Load Dump Analysis

Ansoft Corporation Pittsburgh, PA

14 V Single Battery System

Engine
Starter

or here.
Loads

14V
Alternator

WHY?
Cables corrode and break Nuts & bolts come loose Mechanics disconnect the wrong wire at the wrong time.

OPENs occur here. or here

12V Battery

2-3 kW power generation capability

Instances
A major OEM received six new 42 volt alternators from a supplier. Three were destroyed in testing during the first month. Thats $15,000 up in smoke. They bought SIMPLORER. Another major OEM worked for over a year to create an accurate Saber alternator model that could be fit to parametric data. They have not succeeded. Ansoft and the OEM are discussing the deployment of SIMPLORER.

Why should you be interested?

Solving by hand
Time consuming Error prone

Options are few!

Testing
Destroy or degrade parts Very difficult to repeat Insufficient quantity of parts available

Simulation
Parts are virtualdont smoke Exactly repeatable All are necessary to some extent and support one another.

Ansofts Solution
RMxprt
Motor/generator design tool that can automatically produce a model for SIMPLORER

SIMPLORER
simulate the alternator, the battery, the loads and the devices and strategies that control and regulate the alternator

Design Flow
RMxprt
Optimization Geometry & Material Parameters & Models
Model Generation Model Generation Model Order Reduction

Model Generation

Optimization Parameter Sets, Lookup Tables, Models

Maxwell2D Maxwell3D Static, Harmonic, Transient Optimization

Parametric Solution

Maxwell Equivalent Circuit Generator

Multi Domain Simulation

Maxwell2D/3D
Electromagnetism Electro mechanics

SIMPLORER Simulation Data Bus Simulator Coupling Technology

Simulink

C/C++ Interface

MathCad

Circuit Simulator

Block Diagram Simulator

State Machine Simulator

VHDL-AMS Simulator

Model Database Electrical, Blocks, States, Machines, Automotive, Hydraulic, Mechanics, Power, Semiconductors

RMxprt Data Input

Specifications RMxprt

FEA ECE

Model

Simplorer

RMxprt -> SIMPLORER

RMxprt - LINK

Torque

A
STF STF

Torque
B

MchRStf1 MchRMas1

MchRStf2 MchRMas2 MchRMas3

E2
C

Position

E1 RMxprtLink1

+
V

+
V

Speed

Position

Typical Charging System: Alternator, PCM, Battery, Loads

Alternator Loads
S1

Field
C
3 MS~ C B A

Control from PCM

Battery Motors, Lamps, Solenoids, Sensors, Modules

BJT 1

Powertrain Control Module

Charging System in SIMPLORER

MEAN_I_Field
MEAN VALUE

MEAN_I_Load
MEAN VALUE

OPEN at 350msec
A

S1 RCable
Yt

IGBT1

Field

Alternator
C
Field C

AM1
D2 D3 D4

AM2
+
V

D8 CS

ctrl_1
R1 Position

B
Position Torque A B

VM1

D9

RLOADS

MEAN_Vout
MEAN VALUE

R_Dis
A
D7 D6

+
V

RMxprtLink1

D1 Speed

3000 RPM

C_Bat
D5

L_wire1 R_wire11

42

SUM1.VAL <= 0
SUM1
S&H

COMP1

FCT_ABS1
Abs

SET: ctrl_1:=1

SET: ctrl_1:=0

SUM1.VAL > 0

SAWTOOTHV

Simulation Results
597.38 500.00 400.00 300.00 200.00 100.00 0 -100.00
MEAN_Vout.VAL VM1.V ctrl_1

0.25

0.50

0.75

1.00 t

(Scaled at 100*Control Signal and 10*Average Output)

Output Voltage, Average Output(X10), and Control Signal(X100)

Simulation Results
20.00

R_WandB.I

17.50

15.00

12.50

10.00

7.50

5.00

2.50

0 -2.00

0.20

0.40

0.60

0.80

1.00 t

Field Current

Design Improvement
MEAN_I_Field
MEAN VALUE

MEAN_I_Load
MEAN VALUE

D_Z_ST_56V1
A

OPEN at 350msec
+ +
A

S1 RCable
Yt

Field
IGBT1 R_WandBL_wirec

Alternator
C
Field C

AM1
D2 D3 D4

AM2
+
V

D8 CS

ctrl_1
R1 Position

B
Position Torque A B

VM1

D9

RLOADS

MEAN_Vout

MEAN VALUE

R_Dis
A

+
V

RMxprtLink1

D1 Speed

3000 RPM

C_Bat
D7 D6 D5

L_wire1 R_wire11

42

SUM1.VAL <= 0
SUM1
S &H

COMP1

FCT_ABS1
Abs

SET: ctrl_1:=1

SET: ctrl_1:=0

Bang-bang mode Duty cycle

SAWTOOTHV

SUM1.VAL > 0

Add zener, adjust sawtooth frequency & duty cycle

20Hz Sampling with 90/10 PWM

60.00 50.00 40.00 30.00 20.00 10.00 0 -10.00 0 1.00 2.00 3.00 4.00 5.00 t MEAN_Vout.VAL VM1.V

Output Voltage

50.00 40.00 30.00 20.00 10.00 0 -5.00

Average Output Voltage

0 1.00 2.00 3.00 4.00 5.00 t R_WandB.I

12.00 10.00 8.00 6.00 4.00 2.00 0 0 1.00 2.00 3.00 4.00 5.00 t

Field Current

16Hz Sampling with 90/10 PWM

60.00 50.00 40.00 30.00 20.00 10.00 0 -10.00 0 0.50 1.00 1.50 2.00 t MEAN_Vout.VAL VM1.V

Output Voltage

50.00 40.00 30.00 20.00 10.00 0 -5.00

Average Output Voltage

0 0.50 1.00 1.50 2.00 t R_WandB.I

12.00 10.00 8.00 6.00 4.00 2.00 0 0 0.50 1.00 1.50 2.00 t

Field Current

Summary
RMxprt and SIMPLORER enable the engineer to study all the design alternatives quickly and without destroying or degrading the properties of valuable components. With this information highly focused testing can be carried out to complete the development process. Benefits: Shortened development time Improved performance and reliability Greater customer satisfaction Lower warranty costs