

0.1

0.15

0.23

t [s]

Slave Load voltage

SIMPLORER

L_Converter

BJT_Converter

480u*1 I0 := 0

C_Converter

500k

+ R_loadsmall

750u V0 := 0

R2_Converter

V

0.288*5

50k

B

Mechanical Source

VM3

R3_Converter

D_Converter

A

5m

Louttop

FML_INIT1

D1

ICA:

RLoad:=5

D2

D3

N2_P1_A NX_P1_A

+

A RMxprtLink1

engine_ss

PWM Controller

V

VM1

A

B

M1 K := 0

N2_P2_A NX_P2_A

Engine

for DC-DC application

N2_P1_B NX_P1_B

Lina 50u

ROT1 A

Ra R := RLoad

Rina10m

B

NX_P1_A N1_P1_A

n := 3000*1.0

D4

D5

D6

N2_P2_B NX_P2_B

ROT2

Linb 50u

Rinb10m

Rb R := RLoad

Linc 50u

Rinc10m

Rc R := RLoad

B

A

C

E1

N2_P3_A NX_P3_A

C

NX_P1_B N1_P1_B NX_P2_A N1_P2_A

F1

N2_P3_B NX_P3_B

Loutbot

B

5m

NX_P2_B N1_P2_B

N F2

+ VMphaseA

Cout

NX_P3_A N1_P3_A

C

V

+ VMphaseB V

NX_P3_B N1_P3_B

TFR3P11

+ VMphaseC V

A N2_P1_B NX_P1_B

R_Load

3000u

N2_P1_A NX_P1_A

D7

D8

1.2*100m

+ V

VMout

D9

N2_P2_A NX_P2_A

B

+ V

N2_P2_B NX_P2_B

VM2

30

N0252.V [V]

N2_P3_A NX_P3_A

20 15

C N2_P3_B NX_P3_B

D10

10 5

D11 D12

TFR3P22 -5 0

25m

50m

75m

0.1

0.13

0.15

0.18

0.2

0.23

t [s]

Master Load voltage 1.2m

Position.V [V]

0.6m 0.2m -0.2m 0 25m

75m

0.13

0.18

t [s]

0.23

Gap vs. time 16m

icoil.I [A]

12m

0

LIMIT_TRB1

force.I [A]

-6

8m -10

CTRL := t>=0 S1

4m

-14

0 0

50m

0.1

0.15

0.23

t [s]

0

Maxwell 3D

50m

0.1

0.15

t [s]

