Machine Training PM Synchronous Ansoft Maxwell

Permanent Magnet Synchronous Machine XY Plot 2

Ansoft Corporation

PMSM_CT

1.20

Curve Inf o Bradial Setup1 : Transient Time='0ns'

1.00

0.80

Bradial

0.60

0.40

0.20

0.00

-0.20

0.00

0.20

0.40

0.60

0.80

1.00

Norm alizedDis tance

Cogging Torque

Ansoft Corporation

PMSM_CT_Verify

XY Plot 2

Ansoft Corporation

Core Loss

Ansoft Corporation

3.00

PMSM_OC_EMF

1.20

Curve Info

PMSM_OC_EMF

Optimized Design Setup1 : Transient

150.00

2.2271

Moving1.Torque Imported Nominal Design

2.00

Curve Info CoreLoss Setup1 : Transient

1.00

Y1 [V]

50.00

0.00

Curve Info

1.00 0.5877

0.80 0.4354

CoreLoss [kW]

Y1 [NewtonMeter]

100.00

0.1402

0.00

-1.00

0.60

0.40

InducedVoltage(PhaseA) Setup1 : Transient InducedVoltage(PhaseB) Setup1 : Transient

-50.00

-2.00

InducedVoltage(PhaseC) Setup1 : Transient

0.20 -100.00

-3.00 0.00

1.00

MX1: 0.6379

-150.00 0.00

2.00

4.00

Time [ms ]

6.00

8.00

10.00

Ansoft Maxwell Field Simulator V12 – Training Manual

2.00

3.00

4.00 Time [s]

5.00

6.00

MX2: 5.4031

7.00

8.00

0.00 0.00

2.00

4.00

Time [ms]

6.00

8.00

10.00

P1-1

Permanent Magnet Synchronous Machine: Contents

RMxprt

Maxwell: Open Circuit Back EMF Basic Theory Review Example Add Unique Winding Arrangement Setup Parametric Problem Export Design to Maxwell 2D

Maxwell: Cogging Torque Review Maxwell Setup Create Variables Apply Mesh Operations Solve Nominal Problem Setup Optimization Problem Review Pre-Solved Optimization Results

Define Material Core Loss Characteristics Set Lamination and Stack Factor Consider Power Loss in Magnets Solve Problem and Review Results

Maxwell: Rated Condition – Functional Voltage Source Modify Rotor Geometry using UDP’s Winding Setup Definitions and Variable Definition Choosing Optimal Time Step Solve Problem and Review Results

Drive Design Create a Machine Model Use the Model in Circuit Simulation

Notes: 1. RMxprt/Maxwell V12 or higher is required 2. Basic knowledge of electric machine is required 3. Basic understanding of Finite Element is required Ansoft Maxwell Field Simulator V12 – Training Manual

P1-2

Electric Machine Design Suite A Complete Solution for Modern Electric Machines and Drives Design

Design Requirements 9 9 9 9 9 9 9 9 9 9

Fast Analytical Solution: Narrow the Design Space

Size/Weight Efficiency Torque Speed Cogging/Ripple Inverter Matching Thermal Stress Manufacturability Cost

Transient Analysis using FEA Parametric Analysis Simultaneous Equations:

Magnetostatic/Eddy Current Analysis using FEA

IGBT

D2

IGBT

if − C

duc =0 dt

mα + λω = Tem + Texternal

Motion Equation

ω FM_ROT

IGBT IA A_PHASE_N1

IB

ROT2

A

+ VBC V

+

T

ROT1

A

B_PHASE_N1

IC A

EMF

di dA Circuit Equation: d f dΩ + R if + L f + uc = us S f a ∫∫ dt dt

D3 ECELink

175

∂A − σ∇V + ∇ × Hc + σv × ∇ × A ∂t

Nfl

Parametric Analysis Optimization

Parametric Analysis Optimization

EMF

Field Equation: ∇ ×υ∇ × A = J s − σ

C_PHASE_N1

175

IGBT

IGBT ECE

A

AM_IGB ICA:

PP:=

EQU

ON:=

theta_elect := PP * ECELink theta := MOD(theta_elect

OFF:= THRESH:=4 HYST:=

Torqu

Phase Curre 1.00

IA IB IC

500.0

Phase Voltag To

400.0

300.0

V_A

200.0

Von Mises stress

200.0 0

0 -500.0

0

0

10.00m

-200.0

-100.0 0

-1.00

17.27mt

10.00

-300.0 0

17.27 t

10.00

17.27 t

Drive System using System Level IGBT’s and Analytical Motor Model

Thermal and Stress Analysis

EMSSLink1 EMSSLink1 175

R5

MASS_ROTB1

R1

R3

E5

IA

RA

V

theta>90 AND theta<150

ctrl_6:=ON

C_PHASE_N2

+

R4

R6


ctrl_2:=ON

ctrl_1:=ON

ctrl_3:=ON


A

ICA:

