Electric Machines and Power Electronics

8/12/2019 Electric Machines and Power Electronics

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2011 ANSYS, Inc. June 8, 20121

Electric Machines

Considering Power Electronics

Zed (Zhangjun) Tang, Ph.D.

Presented at ANSYS Confidence by Design

June 5, 2012


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Machine Design Methodology Introduction

RMxprtMaxwell

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


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Introduction: MachineDesign Methodology


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Maxwell 2-D/3-DElectromagnetic Components

Field Solution

Model Generation

HFSS

ANSYS

MechanicalThermal/Stress

ANSYS CFDFluent

PExprtMagnetics

RMxprtMotor Design

Maxwell Design Flow Field Coupling


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SimplorerSystem Design

P P :=6

ICA:

A

A

A

GAIN

A

A

A

GAIN

A

JPMSYNCIA

IB

IC

Torque JPMSYNCIA

IB

IC

Torque

D2D

HFSS, Q3D, SIwave

ANSYS CFDIcepack/Fluent

Maxwell 2-D/3-DElectromagnetic Components

ANSYS

MechanicalThermal/Stress

PExprtMagnetics

RMxprtMotor Design

Simplorer Design Flow System Coupling

Model order Reduction

Co-simulation

Push-Back Excitation


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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


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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


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9/58 2011 ANSYS, Inc. June 8, 20129

Maxwell/RMxprt V15 Axial Flux Machine

AC or PM Rotor

Single or Double Side Stator

Sample Inputs

Sample Outputs


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Maxwell/RMxprt V15 Axial Flux Machine

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


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2011 ANSYS, Inc. June 8, 201211

Design Exploration

P2 - parallel

P1 - cond

Workbench Schematic

Maxwell Project


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2011 ANSYS, Inc. June 8, 201213

Design Exploration Six Sigma


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2011 ANSYS, Inc. June 8, 201214

More Than 30UDP Machine

Components

for 2D and 3D

Integrated Motor Solution


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2011 ANSYS, Inc. June 8, 201215

RMxprt Dynamic Link to Simplorer


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2011 ANSYS, Inc. June 8, 201216

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

Position[mm]

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

CoilCurrent[meter]

TRW/ Ansoft Position & Current Hysteresis Control Close/Open1

CurveInfo

Position

CoilCurrent

DiodeCurrent


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2011 ANSYS, Inc. June 8, 201217

Automatic Adaptive Meshing


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2011 ANSYS, Inc. June 8, 201218

Advanced CapabilitiesCoreloss Computation


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2011 ANSYS, Inc. June 8, 201221

Lamination Core Loss in Time Domain

Instantaneous hysteresis loss

Instantaneous classic eddy current loss

Instantaneous excess loss

where

dt

dBH

dt

dBBkt irrmhh

cos

1)(

2

22

1)(

dt

dBkt cc

dCe 2/

0

5.15.1 cos2

2

21

)( dt

dB

kCt cee


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2011 ANSYS, Inc. June 8, 201223

Core Loss Effects on Field Solutions

Basic concept: the feedback of the core loss istaken into account by introducing an

additional componentof magnetic field Hin

core loss regions. This additional component

is derived based on the instantaneous coreloss in the time domain


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2011 ANSYS, Inc. June 8, 201225

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 feedbackand 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)

Los

s(W)

Input power increase

Core loss 0

2

4

6

8

10

12

0 5 10 15 20 25 30 35 40

Time (ms)

L

oss(W)

Core loss

Input power increase

Three-phase transformer Three-phase motor


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2011 ANSYS, Inc. June 8, 201226

Advanced CapabilitiesDemagnetization Modeling


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2011 ANSYS, Inc. June 8, 201227

Modeling Mechanism

The worst demagnetization pointfor each element is dynamically

determined from a full transient

process

The demagnetization point issource, position, speed and

temperature dependent

Each element uses its own recoil

curve derived at the worst

demagnetization point in

subsequent transient simulation

HHc

B

0

Br'

Br

K

p Recoil lines

Worst demagnetizing point


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2011 ANSYS, Inc. June 8, 201228

HHc

B

0

Br'

Br

K

p Recoil line

Irreversible Demagnetization

If a demagnetizing point Pgoes below the knee point K,

even after the load is reduced or totally removed, thesubsequent 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


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2011 ANSYS, Inc. June 8, 201232

Benchmark Example

8-pole, 48-slot, 50 KW, 245 V, 3000 rpm Toyota Prius IPMmotor with imbedded NdFeB magnet

Two steps in 3D transient FEA:

1. Determine the worst operating point element by elementduring the entire transient process

2. Simulate an actual problem based on the element-basedlinearized 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 solveris further feedback to magnetic transient solver to considertemperature impact on the irreversible demagnetization


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2011 ANSYS, Inc. June 8, 201233

Hc'change in one element during a transient process:

The 1stcycle (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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2011 ANSYS, Inc. June 8, 201234

Contours of loss density distribution Static temperature distribution (K)


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2011 ANSYS, Inc. June 8, 201235

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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2011 ANSYS, Inc. June 8, 201236

Magnetization

Compute magnetization basedon the original non-remanent

B-H curve

Find operating pointp from

nonlinear solutions

Construct line bat the operating

pointp, which is parallel to the

line a at saturation point

Br is the intersection of line b

with B-axis Element by element

B

H0

Br Line b

Slope of line a at saturation point

p


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2011 ANSYS, Inc. June 8, 201237

Br

Magnetostatic case: theoperating point used for computing

magnetization (Br) is from single

source point;

What is the Difference between UsingMagnetostatic 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.

