Machine Training PM Synchronous Ansoft Maxwell

Permanent Magnet Synchronous Machine
Ansoft Corporation
1.20
XY Plot 2
PMSM_CT
Curve Inf o
Bradial Setup1 : Transient Time='0ns'
1.00
0.80
0.60 Bradial 0.40 0.20 0.00 -0.20
0.00
0.20
0.40 Norm alizedDis tance
0.60
0.80
1.00
Ansoft Corporation
Cogging Torque
PMSM_CT_Verify
Ansoft Corporation
3.00
Ansoft Corporation
150.00
Core Loss
PMSM_OC_EMF
XY Plot 2
PMSM_OC_EMF
Curve Info
1.20
2.2271
Optimized Design Setup1 : Transient Moving1.Torque Imported Nominal Design
2.00
100.00
1.00
Curve Info CoreLoss Setup1 : Transient
Y1 [NewtonMeter]
1.00
0.5877
0.80 CoreLoss [kW]

0.4354
50.00
0.00
0.1402
0.60
Y1 [V]
0.00
Curve Info InducedVoltage(PhaseA) Setup1 : Transient
-1.00
0.40
-50.00
InducedVoltage(PhaseB) Setup1 : Transient InducedVoltage(PhaseC) Setup1 : Transient
-2.00
0.20
-100.00
-3.00 0.00
-150.00 0.00 2.00 4.00 Time [ms ] 6.00 8.00 10.00
1.00
2.00
3.00
4.00 Time [s]
5.00
6.00
7.00
8.00
MX1: 0.6379
0.00 0.00
2.00
4.00
MX2: 5.4031
Time [ms]
6.00
8.00
10.00
Ansoft Maxwell Field Simulator V12 Training Manual
P1-1
Permanent Magnet Synchronous Machine: Contents
RMxprt
Basic Theory Review Example Add Unique Winding Arrangement Setup Parametric Problem Export Design to Maxwell 2D
Maxwell: Open Circuit Back EMF

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

Review Maxwell Setup Create Variables Apply Mesh Operations Solve Nominal Problem Setup Optimization Problem Review Pre-Solved Optimization Results
Maxwell: Rated Condition Functional Voltage Source

Modify Rotor Geometry using UDPs 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
P1-2
Electric Machine Design Suite

A Complete Solution for Modern Electric Machines and Drives Design
Design Requirements
Size/Weight Efficiency Torque Speed Cogging/Ripple Inverter Matching Thermal Stress Manufacturability Cost
Fast Analytical Solution: Narrow the Design Space
Transient Analysis using FEA

Parametric Analysis
Magnetostatic/Eddy Current Analysis using FEA

Parametric Analysis Optimization Parametric Analysis Optimization
Simultaneous Equations: Field Equation: A = J s Circuit Equation: Motion Equation
A V + Hc + v A t
if C duc =0 dt
df
di N f l dA d + R if + L f + uc = us S f a dt dt
m + = Tem + Texternal
IGBT
EMF
D2
IGBT
D3
ECELink
FM_ROT
175
IGBT
IA
A
ROT1
IB
A_PHASE_N1
+ VBC V
ROT2 B_PHASE_N1
IC
A
C_PHASE_N1
EMF
175
IGBT
IGBT
ECE
AM_IGB
ICA:
PP:= ON:= OFF:= THRESH:=4 HYST:=
EQU
theta_elect := PP * ECELink theta := MOD(theta_elect
Phase Curre
1.00 500.0 0 -500.0 -1.00 0
Torqu IA IB IC
400.0
Phase Voltag
To
300.0 200.0 V_A
Von Mises stress
200.0 0
-200.0 10.00 17.27 t -300.0 0 10.00 17.27 t
10.00m
17.27mt
-100.0 0
Drive System using System Level IGBTs and Analytical Motor Model
Thermal and Stress Analysis
EMSSLink1
EMSSLink1
EMF2
175
R5
R3
R1
MASS_ROTB1
IA
E1
A
EMF2
175
R1
MASS_ROTB1
IA
A
R5
R3
RA
0.023
A_PHASE_N1
ROTB1
RA
0.023
A_PHASE_N1
ROTB1
E1
ROTB2
E5
E3
IB
RB
A
0.023
A_PHASE_N2 B_PHASE_N1
E5
E3
IB
ROTB2
RB
A
0.023
A_PHASE_N2 B_PHASE_N1
+
VBC
V
+
VBC
V
IC
A
RC 0.023
B_PHASE_N2 C_PHASE_N1 C_PHASE_N2
IC
A
RC 0.023
B_PHASE_N2 C_PHASE_N1 C_PHASE_N2
EMF1
175
R2
R6
EMF1
175
R4
VGE4
R2
A
R6
R4
VGE4
V
A
AM_IGBT
ICA:
E2
E6
E4
E2
E6
E4
AM_IGBT
ICA:
ctrl_1:=ON ctrl_6:=ON
theta>90 AND theta<150