0.23

Amature force

Winding current

EQU

D2D1 force

R := 1500/1.8 icoil

externalforce:=(-100000)*MASS_TRB1.S*1.5

D2D

SPRING_TRB1

MASS_TRB1

A

A R1 igrav

V1

IS := 0.00545*9.807 EQU

EMF := 12*1.5

N_1

N_3

N_2

N_4

NL

NL1

Optimetrics

EMSSLink1

Position XY

XY1 E2

XY

XY2

externalforce:=(-100000)*MASS_TRB1.S*1

What’s Q3D Extractor ? - 패키지 등 신호 전송 구조의 기생회로성분(RLC) Extraction

What is ePhysics ? – Thermal and Stress Analysis

Ex. #1 : Traction Motor Simulation Inverter Bridge

E2

175

TR_5

TR_3

TR_1

TR_51

TR_31

TR_11

Current Sensors for Control A

IB

A _phase_p A _phase_m

RB

Torque A

torque

J

D2D

C_phase_p B _phase_p B _phase_m

A

IC

MchRMas1

PMSYNC

RA

IA

Mechanical Load

RC

theta

A C_phase_m

TR_2 E3

TR_6

GAIN1

TR_4

GAIN

E1

175 ICA:

TR_21

TR_61

TR_41

Maxwell Motor Model PP := 6

ctrl_2:=1

ctrl 1:=1 ctrl 2:=1

GAIN

GAIN

GAIN

ctrl_i1

theta>90 AN D theta<150

ctrl_i2

CONST

c tr l_3:=1

CONST



ctrl_i3 CONST

ctrl_6:=1 ctrl_1:=1

NEG

GAIN

GAIN

NEG

NEG

GAIN

ctrl_i21

ctrl_i11 CONST

CONST

c tr l 3:=1 c tr l_4:=1

ctrl_i31

c tr l_5:=1 c tr l_6:=1

CONST

c trl_4:=1 c trl 5:=1

Drive theta>30 AN D theta<90

Torque

Phase Currents 1 .2 m

2 .5 m

5m

7 .5 m

0 .7 5 k

4m

1 0m I A. I [A ] I B. I [A ] I C. I [A ]

4 .5 m

0 .1 1 k

theta>330 OR theta<30

T o rq u e .I [A

0

5m

25

1 0m c trl _ i 1 .VAL c trl _ i 1 1 . VAL c trl _ i 2 .VAL c trl _ i 2 1 . VAL c trl _ i 3 .VAL c trl _ i 3 1 . VAL

20

0 .5 k


Control Signals 5m

0 .1 k

10

90 0

80

-0 .5 k

PM Synchronous Traction Motor Design Using Maxwell 2D

0

73 1 .2 m

2 .5 m

5m

7 .5 m

1 0 m t [s ]

-5 4m

4 .5 m

5 m t [s ]

0

5m

1 0 m t [s ]

Ex. #2 : Fuel Cell in a Traction Motor D1 C1 -

+ Fuel Cell C

PIPE Level1 PIPE Level1

MchRMas1

FUELCELL_C1

PIPE Level1

PIPE Level1

P1

RHYD1 PI

P2

+

CONST

+

A

A_phase_p A_phase_m

IB

-

PI_1

Torque

PMSYNC

IA

+

J

A

C_phase_p B_phase_p B_phase_m

A

IC +

+

torque

theta

A C_phase_m

GAIN1

D2

GAIN

E1

-

+ Fuel Cell C

ICA:

PP := 6

FUELCELL_C2

C2 RHYD2 CONST

+

PI

theta>90 AND theta<150


ctrl_1:=1 GAIN

GAIN

ctrl_i2

ctrl_i3

CONST

NEG

ctrl_6:=1 ctrl_1:=1

CONST

NEG

GAIN

GAIN

NEG

ctrl_i21

ctrl_i11 CONST

ctrl_5:=1 ctrl_6:=1

2.50m

5.00m

10.00m

1.20m IA.I

2.50m

5.00m



QuickGraph5

QuickGraph4 7.50m

ctrl_4:=1 ctrl_5:=1

CONST


1.20m

ctrl_3:=1 ctrl_4:=1

ctrl_i31

CONST

QuickGraph1 750.00

ctrl_2:=1 ctrl_3:=1

ctrl_2:=1

GAIN

ctrl_i1 CONST

GAIN


-

7.50m

0

10.00m

120.00

Torque.I

5.00m

10.00m

25.00

ctrl_i1.VAL ctrl_i11.VAL ctrl_i2.VAL ctrl_i21.VAL ctrl_i3.VAL ctrl_i31.VAL

IB.I IC.I 20.00

100.00 500.00

75.00

10.00

50.00

0

25.00 0

-500.00

-5.00

0 1.20m

2.50m

5.00m

7.50m

10.00m t

1.20m

2.50m

5.00m

7.50m

10.00m t

0

5.00m

10.00m t

Ex. #3 : Wiper System - DC Motor Drive System 0

50.00m

100.00m

15.00

10.00

10.00

Wiper System 0

0 0

TR D1 R_R ET1

10m

R_S

D2

D3

AM1

L_R

50.00m

20.00

100.00m T

+

Motor Torque and Load Torque

A

0

0.3m

LOAD CD

L_S

t

Y

M

1m

D7

50.00m

ET2

100.00m

DCM R_T

L_T

ET3 D4

DCM.N

D5

P_GAIN

GAIN

GAIN

-16.66m

N_REF

I_GAIN

16.6667

CONST

.1m

KI := 20

KE := 0.544

D6

J := 4m

LIMITER

CONTR_OUT

0

0

LIMIT

KP := 50 CLOCK I

CONST

N_REF N

RA := 1.2 LA := 9.5m

UL := 20 LL := 0

THRES1 := -2.5 THRES2 := 2.5 VAL1 := -1 VAL2 := 1

-10.00

-10.00 0

50.00m

Motor Speed

100.00m

T

The Process of Electric Motor Design RMxprt + Simplorer and/or EM 2D + Q3D Extractor

Integrated Motor Solution RMxprt

14 types of motors/generators

project

design

Maxwell 3D

Maxwell 2D

Equivalent circuits Co-simulation

SIMPLORER

Ansoft Tools for Electric Motor Design RMxprt - Parametrics - Optimization - Export to Simplorer model - Create to Maxwell 2D/3D Project

SIMPLORER - Power Electronics - State Machines - Block Diagrams

Maxwell EM 2D/3D - Fields/Circuits/Motion - Power Electronics - Core Loss - Post Processing - Export to Simplorer model

RMxprt

Parametrics Single Phase Induction Motor

New Setup Panel

RMxprt

Parametrics

C_run: Nominal 6 uF: Sweep 1 to 12uF in 12 Steps Slot_depth: Nominal 8.2mm: Sweep 6 to 10 mm in 9 Steps

Run RMxprt

RMxprt

Parametrics

RMxprt

Optimization Three Phase Synchronous Generator Select Optimization

RMxprt

Run RMxprt

Optimization

RMxprt

Optimization

RMxprt Optimum Solution

Run RMxprt

Optimization

RMxprt

Optimization Original

Objective: sinusoidal air-gap flux density distribution

Optimized

RMxprt

SIMPLORER

DQ0 model written directly by RMxprt

Transient Parameters

Maxwell EM with Schematic Brushless DC Motor • Four Pole • Three Phase • Chopped Current Control Switching Sequence of Phase A vs. Mechanical Degrees

SchematicCurrent Controlled Switches Phase A winding

Switching circuit based on angular position

Position Dependent Sources

Current Controlled Switches

Run EMpulse

Core Loss Steel: 2 2 2 3/2 Loss density = Kh f B max + Kc f B max + Ke (f Bmax) Loss will be a function of Lamination Thickness Power Ferrite: x y Loss density= Cm f Bmax May be expressed in Watts/m3 or Watts/Kg

Core Loss Select Object to for which Core Loss is to be Calculated

Run Maxwell EM

Core Loss

Maxwell EM Post Processing

EMI in the Motor Drive System Radiative Conductive

Normal Mode Current

+ Battery

ECU

Common Mode Current Normal mode current flows --- Loop Common mode current flows --- Open

Common Mode Current Analysis

All components are represented by “Multi-Domain” Simulation model - Battery - Inverter/Converter - Bus bar - Motor - DSP/FPGA

Simulation Model Ⅰ(ECE) EQU

S1 FML1

A

R1 AM1

Rotor

PMSYNC -

+ Fuel Cell

J

A_phase_p

C1

D2D

torque

A_phase_m

IA A

IB

B_phase_p

IC

GAIN

ICA:

A B_phase_m

A

C2

Cell Fuel +

C_phase_p

C_phase_m theta

ctrl 2:=1

ctrl 1:=1 ctrl_2:=1

GAIN

GAIN

GAIN

ctrl_i1


ctrl_i2

CONST

ctrl_3:=1



ctrl_i3

CONST

CONST

ctrl 6:=1 ctrl_1:=1

NEG

GAIN

GAIN

NEG

NEG

GAIN

ctrl_i21

ctrl_i11 CONST

ctrl_i31

CONST

ctrl_5:=1 ctrl_6:=1

CONST


Torque

Phase Current 1.20m

2.50m

5.00m

7.50m

600.00

4.12m

10.00m IA.I [A] IB.I [A] IC.I [A]

