Ansys Electric Machines and Power Electronics

© 2011 ANSYS, Inc. June 8, 2012 1

Electric Machines Considering Power Electronics

Zed (Zhangjun) Tang, Ph.D.

Presented at ANSYS Confidence by Design

June 5, 2012

© 2011 ANSYS, Inc. June 8, 2012 2

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

Outline

© 2011 ANSYS, Inc. June 8, 2012 3

Introduction: Machine Design Methodology

© 2011 ANSYS, Inc. June 8, 2012 4

Maxwell 2-D/3-D Electromagnetic Components

Field Solution

Model Generation

HFSS

ANSYS

Mechanical Thermal/Stress

ANSYS CFD Fluent

PExprt Magnetics

RMxprt Motor Design

Maxwell Design Flow – Field Coupling

© 2011 ANSYS, Inc. June 8, 2012 5

Simplorer System Design

PP := 6

ICA:

A

A

A

GAIN

A

A

A

GAIN

A

JPMSYNCIA

IB

IC

Torque JPMSYNCIA

IB

IC

TorqueD2D

HFSS, Q3D, SIwave

ANSYS CFD Icepack/Fluent

Maxwell 2-D/3-D Electromagnetic Components

ANSYS

Mechanical Thermal/Stress

PExprt Magnetics

RMxprt Motor Design

Simplorer Design Flow – System Coupling

Model order Reduction

Co-simulation

Push-Back Excitation

© 2011 ANSYS, Inc. June 8, 2012 6

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 7

Parametric Sweep:

Stack_Length

Skew/no Skew

Stator_ID

AirGap

Monitor:

Torque

Power

Efficiency

Determine the Best Design

Create FEA Model

Export Circuit Model

RMxprt - Motor Design

© 2011 ANSYS, Inc. June 8, 2012 8

Integrated EMDM Foundations Auto Setup Maxwell Design from RMxprt

© 2011 ANSYS, Inc. June 8, 2012 9

Maxwell/RMxprt V15 – Axial Flux Machine

• AC or PM Rotor

• Single or Double Side Stator

Sample Inputs

Sample Outputs

© 2011 ANSYS, Inc. June 8, 2012 10

Maxwell/RMxprt V15 – Axial Flux Machine • Maxwell 3D auto-setup (Geometry, Motion, Master Slave, Excitations, etc. )

© 2011 ANSYS, Inc. June 8, 2012 11

Design Exploration

P2 - parallel

P1 - cond

Workbench Schematic

Maxwell Project

© 2011 ANSYS, Inc. June 8, 2012 12

Design Exploration

© 2011 ANSYS, Inc. June 8, 2012 13

Design Exploration – Six Sigma

© 2011 ANSYS, Inc. June 8, 2012 14

More Than 30 UDP Machine Components for 2D and 3D

Integrated Motor Solution

© 2011 ANSYS, Inc. June 8, 2012 15

RMxprt Dynamic Link to Simplorer

© 2011 ANSYS, Inc. June 8, 2012 16

Maxwell

0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00Time [ms]

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

Pos

ition

[mm

]

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

Coi

l Cur

rent

[met

er]

TRW / Ansoft Position & Current Hysteresis Control Close/Open1

Curve Info

Position

Coil Current

Diode Current

© 2011 ANSYS, Inc. June 8, 2012 17

Automatic Adaptive Meshing

© 2011 ANSYS, Inc. June 8, 2012 18

Advanced Capabilities Coreloss Computation

© 2011 ANSYS, Inc. June 8, 2012 21

Lamination Core Loss in Time Domain

• Instantaneous hysteresis loss

• Instantaneous classic eddy current loss

• Instantaneous excess loss

where

dt

dBH

dt

dBBktp irrmhh

cos

1)(

2

22

1)(

dt

dBktp cc

dCe 2/

0

5.15.1cos

22

21

)(dt

dBk

Ctp c

e

e

© 2011 ANSYS, Inc. June 8, 2012 23

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

© 2011 ANSYS, Inc. June 8, 2012 25

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.

0

20

40

60

80

100

120

140

160

0 20 40 60 80 100

Time (ms)

Lo

ss (

W)

Input power increaseCore loss 0

2

4

6

8

10

12

0 5 10 15 20 25 30 35 40

Time (ms)

Lo

ss (

W)

Core loss

Input power increase

Three-phase transformer Three-phase motor

© 2011 ANSYS, Inc. June 8, 2012 26

Advanced Capabilities Demagnetization Modeling

© 2011 ANSYS, Inc. June 8, 2012 27

Modeling Mechanism

• The worst demagnetization point

for each element is dynamically

determined from a full transient

process

• The demagnetization point is

source, position, speed and

temperature dependent

• Each element uses its own recoil

curve derived at the worst

demagnetization point in

subsequent transient simulation

H Hc

B

0

Br'

Br

K

p Recoil lines

Worst demagnetizing point

© 2011 ANSYS, Inc. June 8, 2012 28

H Hc

B

0

Br'

Br

K

p Recoil line

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.

