Electromagnetic Force Couplingin - ANSYS PDF

Electromagnetic Force
Coupling in Electric Machines
Mark Solveson, Cheta Rathod, Mike Hebbes,
Gunjan Verma, Tushar Sambharam
ANSYS, Inc.
1 © 2011 ANSYS, Inc. September 6, 2011
Introduction
• Low noise regulation
– Aimed at reduction in noise pollution
• Comfort Criteria
– Noise causes discomfort and fatigue
– Noise suppression demonstrates
technological/marketing edge
• Component Failure
– Sensitivity of structure to acoustic resonances
• The above Applies to many Industry sectors:
– Transportation, Power, Environmental, Building services
Introduction
• Noise and vibration in electric machines come from
many sources.
• ANSYS provides excellent capabilities for the design and
analysis of electric machines:
– Electromagnetic performance
– Electric Drive performance
– Structural analysis
– Thermal analysis
– Acoustics analysis
• ANSYS field coupling technology allows mapping of
electromagnetic forces for Mechanical analysis
Machine Types
• Different machines may have different considerations
depending on their architecture or control strategies.
– Primary Forces are in‐plane (radial and tangential)
• Single and Three Phase Induction Machines.
• PM Synchronous Machines (Surface Mount, IPM).
• Switched reluctance machines
– Primary force are Axial
• Axial Flux Machines
Noise Sources [1]
Magnetic Mechanical Aerodynamic Electronic
Fluid Cooling Switching
Radial Phenomena Harmonics
Self Auxiliaries Load Induced
Slot
Harmonics
Couplings
Magnetic Stator Rotor
Unbalance
Modes of Foundation
Vibration
Static
Bearings Balancing
Eccentricity
Dynamic
Eccentricity
Unbalanced
Rotor
Audible Elliptical
Frequencies Rotor Surface
20 Hz 60 Hz 261.63 Hz 4.186kHz 5 kHz 20 kHz
[1] P. Vigayraghavan, R. Krishnan, “Noise in Electric Machines: A Review,” IEEE, 1998
ANSYS Machine Model
Electromagnetic Design and Analysis
• ANSYS Machine Design Methodology
– RMxprt: calculate rated performance for machine
– Maxwell: Calculate detailed magnetic FEA of machine in time
domain
– Simplorer: Calculate detailed drive design with coupled
cosimulation with either RMxprt or Simplorer.
SINE1 SINE2 SINE3
TRIANG1
IGBT1 D7 IGBT3 D9 IGBT5 D11

E1
RphaseA
PhaseA_in PhaseA_out
RphaseB
PhaseB_in PhaseB_out
+
V
RphaseC
VM1
PhaseC_in PhaseC_out
MotionSetup1_in
MotionSetup1_out
E2
D8
D10 IGBT6 D12
IGBT2
IGBT4 0

+
V_ROTB1
Machine Model in Maxwell ‐ Simplorer
2D IPM (Interior Permanent Magnet) motor model created from RMxprt and
Maxwell UDP (User Defined Primitive) for rotor Model
DModel1
V
Model
SModel1
D40 D42 D44
• 4 pole, 1500 RPM, 220 Volt DC bus.
V
S_46 D35 S_48 D37 S_50 D39
• Two Control Strategies used: +
-
110V
LabelID=V32
LabelID=VIA
0.000512893H*Kle
LA
2.00694ohm
RA
LPhaseA
• 6 step inverter – In Maxwell 0
LabelID=VIB
0.000512893H*Kle
LB
2.00694ohm
RB
LPhaseB
+ LabelID=VIC
• PWM current regulated – Cosimulation
110V
LabelID=V33 0.000512893H*Kle 2.00694ohm LPhaseC
-
LC RC
D41 D43 D45
Maxwell with Simplorer LabelID=IVc1 LabelID=IVc2 LabelID=IVc3 LabelID=IVc4 LabelID=IVc5 LabelID=IVc6
V
S_47 S_49 S_51 100ohm 100ohm 100ohm 100ohm 100ohm 100ohm
D34 D36 D38
R20 R21 R22 R23 R24 R25
+ -1 + -1 + -1 + -1 + -1 + -1
1V 1V 1V 1V 1V 1V
LabelID=V14 LabelID=V15 LabelID=V16 LabelID=V17 LabelID=V18 LabelID=V19
SINE1 SINE2 SINE3
TRIANG1
IGBT1 D7 IGBT3 D9 IGBT5 D11

