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Simulation of Electric Klicken with

Machines bearbeiten
ANSYS
Jens Otto CADFEM GmbH

CADFEM 2017 1
Why Simulation with ANSYS ? Challenges for electric machines

Electromagnetic Design:
Rated power/ Power-Volume-Ratio
Material consumption
Losses/Efficiency
Torque ripple
Circuit interaction
Structural Design:
Housing integrity
Active steel integrity
Winding-end design
Cooling Design
Air/Fluid flow

Coupled Analyses:
Temperature prediction
Vibroacoustics

CADFEM 2017 -2-

 Simulation Driven Product Development Customer Workflow

Marc Brck
EM-motive
a Bosch + Daimler
Company

CADFEM 2017 3
Virtual Prototype: Simulation is Everywhere!

Electromagnetic is just
one aspect of design

EADT also part of

Workbench environment
Thermal
Fluid-flow
Structural
Coupled Simulation

CADFEM 2017 4
Electromagnetic FEM Solution in ANYS Maxwell

Maxwell:

Static
Time-Dependent
Time domain (Transient)
Frequency domain (Harmonic)

Motion (Linear, Rotational)

Source: CADFEM

Advanced physics capability

2D; 2.5D; 3D
Materials
Circuit coupling

CADFEM 2017 -5-

Maxwells Approach: Finite Element Method

Translate differential equation to

algebraic equations Solution
computed
on nodes
Split one big task into a finite
number of simple subtasks
Discretize space by
tetrahedrons/triangles
Solution only at elements nodes Source:CADFEM

Quantities are interpolated between

nodes

CADFEM 2017 -6-

Automatic Adaptive Meshing

Generate Initial
Generate efficient mesh without Start Mesh
expert mesh know-how

Find a compromise accuracy vs

Solve fields using the
simulation time Finite Element Method

User defined convergence criteria

Calculate local Refine Mesh
Global energy error (default)
Solution error
Torque
Force
Inductance End criteria no
reached ?
Adaptive meshing available yes
for all non-transient solvers
Calculate Outputs
(Force, Inductance, etc.)
CADFEM 2017 -7-
Automatic Adaptive Meshing Example

Source ANSYS Inc.

CADFEM 2017 -8-

Mesh Operations

Can be combined with adaptive

approach
Fewer iterations
Faster solution times

Mesh refinement for transient

simulations
Manual mesh refinement
Import mesh from static/harmonic

Source CADFEM

CADFEM 2017 -9-

True Motion in Electromagnetic Simulation

User friendly configuration

Velocity dependent effects

Eddy currents (effect on field)
PMs
Squirrel cage
Conducting slot wedges/
mechanical parts
External particles

CADFEM 2017 10
3D Vector Hysteresis Modeling

Lamination support

Optimization to minimize total error

of major & minor loop

Non-zero initial condition support

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Material properties

Nonlinear and/or anisotropic

permeability

Anisotropic conductivity

Core loss model

Steinmetz approach
electrical steel
power ferrite

Solid or lamination model

Scaling of B-H curve

Temperature dependent

CADFEM 2017 - 12 -
User Friendly Extraction of Steinmetz Coefficients

Select Electrical Steel or Power

Ferrite

Select extraction method

Core loss versus frequency
Core loss at one frequency
Irons conductivity needed
Lamination thickness needed

Input datasheet data

from supplier
Manual
csv, txt import
Sheet scan

Automatic calculation of coefficients

Automatic update in material properties

CADFEM 2017 - 13 -
Simulation Dimensionality

2D Simulation
Planar B-field
General machine sizing

2.5D for skewing approximation

Stepwise approximation

3D
Full flexibility
Detailed eddy current paths
End effects (Stray fields)
Non planar flux

CADFEM 2017 14
Since R17: Time Decomposition Method

HPC-Method for transient magnetic

T1 Tk
designs
Matrix Size
k Time Steps
Simultaneous calculation of k time n Parallel
X k Distribued Tasks
steps
N-Tasks containing k-time steps each
N-Tasks can be distibuted in DMP T1

mode T2

T3

T(k-2)

T(k-1)

T(k)

Source: ANSYS Inc.

