Welcome to The Design of Electrical Machines using

Maxwell & Simplorer

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2011 ANSYS, Inc.

July 16, 2013

The Design of Electrical Machines

using ANSYS Maxwell & Simplorer

Tuesday, 16th July 2013

Andrew Jones, David Twyman
ANSYS UK Ltd
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2011 ANSYS, Inc.

July 16, 2013

Agenda (All Times BST)

14:00 Introduction to the webinar and ANSYS
14.10 Presentation and Software Demonstration
Why LF Simulation?
Validation and technical advances
Overview of ANSYS RMxprt, Maxwell & Simplorer tools for
Electrical Machine Design

15.05 Close
If you have questions, please email them to
andrew.jones@ansys.com or david.twyman@ansys.com

2011 ANSYS, Inc.

July 16, 2013

Our Strengths
Focused
This is all we do.
Leading product technologies in all physics areas
Largest development team focused on simulation

Capable
2,000 employees
60 locations, 40 countries

Trusted
96 of top 100 FORTUNE 500 industrials
ISO 9001 and NQA-1 certified

Proven
Recognized as one of the worlds most innovative
and fastest-growing companies*

Independent
Long-term financial stability
CAD agnostic

2011 ANSYS, Inc.

July 16, 2013

*BusinessWeek, FORTUNE

Our Balance
Europe
34%

Americas
34%

Consolidated Company
Geographic Revenue
Asia
32%

Materials & Chemical

Processing
12%
Industrial Equipment
13%

Academic
8%
Aerospace & Defense
17%

Automotive
15%
Energy and CleanTech
10%

Consumer Products
2%
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2011 ANSYS, Inc.

Percent of Net Sales

Revenue by Industry

Electronics
19%

July 16, 2013

BioMedical
Construction 2%
2%

ANSYS:
A Comprehensive Simulation Platform

Electric Machine
Generator and shaft design

Speed Sensor

Power Electronic

Blade design

Wind farm configuration for

optimal power generation
Transformer
Rotor sizing
and acoustics

Power Distribution

Electromechanical
Component

Tower design
and FSI
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2011 ANSYS, Inc.

July 16, 2013

Offshore Installation and

certification

Site selection, land and

sea

Overview
ANSYS offers a unique solution to electrical machine design through its
Electrical Machine Design Methodology
What is the Electrical Machine Design Methodology?
Five combinable tools which assist engineers in designing and analyzing
electrical machines
Integrates electromagnetic, circuit, and system engineering using a
common desktop environment
The Electrical Machine Design Methodology includes:

RMxprt

Rapid Machine Design

Maxwell

Finite Element Analysis

Optimetrics

Optimization

Simplorer

System Analysis

Mechanical

Thermal, Stress and Acoustic

2011 ANSYS, Inc.

July 16, 2013

ANSYS Electromechanical System Solution

HF/SI
HFSS, Q3D, SIWave

ANSYS Simplorer

RLCG Parasitics

System Design
PMSYNC

IA

SCADE Suite
Control Systems

Torque

IB

D2D

ICA:

IC

PP := 6

GAIN

ANSYS CFD

Xprts

Thermal

Optimetrics
LS-DSO

ANSYS
Mechanical

ANSYS Maxwell
3D FEA Analysis

Thermal/Stress

Generator Design
Power Electronics

Embedded Design
Model order Reduction
Co-simulation
Field Solution
FE Model Generation

2011 ANSYS, Inc.

July 16, 2013

Push Back Excitations

RMxprt

2011 ANSYS, Inc.

July 16, 2013

RMxprt
Analytical Design Software for Electric Machines
Calculate machine performance, make material and size decisions
Flexible design and optimization process for rotating electric machines which
perform hundreds of "what if" analyses in a matter of seconds

Machine Types
Induction Machines : Single-Phase, ThreePhase
Synchronous Machines : Line-Start PM,
Adjustable Speed PM, Salient Pole, NonSalient Pole
Brush commutated: DC, Permanent Magnet
DC, Universal, Claw-pole Alternator
Electronically commutated: Brushless PM,
Switched Reluctance
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2011 ANSYS, Inc.

July 16, 2013

RMxprt User Inputs

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2011 ANSYS, Inc.

July 16, 2013

RMxprt Typical Results

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2011 ANSYS, Inc.

July 16, 2013

RMxprt Complete Results

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2011 ANSYS, Inc.