E1
RphaseA
PhaseA_in PhaseA_out
RphaseB
PhaseB_in PhaseB_out
+
V
RphaseC Sine Triangle Basic_Inverter1 ANSOFT

1.10
VM1
PhaseC_in PhaseC_out Curve Info

SINE1.VAL
TR
SINE2.VAL
0.88 TR
SINE3.VAL
MotionSetup1_in TR
MotionSetup1_out TR
TRIANG1.VAL
E2
D8
D10 IGBT6 D12
IGBT2
IGBT4 0

0.25
+
Y1
V_ROTB1
-0.38
8 © 2011 ANSYS, Inc. September 6, 2011 -1.00
-1.10
20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.50 40.00
Time [ms]
Machine Model in Maxwell ‐ Simplorer
SAS IP, Inc. Torque Basic_Inverter1 ANSOFT SAS IP, Inc. Currents Basic_Inverter1 ANSOFT
15.00 20.00
Curve Info Curve Info
FEA1.TORQUE RphaseA.I
TR TR
RphaseB.I
TR
15.00 RphaseC.I
TR
12.50
10.00
10.00
5.00
FEA1.TORQUE
Y1 [A]
7.50
0.00
-5.00
5.00
-10.00
2.50
-15.00
0.00
20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.50 40.00 -20.00
Time [ms] 20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.50 40.00
Tim e [ms]
Force Calculations
• Force calculation using air gap flux density
• Maxwell Stress Tensor
– Force calculation at a point on the stator.
– Force on a line in the airgap
– Force on a line co‐linear with the stator tooth
• Edge Force Density
– Default field quantity available in Maxwell
– Can be used for creating lumped force
calculations on tooth tips
• Automatic Force mapping from Maxwell to
ANSYS Mechanical. (2D‐2D, 2D‐3D, 3D‐3D)
Edge Force Density in Maxwell
Tangential Force on Tooth Tips 02_DC-6step_IPM ANSOFT
10.00
5.00
0.00
-5.00
Force (Newtons)
-10.00
-15.00
Curve Info
ExprCache(ToothTipTangent_Full1)
-20.00 ExprCache(ToothTipTangent_2)
ExprCache(ToothTipTangent_3)
-25.00
-30.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
Time [ms]
Radial Force on Tooth Tips 02_DC-6step_IPM ANSOFT

50.00
-0.00
-50.00
Force (Newtons)
-100.00
-150.00
Curve Info
ExprCache(ToothTipRadial_Full1)
ExprCache(ToothTipRadial_2)
-200.00
-250.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
Time [ms]
Eccentricity Model
Left Side Right Side
Tooth Tooth
Parametric Study of Eccentricity
Electromagetic Force
• Rotor missaligned
0%, 25%, 50%
• Solved
simultaneously on
multi‐core computer
• Shown: Radial Force
on Right Tooth Tip
• FFT of Radial Force
Edge Force Density, 50% Eccentricity
50% Eccentricity: Radial and Tangential
Force on Right Side and Left Side Tooth
Radial Tooth Tip Forces ANSOFT Tangential Tooth Tip Forces ANSOFT
0.00 15.00
10.00
-50.00
5.00
-100.00 0.00
-5.00
Force (N)
Force (N)
-150.00
-10.00
-200.00 -15.00
-20.00
-250.00
Curve Info Curve Info
-25.00
Radial Force Small Gap Tangential Force Small Gap
Radial Force Large Gap Tangential Force Large Gap
-300.00 -30.00
20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.50 40.00 20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.50 40.00
Time [ms] Time [ms]
ANSYS Force Mapping
Two Approaches
• Direct Force Mapping
– Electromagnetic forces from Maxwell to
Mechanical by linking systems in
Workbench
– Transient Analysis for Stress prediction
• Lumped Force Mapping
– Tooth Tip objects created for mapping
calculated lumped force using
‘EdgeForceDensity’ in Maxwell.
– Apply these lumped forces manually
or through APDL Macro
– Further harmonic and Noise Analysis
Approach 1 ‐ Direct Force Mapping
Scenario: Study the effect of Rotor Eccentricity
– Case 1: 0% Eccentricity
• No misalignment
Peak Edge Force Density 1.5e6 N/m2
– Case 2: 50 % Eccentricity
• Eccentricity amount is set to
50% of gap width
• Creates unbalanced
electromagnetic forces
18 © 2011 ANSYS, Inc. September 6, 2011 Peak Edge Force Density 1.9e6 N/m2