The animation shows how the demagnetization

permanently occurs with varying load current

© 2011 ANSYS, Inc. June 8, 2012 32

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, element-based 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

© 2011 ANSYS, Inc. June 8, 2012 33

Hc' change in one element during a transient process:

The 1st cycle (0 to 5ms) doesn’t 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

© 2011 ANSYS, Inc. June 8, 2012 34

Contours of loss density distribution Static temperature distribution (K)

© 2011 ANSYS, Inc. June 8, 2012 35

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

© 2011 ANSYS, Inc. June 8, 2012 36

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 line a at saturation point

• Br is the intersection of line b with B-axis

• Element by element

B

H 0

Br Line b

Slope of line a at saturation point

p

© 2011 ANSYS, Inc. June 8, 2012 37

Br

• Magnetostatic case: the

operating point used for computing

magnetization (Br) is from single

source point;

What is the Difference between Using Magnetostatic and Transient solver?

• 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.

H 0

Br p

B

H 0

p

B

© 2011 ANSYS, Inc. June 8, 2012 38

• Anisotropic magnetization: magnetization direction is determined by

the orientation of the magnet material and the direction is specified by a

user;

Anisotropic or Isotropic Magnetization

P(T) input

Q(T) input

• 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

© 2011 ANSYS, Inc. June 8, 2012 39

Field-Circuit Co-simulation

© 2011 ANSYS, Inc. June 8, 2012 41

Maxwell Circuit Editor Example

• Commutator bar: model position

• Commutating model: model parameters

(a) (b) (c) (d)

WidB

WidC

Period LagAngle

Position

G

0 WidC+WidB

|WidC-WidB|

a

b c

d

Gmax

© 2011 ANSYS, Inc. June 8, 2012 42

Case Example for Commutating Circuit

Torque

Winding currents

PMDC Motor

Brush commutation

circuit

© 2011 ANSYS, Inc. June 8, 2012 43

Simplorer: Power Electronics

© 2011 ANSYS, Inc. June 8, 2012 44

Simplorer Technology Highlights

© 2011 ANSYS, Inc. June 8, 2012 45

State-of-the-Art Drive System: A Multidomain Challenge

Drive systems

• Simplorer conservative structures (electrical circuits, mechanics, magnetics, hydraulics, thermal, ...)

• Simplorer non-conservative systems (blocks, states, digital, nth-order differential equations.

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. ...

ANSYS provides a comprehensive toolset for multidomain work:

· = M SV RS

© 2011 ANSYS, Inc. June 8, 2012 46

+

-

B 11A 11 C11

A 12 A 2

B 12 B 2

C12 C2

ROT2ROT1

ASMS

3~M

J

STF

M(t)

GN

D

mSTF

F(t)

GN

D

Magnetics

JA

MMF

Mechanics

L

H Q

Hydraulics, Thermal, ...

Simplorer Simulation Data Bus / Simulator Coupling Technology

State-space Models

statetransition

AUS

SET: TSV1:=0SET: TSV2:=1SET: TSV3:=1SET: TSV4:=0

(R_LAST.I <= I_UGR)

(R_LAST.I >= I_OGR)

EIN

SET: TSV1:=1SET: TSV2:=0SET: TSV3:=0SET: TSV4:=1

Cxy

BuAxx

Electrical circuits

Multi-Domain System Simulator

Analog Simulator

Block Diagram Simulator

State Machine Simulator

Digital/VHDL Simulator

PROCESS (CLK,PST,CLR) BEGIN IF (PST = '0') THEN state <= '1'; ELSIF (CLR = '0') THEN state <= '0'; ENDIF;

JK-Flip flop with Active-low Preset and Clear

CLK

INV

CLK

CLK

J Q

QB

CLR

PST

Flip flop

K

CLK

CLK

INV

0 0 0 0 1 1 1 1 1 1X-Axis

Curve Data

ffjkcpal1.clk:TR

ffjkcpal1.j:TR

ffjkcpal1.k:TR

ffjkcpal1.clr:TR

ffjkcpal1.pst:TR

ffjkcpal1.q:TR

ffjkcpal1.qb:TR

MX1: 0.1000

© 2011 ANSYS, Inc. June 8, 2012 47

Electromechanical Design Environment

Simulation Data Bus/Simulator Coupling Technology

Model Database Electrical, Blocks, State Machines, Automotive, Hydraulic,

Mechanics, Power, Semiconductors…

Maxwell Circuits Block

Diagram State

Machine VHDL-AMS

Matlab RTW

UDC MathCAD Matlab Simulink

Maxwell

C/C++ Programming Interface (FORTRAN, C, C++ etc.)