CADFEM 2017
Periodic TDM enhancement R18
Periodic TDM
is only solved for 1 period

Torque

Currents

CADFEM 2017
Periodic TDM enhancement R18: Example

Synchronous generator
350,000 elements, 2nd order
elements 20ms
Eddy current in bars

3 Simulation cases:
8 cores HPC (no-TDM) over 10
electrical periods
112 cores HPC (TDM general
transient) over 10 electrical periods
112 cores HPC (TDM periodic) solving
just 1 electrical period
# of cores HPC Method Used Simulation time Speed up
8 No-TDM 151h45min -
General Transient
112 22h53min 6.6
TDM
Periodic
112 7h33 20
TDM
CADFEM 2017
Coupled Circuit-Motor Analysis in ANSYS Maxwell

Maxwell includes circuit editor

Sources
Passive elements (R-L-C)
Diodes
Switches

Source CADFEM
Couple EM-field to Circuit
Dedicated elements
Winding

CADFEM 2017 - 18 -
System Analysis of Electric Machines

Why SIMPLORER?
Detailed switch models
(Semiconductor)
Control Loops
Terminal coupling to other domains

System simulation using ANSYS

Simplorer
Embedded motor model
PE-Circuit
Control Source CADFEM
Co-simulation with
Simulink and Maxwell
Other Domains
Mechanical
Thermal

CADFEM 2017 - 19 -
Simplorer: Electric Powertrain System with Thermal Simulation

Heat-Sink + Fan
Model Extraction from CFD

Motor
Magnetic FEM
Power Transistor
Co-simulation
Electrothermal
Characterisation

CADFEM 2017
Virtual Prototype: Simulation is Everywhere!

Electromagnetic is just Mechanical

one aspect of design Thermal / Stress

EADT also part of

Workbench environment
Thermal
Fluid-flow
Structural
CFD
Fluid Flow /
Coupled Simulation Thermal

CADFEM 2017 21
Stress & Fatigue Life

Centrifugal and magnetic forces

Nonlinear contact between magnet

and steel

Definition of rotor shape according to

Deformation
Stresses
Fatigue life

CADFEM 2017
Thermal Efficient Fluid Models

Components often cooled Oil flow channels

by fluid flow

Fluid flow by detailed CFD requires

computing power
ANSYS heat pipe model with semi-
analytical approach
Axial air flow
Objective: Reduce simulation time
maintaining global result accuracy Axial T-
gradient
Restriction: Exact knowledge of fluid
flow not of interest

Source: CADFEM GmbH

CADFEM 2017
Application Case: Thermal Integrity Simulation

Losses from EM-Simulation used as

realistic loads
Thermal analysis in Mechanical
Thermal analysis in Fluent

Automatic Mesh interpolation

2D-3D interpolation capability
Energy preserving

CADFEM 2017 25
Dynamic Temperature Dependent Coupled Demagnetization

1st thermal
Maxwell Transient iteration

3A current pulse

2nd thermal
First thermal iteration on original iteration

curve

Second iteration on lower level

CADFEM 2017 26
Coupling: Magnetostriction Analyses
Magnetic characteristic changes under mechanical stress
Applications:
Inverse
Vibration and noise Electro-magnetic
Magnetostriction Displacement Vector
+
analysis Solution Strain & Stress
Tensor
Transformers
Electrical machines
Actuators
Control devices Magnetic Force
Sensors and transducers + Magnetostriction Mechanical
Magnetostriction Structure Solution
Smart materials Force

Physical dimension changes due to magnetic field

CADFEM 2017
Example: Magnetostriction Analyses effecting forces of machines

Force Calculation on a Tooth Tip

Strain = f(H)
Suitable for NVH simulation

EM Force

EM Force + Magnetostriction

CADFEM 2017
Application Case: Vibroacoustic Calculation

CADFEM 2017 29
Parametric Simulation

What is the benefit of a single

simulation? Material Boundary Conditions
5-10% 1-20%

Variation gives most understanding

Geometric shape
Material Geometry Result
0.1-10% ??%
Current
Windings
Circuits
Controller Manufacturing Loads, Signals
5- 30% 0.1-50%

DoE, Optimization,
Robust Design

CADFEM 2017 30
www.cadfemukandireland.com/events

CADFEM 2017 31
 Thank you!

Questions ?
(please use the chat)

CADFEM 2017 footer 32

Germany
CADFEM GmbH Office Berlin Office Dortmund Office Hanover
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T +43 (0) 1 5877073
info@cadfem.at

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Switzerland
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info@cadfem.ch

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