AM_IGBT


ctrl_1:=ON ctrl_2:=ON



ctrl_1:=OFF ctrl_2:=OFF

ctrl_5:=ON





ctrl_5:=ON

Drive System Integration with Manufacturer’s IGBTs Ansoft Maxwell Field Simulator V12 – Training Manual



ctrl_5:=OFF ctrl_6:=OFF ctrl_4:=ON

theta>330 OR theta<30

V




VGE4

E4

E6


ctrl_6:=ON

C_PHASE_N1

175

R2


ctrl_5:=ON

B_PHASE_N2

RC 0.023

ICA:

AM_IGBT

ctrl_6:=ON


B_PHASE_N1

IC A

EMF1

A_PHASE_N2

0.023




V

C_PHASE_N1

V

E4

E2

ctrl_1:=ON

ROTB2

RB A

+ VBC

VGE4

A

ROTB1

0.023 A_PHASE_N1

IB

B_PHASE_N2

RC 0.023

C_PHASE_N2

R4

E6

RA A

B_PHASE_N1

IC A

R6

E2

IA

E1

E3

E5

A_PHASE_N2

0.023

175 R2

R3

R5

ROTB2

RB A

+

EMF1

MASS_ROTB1

R1

175

A_PHASE_N1

IB

VBC

EMF2

ROTB1

0.023

A

E1

E3

+

EMF2

Equivalent Circuit Model : High Fidelity Physics Based Model


ctrl_6:=ON

ctrl_4:=ON theta>330 OR theta<30

ctrl_5:=ON



Complete Transient FEA -Transient System Co-simulation P1-3

RMxprt: Background ASSM: Adjustable-Speed Synchronous Machine Rotor speed is controlled by adjusting the frequency of the input voltage Unlike brushless PMDC motors, ASSM does not utilize the position sensors. Rotor can be either inner or outer type Can operate as a generator or as a motor Motor Mode: Sinusoidal AC source DC source via a DC to AC inverter

Generator Mode: Supplies an AC source for electric loads


P1-4

ASSM: Background Input voltage U is the reference phasor, let the angle I lags U be φ, the power factor angle

I = I∠ − ϕ Let the angle I lags E0 be ψ. The d- and the q-axis currents can be obtained respectively as follows:

Id   sinψ  I =   = I  I cos ψ    q

ψ = tan

−1

Id Iq


P1-5

ASSM: Background

OM can be used to determine the direction of E0 OM = U − I ( R1 + jX 1 + jX aq ) Let the angle E0 lags U be θ, which is called the torque angle for the motor, then the angle ψ is ψ = ϕ −θ For a given torque angle θ : Xd − R  1

R1   I d  U cosθ − E0  =  X q   I q  − U sin θ 

Solving for Id and Iq yields: Id  1 = I  2  q  R1 + X d X q

 X q (U cosθ − E0 ) + R1U sin θ   R (U cosθ − E ) − X U sin θ  0 d  1 


P1-6

ASSM: Background The power factor angle φ is

ϕ = ψ +θ

The Input electric power is

P1 = 3UI cos ϕ

The Output mechanical power is

P2 = P1 − ( Pfw + PCua + PFe )

Pfw : Frictional and Wind Loss PCua: Armature Copper Loss PFe : Iron-core Loss

Torque:

T2 =

P2

ω

Efficiency: η=

P2 × 100% P1


P1-7

RMxprt: Base Project Open the RMxprt project located on your desktop by double clicking on

PM_SyncMotor.mxwl

Save the project under a new name: File > Save As > c:\Training\PM_SyncMotor.mxwl

Select Setup1 under Analysis and click the Right Mouse Button (RMB) and Choose Analyze


P1-8

RMxprt: Results Select Setup1, click the RMB and choose Performance

Choose a Solution Set


P1-9

RMxprt: Results Select Setup1, click the RMB and choose Performance

Choose a Performance Curve


P1-10

RMxprt: Add New Winding Arrangement Double click on Stator > Winding Click on Whole-Coiled Select Editor

1 2

3


P1-11

RMxprt: Add New Winding Arrangement In the Winding Editor Panel, click the RMB and select Edit Layout

Deselect Constant Pitch Change the Layout as shown


P1-12

RMxprt: Add New Winding Arrangement View the new winding arrangement by placing the mouse over one of the A phase coils in the drawing window and click the RMB selecting

Connect One Phase Coils.