ctrl_6:=OFF ctrl_1:=OFF
ctrl_5:=ON
ctrl_4:=ON
ctrl_6:=ON
theta>330 OR theta<30
ctrl_5:=ON
ctrl_5:=ON
ctrl_4:=ON
theta>330 OR theta<30
Drive System Integration with Manufacturers IGBTs

Equivalent Circuit Model : High Fidelity Physics Based Model
ctrl_6:=ON
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 , the power factor angle
I = I
Let the angle I lags E0 be . The d- and the q-axis currents can be obtained respectively as follows:
Id sin I = = I I cos q
= tan
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 , which is called the torque angle for the motor, then the angle is = For a given torque angle :
Xd R 1 R1 I d U cos E0 I = Xq U sin q
Solving for Id and Iq yields:

Id 1 I = 2 q R1 + X d X q X q (U cos E0 ) + R1U sin R (U cos E ) X U sin 0 d 1
P1-6
ASSM: Background The power factor angle is
= +
The Input electric power is
P UI cos 1 =3
The Output mechanical power is
P2 = P 1 ( Pfw + P Cua + P Fe )
Pfw : Frictional and Wind Loss PCua: Armature Copper Loss PFe : Iron-core Loss
Torque:
T2 =
Efficiency:
=
P2
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
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:
1
Current > RMSLineCurrentParameter Power > OutputPowerParameter Misc. > EfficiencyParameter
Click on the Calculations Tab > Setup Calculations and add the following
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
P1-18
RMxprt: Create Maxwell Design Select Setup1, click the RMB and select Create Maxwell Design
4 1
2 deselect Choose 3
P1-19
Maxwell 2D: Base Design
Motion Boundaries Winding Mesh
Material Assignment
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 = 0.25 deg.
D = r (1 cos( / 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( / 2))
= Maximum Surface Normal Deviation
ri
ro
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
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
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

Ansoft Corporation
3.00
Torque
Maxwell2DDesign1
Curve Info Moving1.Torque Setup1 : Transient
2.00
1.00 Moving1.Torque [NewtonMeter]
Click the RMB in the plot and select Export Data. Save the plot on the desktop. 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
0.00
-1.00
-2.00
-3.00 0.00 5.00 Time [s] 10.00 15.00
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
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
P1-36
Maxwell 2D: Cogging Torque, Optimization Variables Change the field for the Offset to PoleOffset and accept the default value of 0mm.
1
P1-37
Maxwell 2D: Cogging Torque, Optimization Variables Select CreateUserDefinedPart under InnerRegion under Vacuum and choose Properties
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
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
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