H0

Br p

B

H0

p

B


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2011 ANSYS, Inc. June 8, 201238

Anisotropic magnetization: magnetization direction is determined bythe 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 isdetermined 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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2011 ANSYS, Inc. June 8, 201239

Field-Circuit

Co-simulation


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2011 ANSYS, Inc. June 8, 201241

Maxwell Circuit Editor Example

Commutator bar: model position

Commutating model: model parameters

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

WidB

WidC

PeriodLagAngle

Position

G

0WidC+WidB

|WidC-WidB|

a

b c

d

Gmax


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2011 ANSYS, Inc. June 8, 201242

Case Example for Commutating Circuit

Torque

Winding currents

PMDC Motor

Brush

commutation

circuit


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2011 ANSYS, Inc. June 8, 201243

Simplorer:

Power Electronics


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2011 ANSYS, Inc. June 8, 201244

Simplorer Technology Highlights

f h i


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2011 ANSYS, Inc. June 8, 201245

State-of-the-Art Drive System:A MultidomainChallenge

Drive systems

Simplorer conservative structures (electricalcircuits, 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


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2011 ANSYS, Inc. June 8, 201246

+

-

B11A11 C11

A12 A2

B 12 B 2

C12 C2

ROT2ROT1

ASMS

3~M

J

STF

M(t)

GND

m

STF

F(t)

GND

Magnetics

JA

MMF

Mechanics

L

HQ

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_OGR)

EIN

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

Cxy

BuAx

Electrical circuits

Multi-Domain System Simulator

Analog Simulator

Block DiagramSimulator

State MachineSimulator

Digital/VHDLSimulator

PROCESS (CLK,PST,CLR)

BEGIN

IF (PST = '0') THEN

state


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2011 ANSYS, Inc. June 8, 201247

Electromechanical Design Environment

Simulation Data Bus/Simulator Coupling Technology

Model Database

Electrical, Blocks, State Machines, Automotive, Hydraulic,

Mechanics, Power, Semiconductors

Maxwell CircuitsBlock

Diagram

State

Machine VHDL-AMS

MatlabRTW

UDC MathCAD MatlabSimulink

Maxwell

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

Co-Simulation


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2011 ANSYS, Inc. June 8, 201249

Transient Electromagnetic

FEM Co-simulationMaxwell2D/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

DETECT

PLUNGERI

TRIG

Solenoidmp2

pp1

75

m := 0.0066s0 := 0.0002

gravity

value := 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


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2011 ANSYS, Inc. June 8, 201250

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. June 8, 201252

IGBT model1. 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)


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2011 ANSYS, Inc. June 8, 201257

IGBT Characterization

G i d i


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2011 ANSYS, Inc. June 8, 201258

IGBT inverter designCircuit 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

Si l I k


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2011 ANSYS, Inc. June 8, 201259

-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 coolingtechnique and

arrangement

Design of substrate radiating route

The simulation in consideration of

change of detailed temperature

environment


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2011 ANSYS, Inc. June 8, 201260

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


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2011 ANSYS, Inc. June 8, 201261

BLDC motor FEA Coupled with Simplorer

FEA

sourceA1

sourceA2

sourceB1

sourceB2

sourceC1

sourceC2

Magnet01

Magnet02

w+

ICA:

+

FGAIN

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 30.00m20.00m

-10.30

10.00

0

0 30.00m20.00m

Output torque

Chopped currents

Inverter fed three phase BLDC

motor drive

Chopped current control

0

8.50

5.00

0 30.00m20.00m


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2011 ANSYS, Inc. June 8, 201262

FEA

A1

A2

B1

B2

C1

C2

AirRotor1

AirRotor2

w

+

26293 rpmICA: LL:=70.6914u

RA:=203m

140 V

100u F

+

F ANGRADGAIN

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 1.00m500.00u

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 1.00m500.00u

10.00u * FEA1.OMEGA

V_ROTB1.TORQUE [Nm]

mechanical

-17.80

18.00

-10.00

0

10.00

0 1.00m500.00u

L1.I [A]

L2.I [A]

L3.I [A]

E1.I [A]

current control variable

SRM FEA Coupled with Simplorer

Electric Machine Design:


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2011 ANSYS, Inc. June 8, 201263

Electric Machine Design:Maxwell Simplorer Co-Simulation

3-ph Windings

Permanent Magnets

Stator & Rotor

Flux Linkages

3ph Line Currents

Co-simulation


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2011 ANSYS, Inc. June 8, 201264

Multi-physics


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2011 ANSYS, Inc. June 8, 201265

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


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2011 ANSYS, Inc. June 8, 201268

Maxwell Couplings

Forced water cooling Forced air cooling Natural air cooling

Mapped Losses2D/3D Losses Temperature

T W CFD Th l A l i R14


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2011 ANSYS, Inc. June 8, 201269

Two Way CFD Thermal Analysis, R14

Geometry

Losses

Maxwell Model

CFD Model

Mapped Losses

Temperature

P L M d i FLUENT


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2011 ANSYS, Inc. June 8, 201270

Power Loss in windings are not displayed.

Power Loss Mapped into FLUENT


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2011 ANSYS, Inc. June 8, 201271

ResultsTemperature Distribution
http://localhost/var/www/apps/conversion/tmp/scratch_9/TemperatureRendering.cvf


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Thank you

Electric Machines and Power Electronics

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