P1-13

RMxprt: Performance Solve the problem by selecting Setup1 under Analysis and click the Right Mouse Button (RMB) and Choose Analyze Select Setup1, click the RMB and choose Performance


P1-14

RMxprt: Add Variables Click on Winding and in the Properties window, next to Conductors Per Slot type in CPS

1 2 Click on Stator and in the Properties window, next to Length type in

Depth

1 2


P1-15

RMxprt: Add Variables Click on Rotor and in the Properties window, next to Length type in

Depth

Select menu item RMxprt > Optimetrics Analysis > Add Parametrics


P1-16

RMxprt: Parametric Setup Click on Add and setup the two variables as follows:

4

2

1

3

Click on the Calculations Tab > Setup Calculations and add the following Current > RMSLineCurrentParameter Power > OutputPowerParameter Misc. > EfficiencyParameter


P1-17

RMxprt: Parametric Solution Select ParametricSetup1 under Optimetrics, click the RMB and Analyze

Select ParametricsSetup1, click RMB and select View Analysis Results Select Table and then click on Efficiency Parameter

Efficiency increased from 89% to over 98% while maintaining output power Ansoft Maxwell Field Simulator V12 – Training Manual

P1-18

RMxprt: Create Maxwell Design Select Setup1, click the RMB and select Create Maxwell Design

2

4

deselect

1

Choose 3 Ansoft Maxwell Field Simulator V12 – Training Manual

P1-19

Maxwell 2D: Base Design

Motion Boundaries Winding

Material Assignment

Mesh

Soln. Setup Results


P1-20

Maxwell 2D: Cogging Torque, Excitation Select the PhaseA winding, click the RMB and select Properties Change the Type to Current with a value of zero

Repeat this for PhaseB and PhaseC


P1-21

Maxwell 2D: Cogging Torque, Mesh Ops Select Length_Magnet under Mesh Operations, click the RMB and select Properties

Decrease the size of the element by half. Just type in 3.75/2


P1-22

Maxwell 2D: Cogging Torque, Mesh Ops. Select Length_Main under Mesh Operations, RMB and select Properties

Decrease the size of the element by 4. Just type in 10.96/4


P1-23

Maxwell 2D: Cogging Torque, Mesh Ops. Select SurfApprox_Mag under Mesh Operations, RMB and select

Properties

Decrease the length of the “Maximum Surface Deviation” to 190 nm. This yields an angular segmentation of Θ = 0.25 deg.

D = r (1 − cos(Θ / 2)) r is the inside radius of the stator which is 81mm


P1-24

Maxwell 2D: Cogging Torque, Mesh Ops. Select SurfApprox_Main under Mesh Operations, RMB and select

Properties

Decrease the length of the “Maximum Surface Deviation” to 190 nm


P1-25

Maxwell 2D: Cogging Torque, Mesh Ops.

Three possible operations: D

D = Maximum Surface Deviation D = r (1 − cos(Θ / 2))

r

Θ = Maximum Surface Normal Deviation

Θ

ri

ro Ansoft Maxwell Field Simulator V12 – Training Manual

2 * ri 2 = ShapeFactor (2 D ) ro 1 3 * ri = SF (3D) AR=2 ro 1 Aspect Ratio of Cells, AspectRatio = SF not of triangles P1-26

Maxwell 2D: Cogging Torque, Mesh Ops. Select Band in the modeler tree, RMB and select Properties

Decrease the SegAngle value to 0.25 degrees

NOTE!: This small value for angular segmentation, 0.25deg, is needed only for very sensitive calculations such as Cogging Torque Ansoft Maxwell Field Simulator V12 – Training Manual

P1-27

Maxwell 2D: Cogging Torque, Mechanical Setup Select Motion Setup1 under Model, RMB to select Properties Select Mechanical Tab and change speed to 1 deg/sec

Select Setup1 under Analysis and RMB to select Properties


P1-28

Maxwell 2D: Cogging Torque, Solution Setup Change to Save Fields tab

1

3

2


P1-29

Maxwell 2D: Cogging torque, Results Solve the cogging torque problem by selecting Setup1 under Analysis, RMB and select Analyze: Once the problem is solved double click on

Results > Torque Torque

Ansoft Corporation

Maxwell2DDesign1

3.00

Click the RMB in the plot and select Export Data. Save the plot on the desktop.

Curve Info Moving1.Torque Setup1 : Transient

2.00

Moving1.Torque [NewtonMeter]

1.00

0.00

-1.00

-2.00

-3.00 0.00

5.00

Time [s]


10.00

15.00

Since the speed is held constant at 1.0 deg/sec, the X-Axis represents both time and position, i.e. 10 sec = 10 deg P1-30

Maxwell 2D: Cogging torque, Results Select menu item View > Set Solution Context, and choose zero seconds.

In the drawing window hit CTRL+A to select all objects, RMB to select Fields > A >

Flux_Lines


P1-31

Maxwell 2D: Cogging torque, Results

Double Click on Legend to change plot properties


P1-32

Maxwell 2D: Cogging torque, Results Select Flux_Lines1 under A under Field Overlays, RMB to select

Animate


P1-33

Maxwell 2D: Cogging torque, Rename Design Rename Maxwell2DDesign1 by selecting its name in the project tree, RMB and select Rename. Change the name to PMSM_CT for Permanent Magnet Synchronous Motor Cogging Torque.


P1-34

Maxwell 2D: Cogging torque, Variables Select CreateUserDefinedPart under Mag_0 under NdFe30_N and choose Properties

3

1

2 In the Value field type in the name PoleEmbrace


P1-35

Maxwell 2D: Cogging Torque, Optimization Variables Change the field for the ThickMag to MagnetThickness and accept the default value of 7.5mm

2

1


P1-36

Maxwell 2D: Cogging Torque, Optimization Variables Change the field for the Offset to PoleOffset and accept the default value of 0mm.