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.
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 2 3 6 10 7 8 9 4
P1-48
Maxwell 2D: Cogging Torque Optimization, Brad AG Plot of B radial in air gap at time zero
Ansoft Corporation
1.20
XY Plot 2
PMSM_CT
Curve Inf o
Bradial Setup1 : Transient Time='0ns'
1.00
0.80
0.60
0.40
0.20
Click the RMB in the plot window and select Export Data. Save the plot on the desktop.
Bradial
0.00 -0.20
0.00
0.20
0.40 Norm alizedDis tance
0.60
0.80
1.00
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.
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
3 4
5
P1-55
Maxwell 2D: Cogging Torque Optimization Setup Include Calculation for the average radial component of the flux density in the air gap
1 3
Type in the rest of the expression and then click on Add Calculation
5
P1-56
Maxwell 2D: Cogging Torque Optimization Setup Include calculation for Magnet Area
Type in the rest of the expression and then click on Add Calculation
4
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
3 2
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
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 Ansofts 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:
P1-63
Maxwell 2D: Cogging Torque Optimization Verify Plot the Cogging Torque
Ansoft Corporation
Cogging Torque
PMSM_CT_Verify
Curve Info Optimized Design Setup1 : Transient
0.50 0.40 0.30 Optimized Design [NewtonMeter] 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.
Ansoft Corporation
Cogging Torque
PMSM_CT_Verify
3.00
Curve Info
2.2271
Optimized Design Setup1 : Transient Moving1.Torque Imported Nominal Design
2.00
Y1 [NewtonMeter]
1.00
0.5877 0.4354
In plot window, RMB and select Marker > Add X Marker Optimized Design Nominal Design
0.00
0.1402
-1.00
-2.00
-3.00 0.00
1.00
2.00
3.00
4.00 Time [s]
5.00
6.00
7.00
8.00
MX1: 0.6379
MX2: 5.4031
P1-65
Maxwell 2D: Cogging Torque Optimization Verify Plot the air gap flux density
Ansoft Corporation
Air Gap Flux Density
PMSM_CT_Verify
1.20
Curve Info 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 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.
Ansoft Corporation
Air Gap Flux Density
PMSM_CT_Verify
1.20
Curve Info Bradial Setup1 : Transient Time='0ns'
1.00
Bradial Imported Nominal Design
0.80
Bradial
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.
The area of the magnet for the nominal design was 383 mm2
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
P1-73
Maxwell 2D: Open Circuit Back EMF, Core Loss Setup Add the core loss curve for 60Hz
Choose the file 4 M470-65A-60Hz.tab
5
P1-74
Maxwell 2D: Open Circuit Back EMF, Core Loss Setup Add the core loss curve for 100Hz
Choose the file 4 M470-65A-100Hz.tab
5
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.
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
The time step is determined by:

1 deg 3600rev 360 deg 1 min 21600 deg * * = = sec 46.3u sec min rev 60 sec
1
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
1 3
2
P1-82
Maxwell 2D: Open Circuit Back EMF, Results

Ansoft Corporation
150.00
XY Plot 2
PMSM_OC_EMF
100.00
50.00
Y1 [V]
0.00
Curve Info InducedVoltage(PhaseA) Setup1 : Transient
-50.00
InducedVoltage(PhaseB) Setup1 : Transient 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

Ansoft Corporation
Core Loss
PMSM_OC_EMF
1.20
1.00
Curve Info CoreLoss Setup1 : Transient
0.80 CoreLoss [kW]
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
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
3
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
4
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
3 2
4
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 Ansofts FTP site:
ftp://ftp.ansoft.com/download/ChinaTraining/PM_SyncMotor_Rated.zip
P1-101
Maxwell 2D: Rated Condition, Results

Ansoft Corporation
3000.00
Winding Currents
PMSM_Rated
Ansoft Corporation
600.00
Torque Quick Report
PMSM_Rated
Curve Info Moving1.Torque Setup1 : Transient
2000.00
Curve Info Current(PhaseA) Setup1 : Transient Current(PhaseB) Setup1 : Transient Current(PhaseC) Setup1 : Transient
500.00
1000.00
400.00
Moving1.Torque [NewtonMeter]
0.00 50.00 Time [ms] 100.00
0.00 Y1 [A]
300.00
-1000.00
200.00
-2000.00
100.00
-3000.00
0.00
-4000.00
-100.00 0.00 50.00 Time [ms] 100.00
Ansoft Corporation
1.90
Core Loss
PMSM_Rated
Curve Info
CoreLoss Setup1 : Transient
1.80
1.70
1.60
CoreLoss [kW]
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.
P1-103

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

4. Build the rest of the schematic like below. Details of each component are shown on the next page.
B6U1
B6U
+
V
VM1 VALUE := 1000*(1+(t>0.02))