July 16, 2013

Rmxprt Maxwell Link

One-click automatic creation of complete 2D/3D transient design including:
Geometry, Materials, Master/Slave Boundaries, Sources, Mesh Operations,
External Circuits, Motion, and Solution Setup
Access this by clicking on Analysis > Setup > Create Maxwell Design

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2011 ANSYS, Inc.

July 16, 2013

Winding Configurations

Lap winding with

coil pitch=1

Concentric
winding

Single-layer lap
winding
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2011 ANSYS, Inc.

July 16, 2013

Double-layer lap
winding

DC winding

Common Slot Types Support

Single/double
squirrel-cage cores

Inner/outer AC/DC
armature cores

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2011 ANSYS, Inc.

July 16, 2013

Interior Permanent Magnet (IPM) Machine

Different IPM
rotor structures

Full solution

Complete 2D and 3D setup (Mesh ops, Sources, )

Multi duct layers supported

2D FE full setup

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2011 ANSYS, Inc.

July 16, 2013

3D FE full setup

Maxwell

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2011 ANSYS, Inc.

July 16, 2013

Maxwell
Solves 2D and 3D electromagnetic
problems using FEA
Five Solution Types: Electrostatic,
Magnetostatic, Eddy Current, Transient
Electric, Transient Magnetic
Determines R,L,C, Forces, Torque,
losses, Saturation, Time-induced effects
Parameter extraction for:
Power Magnetics: Inductors,
Transformers
Machines: Motors, Generators, Actuators
Electrical Parasitic: Cables, vias, bus
bars
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2011 ANSYS, Inc.

July 16, 2013

Maxwell Desktop

Project
Manager

Modeller

Properties

Progress

Messages
History
Tree
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2011 ANSYS, Inc.

July 16, 2013

Geometry Utilities
Automatically create complicated 2D/3D geometries
Shape optimized for minimum count, Good quality mesh

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2011 ANSYS, Inc.

July 16, 2013

General Machine Parts

Typical
Components

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2011 ANSYS, Inc.

July 16, 2013

Shared Variables

Convenient for geometry

parametric sweep and
optimization

Maxwell geometry
automatic update with
variables changed in
RMxprt

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2011 ANSYS, Inc.

July 16, 2013

Maxwell Auto-Adaptive Meshing

Initial
Geometry
(no mesh data)

Create Initial Mesh

Calculate Field

Calculate
Field Accuracy

Error Acceptable?

Yes

Postprocess

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2011 ANSYS, Inc.

July 16, 2013

Final
No

Refine Mesh

Example: TEAM Problem #20

Small Air Gaps

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2011 ANSYS, Inc.

July 16, 2013

Automatic Adaptive Meshing

Measured

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2011 ANSYS, Inc.

July 16, 2013

Comparison to Measurement

Measured

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2011 ANSYS, Inc.

July 16, 2013

Double Rotor Motion

Two Bands in Transient Solver
For transient motion solver, two bands with two independently moving
objects now allowed
Both rotational and translational solvers can handle this

Stator
Rotor I
Rotor II

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2011 ANSYS, Inc.

July 16, 2013

Multiple End Connected Conductors

In transient solver, independently connected squirrel cage rotors

Squirrel cage I
Squirrel cage II

Induction Motor with Dual Rotor Cages

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2011 ANSYS, Inc.

July 16, 2013

External Circuit Coupling

Use Maxwell Circuit Editor for control and drive circuitry
Re-adjusts time step of field computation when:

Switching
Sharp variations in external sources
Large change in winding inductance
Schematic
Project and
Components

Properties
Message

Progress
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2011 ANSYS, Inc.

July 16, 2013

Pm Loss Reduction
Add cuts using insulation
boundaries
Reduce Eddy Currents
Reduce Loss

Up to 16 Magnet Segments were

simulated
Needed to find optimum number of
segments
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2011 ANSYS, Inc.

July 16, 2013

Temperature Dependence
Coercivity (Hc)

Flux
Density

Coercivity change shows dynamic irreversible demagnetization during

a transient process in one element
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2011 ANSYS, Inc.

July 16, 2013

3D-Vector Hysteresis Modeling

Epstein Frame with Hysteresis Core
(Hc = 5 kA/m)

B vs. H

Simulated B=f(H)

Flux vs. Current

B = f(t)
H = f(t)

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2011 ANSYS, Inc.