2

1 Ansoft Maxwell Field Simulator V12 – Training Manual

P1-37

Maxwell 2D: Cogging Torque, Optimization Variables Select CreateUserDefinedPart under InnerRegion under Vacuum and choose Properties

1

2 In the Value field type in the names: PoleEmbrace MagnetThickness PoleOffset


P1-38

Maxwell 2D: Cogging Torque, Optimization Variables Select CreateUserDefinedPart under Rotor under M19_26G_SF0.950 and choose Properties

1 2 In the Value field type in the names: PoleEmbrace MagnetThickness PoleOffset


P1-39

Maxwell 2D: Cogging Torque, Optimization Variables Select menu item Maxwell 2D > Design Properties and change the value of the variables just defined:

Select the Optimization radio button and Include each variable:


P1-40

Maxwell 2D: Cogging Torque, Optimization Variables Modify the variable to see the effect on the geometry

For this exercise, the range for each is: 6.5 mm < MagnetThickness < 9.5 mm 0.6 < PoleEmbrace < 0.9 0 < PoleOffset < 30 mm

PE

MT

Pole Offset Ansoft Maxwell Field Simulator V12 – Training Manual

P1-41

Maxwell 2D: Cogging Torque Optimization, Air Gap Arc Create an arc in the air gap to be used for post processing purposes, by selecting menu item Draw > Arc > Center Point

Using the mouse select the origin, any point in the air gap along the X axis and any point in the air gap at the 45 degree angle. Any value used if valid, it will be modified in the next step. Double 3 click to end

1 2 Ansoft Maxwell Field Simulator V12 – Training Manual

P1-42

Maxwell 2D: Cogging Torque Optimization, Air Gap Arc Select CreateAngularArc under CreatePolyline under Polyline1 under Lines, RMB and select Properties

Change the value for the starting point to 80.8, 0, 0. This will place the arc between the band object and the stator ID

Select Polyline1. In the Properties window change its name to AG_Arc Ansoft Maxwell Field Simulator V12 – Training Manual

P1-43

Maxwell 2D: Cogging Torque Optimization, Variables Select menu item Maxwell 2D > Field > Calculator Perform the following commands to calculate the radial component of the flux density in the air gap Quantity > B Scal? > Scalar X Function > PHI Trig > cos Multiply * Quantity > B Scal? > Scalar Y Function > PHI Trig > sin Multiply * Add + -- this gives Bx*cos(PHI) + By*sin(PHI) Add … > Name: Bradial -- this adds the express to the stack


P1-44

Maxwell 2D: Cogging Torque Optimization, Variables Continue to calculate the average radial component of the air gap flux density Select Bradial under Named Expressions Copy to Stack Geometry > Line > AG_Arc Integrate Number > Scalar > Value = 1 Geometry > Line > AG_Arc Integrate Divide / -- this give the average radial flux density in the air gap Add … > Name: Brad_Avg -- this adds this expression to the stack


P1-45

Maxwell 2D: Cogging Torque Optimization, Variables Continue to calculate the area of the permanent magnet Number > Scalar > Value = 1 Geometry > Surface > Mag_0 Integrate Number > Scalar > Value = 1e6 -- this converts from m2 to mm2 Multiply * Add … > Mag_Area -- this adds this expression to the stack

Select the Maxwell 2D Design PMSM_CT and in the Properties window change the variables back to their default values

Even though the design variables and thus the geometry has changed, once the design variables are set to their previous values, the solution is automatically reloaded; there is no need to solve the problem again. Ansoft Maxwell Field Simulator V12 – Training Manual

P1-46

Maxwell 2D: Cogging Torque Optimization, Variables Plot the radial flux density in the air gap by selecting Results, RMB to select Create Field Report > Rectangular Plot


P1-47

Maxwell 2D: Cogging Torque Optimization, Brad AG Plot B_rad on the AG_Arc

5 1

4 2 3

6

10 7


8

9

P1-48

Maxwell 2D: Cogging Torque Optimization, Brad AG Plot of B radial in air gap at time zero XY Plot 2

Ansoft Corporation

PMSM_CT

1.20

Curve Inf o Bradial Setup1 : Transient Time='0ns'

1.00

Click the RMB in the plot window and select Export Data. Save the plot on the desktop.