…

Co-Simulation

© 2011 ANSYS, Inc. June 8, 2012 49

Transient Electromagnetic FEM Co-simulation – Maxwell 2D/3D

Future: Multidomain model extraction and co-simulation

plunger

limit

spring

F

F

em_force

Battery- +

bjt1 bjt2

accumulator

Digital Control

TRIG

CTRL2

CTRL1 BS=>Q

BS=>Q

DETECTPLUNGER

I

TRIG

Solenoidmp2

pp1

75

m := 0.0066 s0 := 0.0002

gravity

v alue := 0.0066*9.8

spacer

sul := 0.0002sll_ := 0.0

Digital Electrical

Mechanical Hydraulic

Solenoid

A

orifice

75

ctrl1

ctrl2

plunger_control

Multi-Physics Co-Simulation

© 2011 ANSYS, Inc. June 8, 2012 50

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 Simplorer’s 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

© 2011 ANSYS, Inc. June 8, 2012 52

IGBT model 1. System model

• Nonlinear resistance – verification of operation

2. Average model

• Static char. & average loss. – Heating & temp. rise

3. Basic Dynamic model

• Dynamic char.& Energy – Switching loss & heating.

4. Advanced Dynamic model

• Detailed dynamic char. – Inverter surge & noise

1) 2)

3) 4)

© 2011 ANSYS, Inc. June 8, 2012 58

IGBT inverter design Circuit design (loss) + thermal model

Line current

1T, 1D SW loss + DC loss

1T, 1D junction temperature

Package temperature

Examination of temperature cycle

1T 1D

Ambient temperature = 20 cel

© 2011 ANSYS, Inc. June 8, 2012 59

-231.0n 618.0n0 200.0n 400.0n-50.0

700.0

0

166.7

333.3

500.0

Simplorer + Icepak = Detailed modeling of thermal system

Simplorer

ANSYS Icepak Q3D Extractor

Parasitism LCR extraction

Device property and loss consultation

CAD Import

Design of the cooling technique and arrangement

Design of substrate radiating route

The simulation in consideration of change of detailed temperature environment

© 2011 ANSYS, Inc. June 8, 2012 60

Induction Motor FEA Coupled with Simplorer

FEA

PhaseA1

PhaseA2

PhaseB1

PhaseB2

PhaseC1

PhaseC2

Rotor1

Rotor2

w +

ICA:

1400 rpm

LL:=237.56u

RA:=696.076m

B6U

D1 D3 D5

D2 D4 D6

2L3_GTOS

g_r1

g_r2

g_s1

g_s2

g_t1

g_t2

~

3PHAS

~

~

A * sin (2 * pi * f * t + PHI + phi_u)

PHI = 0°

PHI = -120°

PHI = -240°

LDUM:=100m

CDC:=10m

LDC:=10m

RDC:=10

VZENER:=650

AMPLITUDE := 800 V

FREQUENCY := 60 Hz

-297.50

300.00

-200.00

0

200.00

0 100.00m 50.00m

LA.I [A]

LB.I [A]

LC.I [A]

FREQ := 800 Hz

AMPL := 800

PHASE := 0 deg

AMPL := 500

PHASE := -315 deg

FREQ := 50 Hz

PHASE := -195 deg

PHASE := -75 deg

SA

SB

SC

G_R1 := SA.VAL

G_R2 := -SA.VAL

G_S1 := SB.VAL

G_S2 := -SB.VAL

G_T1 := SC.VAL

G_T2 := -SC.VAL

+ V

Name Value

SIMPARAM1.RunTime [s] 111.29k

SIMPARAM1.TotalIterations 40.51k

SIMPARAM1.TotalSteps 10.00k

FEA1.FEA_STEPS

-500.00

1.50k

0

1.00k

0 100.00m 50.00m

100.00 * LD.I [A]

VDC.V [V]

-715.00

425.00

-500.00

0

0 100.00m 50.00m

Current Torque

Speed

Fed by ac-dc-ac inverter

Frequency controlled speed

© 2011 ANSYS, Inc. June 8, 2012 61

BLDC motor FEA Coupled with Simplorer

FEA

sourceA1

sourceA2

sourceB1

sourceB2

sourceC1

sourceC2

Magnet01

Magnet02

w +

ICA:

+

F GAIN

CONST

CONST

EQUBL

EQUBL

EQUBL

1500 rpm

LL:=922u

RA:=2.991

ANGRAD

57.3

-60+PWM_PER

-30+PWM_PER

QS1

QS2

QS3

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

PWM_T:=60

I_TARG:=9

I_HYST:=0.2

Q1

Q2

Q3 Q5

Q4 Q6

400 V

THRES := PWM_T

EQUBL

CONST

QS4

-90+PWM_PER

EQUBL

CONST

QS5

-120+PWM_PER

EQUBL

CONST

QS6

-150+PWM_PER

RA Ohm LL H

PWM_PER:=180

INPUT[1] := PWM_PER

INPUT := -LB.I

LC.I

-LA.I

LB.I

-LC.I

LA.I

THRES1 := I_TARG - I_HYST

0

8.50

5.00

0 20.00m 30.00m

-14.50

7.80

0

0 30.00m 20.00m

-10.30

10.00

0

0 30.00m 20.00m

Output torque

Chopped currents

Inverter fed three phase BLDC motor drive

Chopped current control

0

8.50

5.00

0 30.00m 20.00m

© 2011 ANSYS, Inc. June 8, 2012 62

FEA

A1

A2

B1

B2

C1

C2

AirRotor1

AirRotor2

w +

26293 rpm ICA: LL:=70.6914u

RA:=203m

140 V

100u F

+

F ANGRAD GAIN

57.3

CONST -30+90

CONST -60+90

EQUBL

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

QB

QC

EQUBL

EQUBL

Name Value

FEA1.FEA_STEPS 1.00k

SIMPARAM1.RunTime [s] 6.90k

SIMPARAM1.TotalIterations 4.05k

SIMPARAM1.TotalSteps 1.00k

0

100.00

50.00

0 1.00m 500.00u

10.00 * QA.VAL

10.00 * QB.VAL + 30.00

10.00 * QC.VAL + 60.00

ROTA.VAL[0] ROTB.VAL[0] ROTC.VAL[0]

-54.00m

264.00m

0

100.00m

200.00m

0 1.00m 500.00u

10.00u * FEA1.OMEGA

V_ROTB1.TORQUE [Nm]

mechanical

-17.80

18.00

-10.00

0

10.00

0 1.00m 500.00u

L1.I [A] L2.I [A] L3.I [A] E1.I [A]

current control variable

SRM FEA Coupled with Simplorer

© 2011 ANSYS, Inc. June 8, 2012 63

Electric Machine Design: Maxwell – Simplorer Co-Simulation

3-ph Windings

Permanent Magnets

Stator & Rotor

Flux Linkages

3ph Line Currents

Co-simulation

© 2011 ANSYS, Inc. June 8, 2012 65

Multiphysics Coupling through WB

• Maxwell 3D provide volume/surface forces to ANSYS Structural

• Solver improvements

– Surface forces are supported

Deformation of the stator Deformation of coils The electromagnetic force density from Maxwell is used as load in Structural

Thermal-Stress with Electromagnetic Force load

© 2011 ANSYS, Inc. June 8, 2012 66

Force Coupling – Maxwell to Mechanical

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00Time [ms]

-250.00

-200.00

-150.00

-100.00

-50.00

-0.00

50.00

Forc

e (N

ewto

ns)

02_DC-6step_IPMRadial Force on Tooth Tips ANSOFT

Curve InfoExprCache(ToothTipRadial_Full1)ExprCache(ToothTipRadial_2)ExprCache(ToothTipRadial_3)ExprCache(ToothTipRadial_4)ExprCache(ToothTipRadial_5)ExprCache(ToothTipRadial_6)

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00Time [ms]

-30.00

-25.00

-20.00

-15.00

-10.00

-5.00

0.00

5.00

10.00

Forc

e (N

ewto

ns)

02_DC-6step_IPMTangential Force on Tooth Tips ANSOFT

Curve InfoExprCache(ToothTipTangent_Full1)ExprCache(ToothTipTangent_2)ExprCache(ToothTipTangent_3)ExprCache(ToothTipTangent_4)ExprCache(ToothTipTangent_5)ExprCache(ToothTipTangent_6)

© 2011 ANSYS, Inc. June 8, 2012 67

Force Coupling – Maxwell to Mechanical

• Case 1 0% Eccentricity

• Case 2 50 % Eccentricity

Max Deformation vs time

© 2011 ANSYS, Inc. June 8, 2012 68

Maxwell Couplings

Forced water cooling Forced air cooling Natural air cooling

Mapped Losses 2D/3D Losses Temperature

© 2011 ANSYS, Inc. June 8, 2012 69

Two Way CFD Thermal Analysis, R14

Geometry

Losses

Maxwell Model

CFD Model

Mapped Losses

Temperature

Ansys Electric Machines and Power Electronics

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