July 16, 2013

3D-Vector Hysteresis Modeling

Hysteresis Motor with Solid Rotor
(Hc = 50 kA/m)
B
Input only
descending
BH curve

Power Balance within <2%

Non-Linear
H
Eddy-Current
Hysteresis
HPC

Torque vs. Time

Hysteresis torque vs. Time

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2011 ANSYS, Inc.

July 16, 2013

RMxprt to Maxwell link

One-click automatic creation of complete 2D/3D transient design including:
Geometry, Materials, Master/Slave Boundaries, Sources, Mesh Operations,
External Circuits, Motion, and Solution Setup
Access this by clicking on Analysis > Setup > Create Maxwell Design

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2011 ANSYS, Inc.

July 16, 2013

Simplorer

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2011 ANSYS, Inc.

July 16, 2013

Simplorer
Circuits

Multi-domain, system simulator for designing high

performance systems

R1
N0002

Three Basic Simulation Engines: Circuits, Block

Diagrams, State Machines

R2

50

1k

1k

R4
C2

C1

50

3.3u
3.3u
V0 := 5

12

R3

N0004
N0003

V0 := 0
N0005

Mixed Signal Mixed Mode Modeling

Digital / Analog

Block Diagrams
I_PART_id

Magnetic, Mechanical, Thermal

LL := -9

Integrated analysis with electromagnetic simulation

tools (Maxwell, PExprt, RMxprt, Q3D)
Analysis Types: AC, DC, Transient

CONST

UL := 9
id_ref

P_PART_id

LIMIT

GAIN

yd

KP := 0.76

id
G(s)

GAIN

GS2
SUM2_6

State Machines
IMP = 0 and RLine.I <= ILOW

Co-simulation with Maxwell and Simulink

Statistical Analysis and Optimization
VHDL-AMS Capability

SET: CS1:=-1
SET: CS2:=-1
SET: CS3:=-1
SET: CS4:=-1

IMP = 0 and RLine.I >= IUP

IMP = 0

IMP = 1
IMP = 0

SET: CS1:=1
SET: CS2:=-1
SET: CS3:=-1
SET: CS4:=-1

IMP = 1

IMP = 1 and RLine.I <= ILOW

IMP = 1 and RLine.I >= IUP

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2011 ANSYS, Inc.

July 16, 2013

SET: CS1:=-1
SET: CS2:=1
SET: CS3:=-1
SET: CS4:=-1

SET: CS1:=-1
SET: CS2:=-1
SET: CS3:=-1
SET: CS4:=-1

Simplorer Architecture
C/C++
User Defined
Model

Matlab
Real Time
Workshop

Co-Simulation
ANSYS
RBD

Matlab
Simulink

ANSYS
Maxwell

ANSYS CFD

Simulation Data Bus/Simulator Coupling Technology

Blocks:

States:

Circuits:

Model Extraction: Equivalent Circuit, Impulse

Response Extracted LTI, Stiffness Matrix
Electromagnetic
(FEA)

Mechanical
(FEA)

Thermal
(FEA/CFD)

Fluidic
(CFD)

VHDL-AMS
IF (domain = quiescent_domain)

V0 == init_v;
ELSE

Current == cap*voltage'dot;
END USE;

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2011 ANSYS, Inc.

July 16, 2013

ANSYS and Process Engineering

System

ANSYS - Simplorer
Mixed--Signal MultiMixed
Multi-Domain
System Simulator
Sub-System

Model Order Reduction

Cosimulation
Component

ANSYS Workbench
Electrical

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2011 ANSYS, Inc.

July 16, 2013

Magnetic

Fluid

Mechanical Thermal

Acoustic

Simplorer: Design Environment

Windows-like

Single project file

Modeling

Graphical, SML, C/C++

VHDL-AMS, PSpice

Hierarchical models

All quantities
accessible

Postprocessing on
sheet or in reports

VB, Java, Python, ...

Model libraries

Wizards

Optimetrics

Distributed Solve

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2011 ANSYS, Inc.

July 16, 2013

Simplorer to Maxwell Coupling

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2011 ANSYS, Inc.