0.80

Bradial

0.60

0.40

0.20

0.00

-0.20

0.00

0.20

0.40

0.60

0.80

1.00

Norm alizedDis tance


P1-49

Optimization: Solution Setup Change the Stop Time of the Simulation from 15 seconds to 3.75 sec. The cogging torque waveform is symmetric after 3.75 deg (equal to 3.75 sec) and to save simulation time we only need to solve up to this point. Select Setup1 under Analysis and RMB to select Properties


P1-50

Maxwell 2D: Cogging Torque Optimization, Variables Select Optimetrics and RMB to select Add > Optimization

Next to Optimizer select Genetic Algorithm


P1-51

Maxwell 2D: Cogging Torque Optimization Setup Click on Setup

Change the values as shown here


P1-52

Maxwell 2D: Cogging Torque Optimization Setup Cogging Torque Peak Nominal Value* = 2.2 N-m Maximum Value** = 5.5 N-m Optimal Goal = 0.2 N-m (subjectively chosen, we want to reduce CT by >10x) Normalize Solution Range: 1 to 10 G1 = 1 + (max(abs(Torque)) – 0.2) * 9 / 5.3 Objective: G1 = 1.0 *Note:

The Peak Nominal Value is when: MagnetThickness = 7.5 mm PoleEmbrace = 0.85 PoleOffset = 0 mm

**Note:

The Maximum Value is determined when these values are a Maximum: MagnetThickness = 9.5 mm PoleEmbrace = 0.90 PoleOffset = 0 mm

The maximum value of cogging torque may lay outside these parameter values, i.e somewhere else in the solution domain. These values are used just to define a range for the objective. Ansoft Maxwell Field Simulator V12 – Training Manual

P1-53

Maxwell 2D: Cogging Torque Optimization Setup Nominal Bavg Value = 0.76 Tesla Range*: 0.50 < Bavg < 0.81 Tesla Optimal Goal = 0.76 Tesla (we want to maintain the Air Gap Flux Density) Normalize Range: 1 to 10 G2 = 1 + (Brad_Avg – 0.5) * 9 / 0.31 Objective: G2 = 8.55

Magnet Area Range*: 220 < Mag_area < 510 mm2 Normalize Range: 1 to 10 G3 = 1 + (Mag_area – 220) * 9 / 290 Objective: G3 = 1.0

*Note:

The Range was calculated by simulation the minimum and maximum values: MagnetThickness … 6.5 mm and 9.5 mm PoleEmbrace … 0.6 and 0.9 PoleOffset .. 0 mm and 30 mm


P1-54

Maxwell 2D: Cogging Torque Optimization Setup In the Calculation Expression field type in the function as shown below

1

3

2

4


P1-55

Maxwell 2D: Cogging Torque Optimization Setup Include Calculation for the average radial component of the flux density in the air gap

1

2

3

4

Type in the rest of the expression and then click on Add Calculation


P1-56

Maxwell 2D: Cogging Torque Optimization Setup Include calculation for Magnet Area

1

2

3

Type in the rest of the expression and then click on Add Calculation


P1-57

Maxwell 2D: Cogging Torque Optimization Setup For the calculation expressions for Brad_Avg and Mag_Area click on Calc. Range and select 0ns for time zero

1


P1-58

Maxwell 2D: Cogging Torque Optimization Setup

Set the Goal and Weigh for each objective

Cost1 = (G1 – 0.2)2 * W1 Cost2 = (G2 – 0.75)2 * W2 Cost3 = (G3 – 230)2 * W3 Cost = Cost1+Cost2+Cost3

where G1 = max(abs(Torque)) where G2 = abs(AirGap_Bavg) where G3 = Mag_area

Note: The Cogging Torque and Air Gap Flux Density have equal weight, which is twice that of the magnet area Ansoft Maxwell Field Simulator V12 – Training Manual

P1-59

Maxwell 2D: Cogging Torque Optimization Setup Click on the Variables tab and change the values accordingly:

This problem takes too long to solve during the class. The full solution can be downloaded from Ansoft’s FTP site: ftp://ftp.ansoft.com/download/ChinaTraining/PM_SyncMotor_Opt.zip

To solve the problem, select OptimizationSetup1 under Optimetrics, RMB and select Analyze


P1-60

Maxwell 2D: Cogging Torque Optimization Results


P1-61

Maxwell 2D: Cogging Torque Optimization Setup Since the field solution was not saved for each variation in the optimization solution, create a second Maxwell 2D design and solve the problem with the optimized design variable values. Select the Maxwell 2D design PMSM_CT, RMB and select Copy

Select the project name PM_SyncMotor, RMB and select Paste

Select the Maxwell 2D design PMSM_CT1, RMB and select Rename, and change the design name to PMSM_CT_Verify


P1-62

Maxwell 2D: Cogging Torque Optimization Verify Select the design PMSM_CT_Verify and in the Properties window change the design variables to the Optimized value

Increase the Stop Time to 7.5 sec and then solve the design:

1

2

3


P1-63

Maxwell 2D: Cogging Torque Optimization Verify Plot the Cogging Torque Cogging Torque

Ansoft Corporation

PMSM_CT_Verify

0.50

Curve Info Optimized Design Setup1 : Transient

0.40

Optimized Design [NewtonMeter]

0.30 0.20 0.10 0.00

-0.10 -0.20 -0.30 -0.40 -0.50 0.00

1.00


2.00

3.00

4.00 Time [s]

5.00

6.00

7.00

8.00 P1-64

Maxwell 2D: Cogging Torque Optimization Verify In the plot window RMB to select Import Data and pick the cogging torque plot that was exported earlier. Cogging Torque