C B A ROT2
RMXROT1
C := 1u R_Load R := 1k C1
D5
D3
D1
D6
D4
D2
RMxprtLink1
V_ROT1
DC Link Voltage 92.00 84.00 50.00
Back EMF (A-B
50.00
R_Load.V [V]
VM1.V [V]
-50.00 0 0 20.00m Rotor Position (Deg -3.55f -100.00 RMxprtLink1.Pos 1.00k V_ROT1.OMEGA [rpm] -300.00 -362.00 0 20.00m 40.00m 0 0 20.00m 40.00m 2.00k 40.00m -94.00 0 20.00m 40.00m
Input Speed from Shaft
-200.00
P1-105

5. ModelAgent > Add Ons tab > power > Line-commutated Converters > B6 Diode Bridge
P1-106

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

8. ModelAgent > Basics tab > Physical Domains > Mechanical > Velocity-Force-Representation > Rotational_V > Angular Velocity Source
P1-108

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

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.

P1-110
This completes the one day training course on permanent magnet synchronous machines using Ansofts RMxprt, Maxwell 2D and Simplorer
P1-111

Machine Training PM Synchronous Ansoft Maxwell

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Machine Training PM Synchronous Ansoft Maxwell

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Permanent Magnet Synchronous Machine

0.60 Bradial 0.40 0.20 0.00 -0.20

0.40 Norm alizedDis tance

Optimized Design Setup1 : Transient Moving1.Torque Imported Nominal Design

Curve Info CoreLoss Setup1 : Transient

0.80 CoreLoss [kW]

Curve Info InducedVoltage(PhaseA) Setup1 : Transient

InducedVoltage(PhaseB) Setup1 : Transient InducedVoltage(PhaseC) Setup1 : Transient

4.00 Time [s]

Ansoft Maxwell Field Simulator V12 Training Manual

Permanent Magnet Synchronous Machine: Contents

Maxwell: Open Circuit Back EMF

Maxwell: Cogging Torque

Maxwell: Rated Condition Functional Voltage Source

Electric Machine Design Suite

Fast Analytical Solution: Narrow the Design Space

Transient Analysis using FEA

Magnetostatic/Eddy Current Analysis using FEA

Simultaneous Equations: Field Equation: A = J s Circuit Equation: Motion Equation

PP:= ON:= OFF:= THRESH:=4 HYST:=

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

Von Mises stress

-200.0 10.00 17.27 t -300.0 0 10.00 17.27 t

Thermal and Stress Analysis

B_PHASE_N2 C_PHASE_N1 C_PHASE_N2

B_PHASE_N2 C_PHASE_N1 C_PHASE_N2

theta>90 AND theta<150

theta>150 AND theta<210

theta>210 AND theta<270

theta>90 AND theta<150

theta>150 AND theta<210

theta>210 AND theta<270

theta>30 AND theta<90

theta>270 AND theta<330

Drive System Integration with Manufacturers IGBTs

Equivalent Circuit Model : High Fidelity Physics Based Model

theta>30 AND theta<90

theta>270 AND theta<330

Complete Transient FEA -Transient System Co-simulation

RMxprt: Background ASSM: Adjustable-Speed Synchronous Machine

Ansoft Maxwell Field Simulator V12 Training Manual

Ansoft Maxwell Field Simulator V12 Training Manual

OM can be used to determine the direction of E0

Solving for Id and Iq yields:

Ansoft Maxwell Field Simulator V12 Training Manual

ASSM: Background The power factor angle is

The Input electric power is

The Output mechanical power is

Ansoft Maxwell Field Simulator V12 Training Manual

Save the project under a new name:

Ansoft Maxwell Field Simulator V12 Training Manual

Choose a Solution Set

Ansoft Maxwell Field Simulator V12 Training Manual

Choose a Performance Curve

Ansoft Maxwell Field Simulator V12 Training Manual

Ansoft Maxwell Field Simulator V12 Training Manual

Deselect Constant Pitch Change the Layout as shown

Ansoft Maxwell Field Simulator V12 Training Manual

Connect One Phase Coils.

Ansoft Maxwell Field Simulator V12 Training Manual

Ansoft Maxwell Field Simulator V12 Training Manual

Ansoft Maxwell Field Simulator V12 Training Manual

Ansoft Maxwell Field Simulator V12 Training Manual

Ansoft Maxwell Field Simulator V12 Training Manual