July 16, 2013

Induction Motor Coupled with Simplorer

Frequency controlled speed

G_R1 := SA.VAL

G_S1 := SB.VAL

G_T1 := SC.VAL

G_R2 := -SA.VAL

G_S2 := -SB.VAL

G_T2 := -SC.VAL

1400 rpm

2L3_GTOS

+
PhaseA1

Rotor1

PhaseA2

Rotor2

3PHAS
B6U

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

g_r1

PHI = -120

PHI = -240

g_s1

g_t1

PHI = 0
D1

D3

D5

D2

D4

D6

PhaseB1

PhaseB2
g_r2

g_s2

g_t2
PhaseC1

FREQ := 800 Hz
ICA:

AMPL := 800
PHASE := 0 deg

AMPLITUDE := 800 V
FREQUENCY := 60 Hz

Fed by ac-dc-ac inverter

LL:=237.56u

PhaseC2
FEA

RA:=696.076m
LDUM:=100m

FREQ := 50 Hz
AMPL := 500

CDC:=10m
SA

PHASE := -75 deg

Name

LDC:=10m

PHASE := -315 deg

RDC:=10
VZENER:=650

SB

PHASE := -195 deg

SIMPARAM1.RunTime [s]

111.29k

SIMPARAM1.TotalIterations

40.51k

SIMPARAM1.TotalSteps

SC

Value

10.00k

FEA1.FEA_STEPS

300.00

Current

200.00

LA.I [A]

Torque

LB.I [A]
425.00

LC.I [A]

1.50k

1.00k

100.00 * LD.I [A]

VDC.V [V]

Speed

0
-500.00
-200.00

-500.00

-715.00
-297.50

0
0

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2011 ANSYS, Inc.

50.00m

100.00m

July 16, 2013

50.00m

100.00m

50.00m

100.00m

Conservative electromechanical systems

System Level
(Park Transformation)

MS

3~

3~

( w. Damper )

A B C

System Level

N1

(Park Transformation,
Mechsim1D components)

N2

B12

ROT2

DCMP

RMxprt equivalent
circuit generation

ASMS

A11 B11 C11

A2

A12

B2

B12

C2

C12

ROT2

3~

ROT1

SYMPD

N_1
N_2

Maxwell2D/3D

N_4

ROT2

Linear and nonlinear,

lumped parameters,
provides advanced
mechanical properties
Nonlinear, losses,
space harmonics,
lookup tables
As accurate as FEA
simulation performed

(Static and Transient)

+ Additional component libraries

+ VHDL-AMS and Spice models
+ Customized components at
model.simplorer.com
2011 ANSYS, Inc.

3~

ROT1

N_3

43

C12

ROT1

A B C

A11 B11 C11

A12

Linear and nonlinear,

lumped parameters

July 16, 2013

Multi-Level Techniques Cosimulation:

Compare Modeling Depth
Simplorer internal model

Analytical model, linear

Park transformation
Simplorer with RMxprt ECE

Analytical model, look-up table

Nonlinear saturation, eddy effects
Maxwell Transient + External Circuits
(Cosimulation)

Transient field simulation model

All dynamic effects from dB/dt
Saturation, slot harmonics
Eddy, current displacement
Skin, proximity, diffusion, etc

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2011 ANSYS, Inc.

July 16, 2013

Multi-Level Techniques Cosimulation:

Compare Modeling Depth
Compare
M

Torque

3~

ASMS

L = L(f, )
Inrush:
A

Smaller inductance
Higher current
Stronger damping

Maxwell most accurate

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2011 ANSYS, Inc.

July 16, 2013

ROT1

B
C
N

ROT2
RMX

Multi-Level Techniques Cosimulation:

Compare Modeling Depth
Compare

3~

Currents

ASMS

ROT1

B
C
ROT2
N

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2011 ANSYS, Inc.

July 16, 2013

RMX

Multi-Level Techniques Cosimulation:

Compare Modeling Depth
Implications for system design

Doubled inrush current affects electrical

system design
Doubled inrush torque burdens mechanical
system
Stronger damping affects control dynamics
Slot harmonics affect motion quality,
control/inverter design

Motor design considerations

Interactions with system affect motor design,

e.g. losses

Need transient-transient link to examine

this further!

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2011 ANSYS, Inc.

July 16, 2013

The Design of Electrical Machines using Maxwell &

Simplorer
Thank you for your attendance today
To Ask a Question, please email :
andrew.jones@ansys.com or david.twyman@ansys.com

Webinar Recording:
Available shortly afterwards.

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2011 ANSYS, Inc.

July 16, 2013