Ansoft Corporation

PMSM_CT_Verify

3.00 Curve Info Optimized Design Setup1 : Transient

2.2271

Moving1.Torque Imported Nominal Design

Y1 [NewtonMeter]

2.00

1.00 0.5877

0.4354

In plot window, RMB and select Marker > Add X Marker Optimized Design

0.1402

0.00

Nominal Design -1.00

-2.00

-3.00 0.00

1.00

2.00

MX1: 0.6379


3.00

4.00 Time [s]

5.00

6.00

7.00

8.00

MX2: 5.4031

P1-65

Maxwell 2D: Cogging Torque Optimization Verify Plot the air gap flux density Air Gap Flux Density

Ansoft Corporation

PMSM_CT_Verify

1.20

Curve Info Bradial Setup1 : Transient Time='0ns'

1.00

Bradial

0.80

0.60

0.40

0.20

0.00

-0.20 0.00

0.20


0.40 0.60 NormalizedDistance

0.80

1.00 P1-66

Maxwell 2D: AG Flux Density In the plot window RMB to select Import Data and pick the Air Gap flux density plot that was exported earlier. Air Gap Flux Density

Ansoft Corporation

PMSM_CT_Verify

1.20

Curve Info Bradial Setup1 : Transient Time='0ns' Bradial Imported Nominal Design

1.00

Bradial

0.80

0.60

0.40

0.20

0.00

-0.20 0.00

0.20


0.40 0.60 NormalizedDistance

0.80

1.00 P1-67

Maxwell 2D: AG Flux Density Determine the average air gap flux density.

1 2 3 The target optimized value is 0.76T


4

P1-68

Maxwell 2D: Magnet Area Determine the magnet area.

1

The area of the magnet for the nominal design was 383 mm2


2

3

P1-69

Maxwell 2D: Open Circuit Back EMF Select the design PMSM_CT_Verify, RMB and select Copy

Select the project PM_SyncMotor, RMB and select Paste

Select the new design PMSM_CT_Verify1, RMB and select Rename. Change the name to PMSM_OC_EMF


P1-70

Maxwell 2D: Open Circuit Back EMF Select MotionSetup1 under Model, RMB to select Properties

Select the Mechanical tab and change the speed to 3600 rpm


P1-71

Maxwell 2D: Open Circuit Back EMF, Core Loss Setup

Calculate the core loss coefficients from multiple core loss curves


P1-72

Maxwell 2D: Open Circuit Back EMF, Core Loss Setup Select the Stator and in the Properties widow click on the material M19_26G_SF0.950 and then select View/Edit Material

1 2 3 Ansoft Maxwell Field Simulator V12 – Training Manual

P1-73

Maxwell 2D: Open Circuit Back EMF, Core Loss Setup Add the core loss curve for 60Hz

3

Choose the file 4 M470-65A-60Hz.tab

1

2


P1-74

Maxwell 2D: Open Circuit Back EMF, Core Loss Setup Add the core loss curve for 100Hz

3

Choose the file 4 M470-65A-100Hz.tab

1

2


P1-75

Maxwell 2D: Open Circuit Back EMF, Core Loss Setup Continue to add the following curves: M470-65A-200Hz.tab M470-65A-600Hz.tab


M470-65A-400Hz.tab M470-65A-700Hz.tab

M470-65A-1kHz.tab

P1-76

Maxwell 2D: Open Circuit Back EMF, Magnet Loss Select Mag_0 and in the Properties next to Materials click on NdFe30_N and then on View/Edit Materials. Change the conductivity to 625000 S/m

Material properties are global quantities, the affect all designs. Thus when modifying materials that are common to various designs, the solutions to the designs become invalid.


P1-77

Maxwell 2D: Open Circuit Back EMF, Magnet Loss Select Mag_0, RMB to select Assign Excitation > Current

By assigning zero current to the magnet it is assured that total current into and out of this magnet is zero. If there were more than one magnet, each one should have a separate excitation of zero amps. Ansoft Maxwell Field Simulator V12 – Training Manual

P1-78

Maxwell 2D: Open Circuit Back EMF, Magnet Loss Select Excitations, RMB to select Set Eddy Effect


P1-79

Maxwell 2D: Open Circuit Back EMF, Core Loss Select Excitations, RMB to select Set Core Loss. Add Core Loss for the Rotor and Stator


P1-80

Maxwell 2D: Open Circuit Back EMF, Solution Setup Modify the solution setup by selecting Setup1, RMB and select Properties

2

The time step is determined by: 1 deg 3600rev 360 deg 1 min 21600 deg * * = = sec 46.3u sec min rev 60 sec


The frequency is 240 Hz, which gives a period of 4.2 msec. Thus 10 msec is ~2.5 cycles P1-81

Maxwell 2D: Open Circuit Back EMF, Results Solve the transient problem by selecting Setup1 under Analysis, RMB to select Analyze After the problem is solved, click on Results, RMB to select Create Transient Report > Rectangular Plot