Directional Deformation Radial
This image cannot currently be display ed.
Max Deformation vs time
• Case 1 0% Eccentricity
19 © 2011 ANSYS, Inc. September 6, 2011 • Case 2 50 % Eccentricity

Von Misses Stress
Max Stresses vs time
• Case 1 0% Eccentricity
• Case 2 50 % Eccentricity
Results: Comparison
Higher the amount of eccentricity, higher is the variation of
electromagnetic forces, causing deformation of stator,
vibration and noise
• Total Deformation
– Deformation higher for eccentric model
Stresses at time=12 ms
• Peak Stresses
– Stator Stresses are non symmetric and higher for eccentric model where the air
gap is minimum
Approach 2 Lumped Force Mapping
Electromagnetic Forces
Export forces
ANSYS Lumped Forces in Time Domain
Maxwell
Perform FFT in Maxwell
Workbench
Real/Imaginary Forces
Flow Chart for In Frequency Domain
Noise Prediction APDL in Workbench
ANSYS
Harmonic Response
Mechanical
APDL in Workbench
ANSYS
Extract Acoustic Pressures
Acoustics
ANSYS Harmonic Analysis
Modal Analysis: Get Resonant Frequencies
Mode #1, 8502 Hz Mode #2, 8708 Hz
Mode #3, 8708 Hz
First four Natural Frequency and
corresponding mode shapes
Mode #4, 9080 Hz
Why Harmonic Analysis
• To make sure that a given design can withstand sinusoidal loads at
different frequencies
• To detect resonant response and avoid it if necessary (by using dampers,
for example)
• To determine Acoustic response
Boundary Conditions
Input Forces
Appling harmonic forces from
Maxwell into ANSYS Mechanical
Harmonic Response – Bode plot
Frequency response at a selected node location of the model.
Helps determine that
Max Amplitude (1.7mm)
occurs at 8710 Hz on the
selected vertex
Harmonic Response – Contour plot
Amplitude distribution of the displacements at a specific frequency,
Deformation plot at 8710 Hz
ANSYS Acoustics
Acoustics Capabilities in ANSYS
• Acoustics is the study of the generation, propagation, absorption,
and reflection of sound pressure waves in an acoustic medium.
• Acoustic problems can be identified as
– Vibro‐Acoustics: Sound generated structurally (ANSYS Mechanical)
– Aero‐Acoustics : Sound generated aerodynamically (ANSYS CFD)
Modeling Aero‐Acoustics (ANSYS CFD)
• Free‐Space Problem with no solid surfaces:
– sound generated from turbulence, jet noise
• Free‐Space Problem with solid surfaces:
– Fan noise, airframe noise, rotor noise, boundary layer noise,
cavity noise
• Interior problem:
• Duct noise, mufflers, ducted fan noise
Sound pressure fluctuations
Vibro‐Acoustics (ANSYS Mechanical)
Computing the acoustic field radiated by a vibrating structure
• Structure modeled in ANSYS Mechanical where vibration
patterns are calculated (Modal, Harmonic Analysis). Applied
loads are obtained from Maxwell.
• Vibration patterns used as boundary conditions to compute
acoustic field radiated by structure (ANSYS MAPDL, ANSYS
Acoustic Structures‐ACTRAN)
ANSYS Acoustics Structure
ANSYS Acoustics
Structures computes
noise radiated by
vibrating structures.
From Harmonic
Vibrations to Noise
Estimates.
ANSYS Acoustics
Structures integrates with
your current simulation
tools.
Acoustic Analysis – Pressure Plot
Acoustic Analysis – Pressure Plot
0.5 m
Pres_1 Pres_2
Pres_3 Pressure vs Freq
Pressure (Pa)
34 © 2011 ANSYS, Inc. September 6, 2011 Freq(Hz)