500.00

4.25m

4.50m

ctrl_4:=1 ctrl_5:=1



Control Signals 4.75m

104.40

4.85m Rotor.M1

100.00

250.00

ctrl 3:=1 ctrl_4:=1

0

5.00m

25.00

10.00m ctrl_i1.VAL ctrl_i11.VA... ctrl_i2.VAL ... ctrl_i21.VA... ctrl_i3.VAL ... ctrl_i31.VA...

20.00

95.00

0

90.00

10.00

85.00

-250.00

0

80.00 -500.00 -600.00

75.40 1.20m

2.50m

5.00m

7.50m

10.00m t [s]

-5.00 4.12m

4.25m

4.50m

4.75m

4.85m t [s]

0

5.00m

10.00m t [s]

Common Mode Current

Terminal Currents

f = 1/0.00076 = 1.3kHz

FFT of Common Mode Current 25.00u

-1.07k

0

3.33k

6.67k

10.00k

13.33k

15.99k AM1.I = f(...

20.00u

20.00u

5.00u

15.00u

0.00u

10.00u

5.00u

5.00u

0 -1.07k

0

3.33k

f1=1.3kHz

6.67k

f3=3.9kHz

10.00k

13.33k

0 15.99k

Simulation Model Ⅱ(Tr-Tr Link) LA.I [A] 2DGraphSel6 LB.I [A] LC.I [A]

9.30

Torque Output ICA:

5.00

LL:=922u

LDUM:=10m

5.00m

RA:=2.991 LA.I [A] LB.I [A] LC.I [A]

0

-5.00

PWM_T:=60 PWM_PER:=180

-5.00

I_TARG:=9

-9.30 0

5.00m

10.00m

13.30m

-10.00 -14.60

I_HYST:=0.2

0

5.00m

10.00m

13.30m 1500 rpm

+ Q3

Q1

RA Ohm

Q5

sourceA1

Magnet01

sourceA2

Magnet02

ω

LL H

sourceB1

sourceB2

400 V sourceC1

Q4

Q2

Q6

LDUM H

A

R4

sourceC2

AM1

FEA

THRES := PWM_T

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

QS1

INPUT[1] := PWM_PER

+

LA.I

QS2

FEA Outputs

1.00k

0 -430.00 0

5.00m

13.30m

CONST

-30+PWM_PER

CONST

-60+PWM_PER

CONST

-90+PWM_PER

CONST

-120+PWM_PER

CONST

-150+PWM_PER

EQUBL

QS3

LB.I

1.51k

57.3

EQUBL

-LC.I

FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1... FEA1...

ANGRAD

Φ

GAIN

probe model (Q3D)

EQUBL

QS4

-LA.I

EQUBL

QS5

LC.I

QS6

INPUT := -LB.I THRES1 := I_TARG - I_HYST

EQUBL

EQUBL

VAL1 := 1 THRES2 := I_TARG + I_HYST Y0 := 1 VAL2 := 0

8.50

8.50 Name FEA1.FEA STEPS SIMPARAM1.RunTime [s] SIMPARAM1.TotalIterations SIMPARAM1.TotalSteps

Value

Q1.C... Q2.C... Q3.C... Q4.C... Q5.C... Q6.C...

5.00

0 0 2.64k 0 0

5.00m

10.00m

13.30m

QS1.... QS2.... QS3.... QS4.... QS5.... QS6....

5.00

0 0

5.00m

10.00m

13.30m

FFT of Common Mode Current 0

1.667m

3.333m

5.000m

6.667m 7.840m AM...

343.9m 300.0m 0

25k

50k

300.0m

250.0m

75k

100k

39.09m

250.0m

126k AM1.I ...