2 P1-82

Maxwell 2D: Open Circuit Back EMF, Results XY Plot 2

Ansoft Corporation

PMSM_OC_EMF

150.00

100.00

Y1 [V]

50.00

0.00

Curve Info InducedVoltage(PhaseA) Setup1 : Transient InducedVoltage(PhaseB) Setup1 : Transient

-50.00

InducedVoltage(PhaseC) Setup1 : Transient

-100.00

-150.00 0.00

2.00


4.00

Time [ms]

6.00

8.00

10.00

P1-83

Maxwell 2D: Open Circuit Back EMF, Results Click on Results, RMB to select Create Transient Report > Rectangular Plot

1 2 3


P1-84

Maxwell 2D: Open Circuit Back EMF, Results Core Loss

Ansoft Corporation

PMSM_OC_EMF

1.20


1.00

CoreLoss [kW]

0.80

0.60

0.40

0.20

0.00 0.00

2.00


4.00

Time [ms]

6.00

8.00

10.00 P1-85

Maxwell 2D: Rated Condition To solve the problem for the rated condition, select the Maxwell 2D design PMSM_OC_EMF, RMB and select Copy Select the project name PM_SyncMotor, RMB and select Paste Select the Maxwell 2D design PMSM_OC_EMF1, RMB and select Rename, and change the design name to PMSM_Rated

Delete the Mag_0, Rotor, and InnerRegion


P1-86

Maxwell 2D: New Rotor Geometry Select menu item Draw > User Defined Primitive > SysLib > RMxrpt > IPMCore. Modify the Values as shown below.


P1-87

Maxwell 2D: New Rotor Geometry Select the object IPMCore1 and then Edit > Arrange > Rotate

Select Modeler > Boolean > Split

Select Edit > Arrange > Rotate and use -45 degrees about the Z axis Select Modeler > Boolean > Split in the XZ Plane Keeping Fragments on

the Negative Side Select Edit > Arrange > Rotate and use +45 degrees about the Z axis Ansoft Maxwell Field Simulator V12 – Training Manual

P1-88

Maxwell 2D: New Rotor Geometry Select IPMCore1 and in the Properties window Name: Rotor Material: M19_26G_SF0.950

Select Rotor, RMB to select Edit > Copy In the drawing window, RMB to select Edit > Paste Select CreateUserDefinedPart under Rotor1, RMB to select Properties Change InfoCore to 1

Select Rotor1 and then Maxwell Model > Boolean > Separate Bodies. This will create two magnets. Change the name of the magnets to Mag_0 and Mag_1 and change their color.


P1-89

Maxwell 2D: New Rotor Geometry Select Rotor, RMB to select Edit > Copy In the drawing window, RMB to select Edit > Paste Select CreateUserDefinedPart under Rotor1, RMB to select Properties Change InfoCore to 2

Select Rotor1 and in the Properties window Name: Duct Material: Vacuum


P1-90

Maxwell 2D: Rated Condition, PM Setup Select Mag_0 and in the Properties window click on the material M19_26G_SF0.950 and select NdFe30 and then Clone Material(s)

2 1


P1-91

Maxwell 2D: Rated Condition, PM Setup Change the name to NdFe30_NV for North Pole V Core

Cartesian CS with the pole aligned with the X axis

Repeat the same for Mag_1


P1-92

Maxwell 2D: Rated Condition, PM Setup The drawing tree should look like this


P1-93

Maxwell 2D: Rated Condition, PM Setup A local coordinate system needs to be create for each magnet. Zoom into Mag_0. Select the Create Relative CS Icon

1

3

2


A local CS is create with X and Y axis as shown. Magnetization will be along the X axis P1-94

Maxwell 2D: Rated Condition, PM Setup Zoom into Mag_1. Select the Create Relative CS Icon

1

3 2


A local CS is create with X and Y axis as shown. Magnetization will be along the X axis P1-95

Maxwell 2D: Rated Condition, PM Setup Select Mag_0 and in the Properties Window change Orientation to

RelateiveCS1

Select Mag_1 and in the Properties Window change Orientation to

RelateiveCS2


P1-96

Maxwell 2D: Rated Condition, PM Mesh Ops. Select Mag_0 and Mag_1, RMB to assign mesh operations


P1-97

Maxwell 2D: Rated Condition, Excitation Select Rotor, Mag_0, Mag_1, and Duct. Select Moving1 under Motion, RMB to select Add Selected Object

Select PhaseA under Excitations, RMB to select Properties

163.299 * sin(2*pi*240*time+18.2635*pi/180)


P1-98

Maxwell 2D: Rated Condition, Excitation Select PhaseB and then PhaseC under Excitations, RMB to select

Properties.