200.0m

200.0m

35.00m

35.00m

50.0m 30.00m

150.0m 30.00m

00.0m 50.0m

25.00m

25.00m

10.6m 0

20.00m

1.667m

3.333m

15.00m

FFT

0.00m

10.00m

5.00m

5.00m

0 0

25k

50k

75k

Freq.

100k

50.0m

-10.6m 5.000m 20.00m 6.667m 7.840m

Time 5.00m

100.0m

0 126k

Maxwell EM Roadmap

What’s New in Maxwell 11 Nonlinear anisotropy and nonlinear lamination

Designer schematic for external circuit coupling New electric solver

Non-cylindrical rotation Non-Cartesian local CS for easy setup

NextGen Ansoft Desktop

ECE with distributed analysis

RMxprt integrated

Dynamic demagnetization

Maxwell 3D Desktop

What’s New in Maxwell 11

More motion types in 3D transient

Relay

Sensor

Non-cylindrical rotation for relay, DC contactor, circuit breaker applications

Allows general moving bands with different radii for rotational motion

Dynamic Demagnetization Results

Source H field in the PM

Target H field in the PM

B Field in rotor and stator

Example: Reluctance Motor

r

Rotor lamination is defined along r direction in the local cylindrical coord system

Y

X

The rotor local coordinate system is attached to the moving rotor

Flux density plot

Torque with different load angle

Create Maxwell 3D Transient Circuit

Use .sph extension for exported files

What’s New in RMxprt 11 Dynamic geometry display with data input

Consistent material library with Maxwell FEA Any load type for all machines

Maxwell 3D geometry model creation

Winding editor for arbitrary winding configration

NextGen Ansoft Desktop

(constant speed, constant power, constant torque, linear torque or fan load)

Integrated in the same desktop with Maxwell

3D Geometry Creation Complete Completegeometry geometrycreation creation ¾¾ One-click One-clickFEA FEAdesign design

¾¾Option Optionfor forperiodic periodicor orfull fullmodels models ¾¾Automatic Automaticupdate updatewith withproject project

variables variables

Geometry Geometrycomponent componentcreation creation ¾¾General Generaland anddedicated dedicated

machine machineparts parts

¾¾Arbitrary Arbitrarycombination combination––

create createnew newmachine machinetypes types

¾¾Dimension Dimensionvariables variables

supported supported

Periodic or Whole Model Option

Geometry Geometrymodel modelwith with aaminimum minimumperiod period

One-Click Insert of Maxwell Design

Geometry Variables Sharing with RMxprt Convenient Convenientfor forgeometry geometry parametric parametricsweep sweepand and optimization optimization

Maxwell Maxwellgeometry geometry automatic automaticupdate update with withvariables variables changed changedininRMxprt RMxprt

Arbitrary Winding Configurations Lap winding with coil pitch=1

Concentric winding

Single-layer lap winding

Double-layer lap winding

DC winding

Common Slot Type Support

Single/double Single/double squirrel-cage squirrel-cagecores cores

Inner/outer Inner/outerAC/DC AC/DC armature armaturecores cores

Geometry Component Creation in Maxwell General and dedicated machine parts

Integrated in Maxwell 3D Modeler

Arbitrary combination, possible for a new machine type

Machine Parts Integrated in 3D Modeler

General Machine Parts

Components for most machines

Dedicated Machine Parts

Components for specific machines

Easy Swap between Outer and Inner Cores

Inner Innercore: core: DiaYoke DiaYoke<
Outercore: core: Outer DiaGap<
Easy Swap between 3D and 2D Models

3D core: Length > 0

2D 2Dcore: core:Length Length==00

Arbitrary Combination of Machine Parts, Possible for a New Machine Type

A three-phase claw-pole rotor

A cylindrical rotor of synchronous machines

Tips to Mesh Success Addaxial axialsheets sheets Add

Use Usestraight straightcoils: coils: ••add addaahalf halfspan spanlength lengthto toEndExt; EndExt; ••set setSpanExt SpanExt==00

Ansoft Solution Motors[1]

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