VB = 163.299 * sin(2*pi*240*time+18.2635*pi/180-2*pi/3) VC = 163.299 * sin(2*pi*240*time+18.2635*pi/180-4*pi/3)


P1-99

Maxwell 2D: Rated Condition, Excitation Select Excitation, RMB to select Setup Y Connection

1 2 3


P1-100

Maxwell 2D: Rated Condition, Solution Setup Select MotionSetup1 under Model, RMB to select Properties and then Data to change the Initial Position, and then Mechanical to set the speed

Select Setup1 under Analysis, RMB and select Properties

This problem takes too long to solve during the class. The full solution can be downloaded from Ansoft’s FTP site: ftp://ftp.ansoft.com/download/ChinaTraining/PM_SyncMotor_Rated.zip Ansoft Maxwell Field Simulator V12 – Training Manual

P1-101

Maxwell 2D: Rated Condition, Results Ansoft Corporation

Winding Currents

Torque Quick Report

Ansoft Corporation

PMSM_Rated

600.00

3000.00

PMSM_Rated Curve Info Moving1.Torque Setup1 : Transient

500.00

2000.00 Curve Info Current(PhaseA) Setup1 : Transient Current(PhaseB) Setup1 : Transient

1000.00

400.00

Moving1.Torque [NewtonMeter]

Current(PhaseC) Setup1 : Transient

Y1 [A]

0.00

-1000.00

300.00

200.00

-2000.00

100.00

-3000.00

0.00

-4000.00

-100.00 0.00

50.00 Time [ms]

100.00

0.00

Core Loss

Ansoft Corporation

50.00 Time [ms]

100.00

PMSM_Rated

1.90


1.80

1.70

CoreLoss [kW]

1.60

1.50

1.40

1.30

1.20

85.00


87.50

90.00

92.50 Time [ms]

95.00

97.50

100.00

P1-102

Simplorer: Drive Design 1. Create Permanent Magnet Synchronous Machine Model from RMxprt: Double click on the original RMxprt design, click on menu RMxprt > Analysis Setup > Export …, choose “Simplorer Model” from the list and select a path where you want the model to be saved.

2. View the text of the model: Run Simplorer V7.0.5, in “SSC 7.0 Commander” window, click on Programs > Editor, open the model file we just created from RMxprt (*.sml).

Note: The model is not simply a linear model you can typically find from a textbook any more. It has nonlinear effect considered for both main and leakage flux magnetic paths. This model can also be used as both motor and generator. Ansoft Maxwell Field Simulator V12 – Training Manual

P1-103

Simplorer: Drive Design 3. Use the RMxprt created model in Simplorer as a generator: Open a new Simplorer Schematic, click on the “Add Ons” tab of the “ModelAgent”, click on “interfaces”, drag and drop “RMxprt” component on the schematic. Double click on the “RMxprtLink1” and then click on “Import Model (*.sml)”, browse to the location where the model was saved. Select the model > Open > OK, you should have the model show up like the following graph, with electrical nodes on the left and mechanical nodes on the right.


P1-104

Simplorer: Drive Design 4. Build the rest of the schematic like below. Details of each component are shown on the next page. B6U1

C := 1u

D3

D5

B6U

+ V

VM1 VALUE := 1000*(1+(t>0.02))

D1

C B A

C1

R_Load R := 1k

D6

D4

ROT2 RMXROT1

+

V_ROT1

RMxprtLink1

D2

ω

Back EMF (A-B

DC Link Voltage 84.00

92.00

50.00

50.00

R_Load.V [V]

0

VM1.V [V]

-50.00 -94.00

0 0

20.00m

0

40.00m

Rotor Position (Deg

20.00m

40.00m

Input Speed from Shaft

-3.55f

2.00k

-100.00 RMxprtLink1.Pos

-200.00

1.00k V_ROT1.OMEGA [rpm]

-300.00 0

-362.00 0


20.00m

40.00m

0

20.00m

40.00m

P1-105

Simplorer: Drive Design 5. ModelAgent > Add Ons tab > power > Line-commutated Converters > B6 Diode Bridge


P1-106

Simplorer: Drive Design 6. ModelAgent > Basics tab > Measurement > Electrical > Voltmeter 7. ModelAgent > Basics tab > Circuit > Passive Elements > Resistor and Capacitor

Note: Select the component and right mouse click to Flip or Rotate the component. Or you can use quick shortcut “F’ for Flip and “R” for Rotate.


P1-107

Simplorer: Drive Design 8. ModelAgent > Basics tab > Physical Domains > Mechanical > Velocity-Force-Representation > Rotational_V > Angular Velocity Source


P1-108

Simplorer: Drive Design 9. Click on Simulation > Parameters, or Alt + F12, or just double mouse click on any empty space on the schematic, define simulation parameters as seen from the picture.


P1-109

Simplorer: Drive Design 10. ModelAgent > Displays tab > Displays > 2D View Create plots of R_Load.V, VM1.V, RMxprtLink1.Pos, V_ROT1.OMEGA (rpm).

11. Run the simulation and view the results. Ansoft Maxwell Field Simulator V12 – Training Manual

P1-110

This completes the one day training course on permanent magnet synchronous machines using Ansoft’s RMxprt, Maxwell 2D and Simplorer


P1-111

Machine Training PM Synchronous Ansoft Maxwell

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