Summary
• Investigated different noise sources for electric machines
• Demonstrated an integrated approach from Electromagnetics
to Structural to Acoustics.
• Showed the effects of static eccentricity on stator tooth forces,
deformation and stresses.
• Performed modal analysis to find the acoustic resonances
Future Work:
• Investigation of different noise scenarios (machine types, drives)
• Include more mechanical details (windings, housing, etc)
• Expand harmonic analysis to include higher frequency content of forces
• Further investigation of Aero‐acoustics with ANSYS CFD
References
– P. Vijayraghavan, R. Krishnan, “Noise in electric machines: A Review”, IEEE, 1998
– K. Shiohata, R. Kusama, S.Ohtsu, T.Iwatsubo, “The Study on Electromagnetic Force
Induced Vibration and Noise from a Normal and Eccentric Universal Motors”, PIERS
Proceedings, 2011.
– S. Fink, S. Peters, “Anosft ‐ Noise Prediction for Electrical Motors,” CADFEM/ANSYS
Presentation, 2011.
– Wei Wang, Quanfeng Li, Zhihuan Song, Shenbo Yu, Jian Chen, Renyuan Tang, “Three‐
Dimensional Field Calculation and Analysis of Electromagnetic Vibration and Noise for Disk
Permanent Magnet Synchronous Machines”, Shenyang University of Technology, China.
– R. Belmans, D. Verdyck, W. Geysen, R. Findlay, “Electro‐Mechanical Analysis of the Audible
Noise of an Inverter‐Fed Squirrel‐Cage Induction Motor”, IEEE, 2008.
– M. Anwar, I. Husain, “Design Perspectives of a Low Acoustic Noise Switched Reluctance
Machine”, IEEE, 2000.
– S. Huang, M. Aydin, T.A. Lipo, “Electronmagnetic Vibration and Noise Assessment for
Surface Mounted PM Machines,” IEEE, 2001.
– Rakib Islam, Iqbal Hussain, “Analytical Model for Predicting Noise and Vibration in
Permanent Magnet Synchronous Motors,” IEEE 2009.
– Pragasen Pillay, William (Wei) Cai, “An Investigation into Vibration in Switched Reluctance
Motors,” IEEE Transactions on Industry Applications, Vol. 35, NO. 3, May/June/ 1999.
Thank You
Title and Abstract
Electromagnetic Force Coupling in Electric Machines
Including Stress, Deformation, and Acoustic Analysis.
Understanding the impact of electromagnetic forces on
noise generation for electric machines can include many
factors. This presentation will review these issues and
illustrate electromagnetic forces, stress, deformation, and
acoustic coupling in ANSYS Workbench. An example
showing automatic mapping of magnetic time‐domain
forces, and a comparison of stresses for different rotor
eccentricities will be shown.
Presentation Outline (Goal 30 total Slides)
1. Introduction
2. Literature review – what are the noise comonents for electric machines
a. Noise Sources, examples
b. Acoustic Definition, examples
3. EM Motor Methodology
a. RMxprt to Maxwell, Simplorer
b. Force calculations
c. Eccentricity Model
4. Mechanical Analysis
a. 2D (3D?) transient force mapping results
b. Discussion of FFT approaches (by inspection or 3rd party tools/scripts)
c. 2D (3D?) harmonic Analysis
5. Acoustic analysis
a. General capabilities (acoustic elements, Actran coupling? )
b. Results for stator lamination
Noise Sources
• Magnetic
– The interaction of magnetic fields and currents in the machine cause
electromagnetic torque and thus rotation of the rotor.
– Evaluation of the radial and tangential forces on the tooth tips are important.
• This can be accomplished through evaluation of the air gap flux density, or using
Force Density field calculations available within Maxwell.
– If one of the radial force frequencies coincides with the natural frequency of the
machine, resonance occurs leading to acoustic noise.
• Mixed product of stator and rotor winding space harmonics.
• Slot Harmonics
• Rotor Eccentricity: improper rotor alignment causing unbalanced magnetic
forces on the stator.
– Lamination vibration due to magnetorestrictive forces (worst when not stacked
properly)
• Electronic
– Switching noise
• Inverter PWM frequencies can be in audible range.
40 – Current through the winding –
© 2011 ANSYS, Inc. September 6, 2011 Lorentz forces
Noise Sources
• Mechanical
– Self resonance – natural resonance frequencies
• Closed form equations
• FEA
– Load induced
• Coupling of machine to load, and mounting.
– Auxiliaries
• Bearing Vibration
• Brush commutators
– Chattering
• Intra‐lamination
• Function of Bolt force
• Involves 3D Mechanical transient vibration analysis
– Manufacturing asymmetries of the rotor and stator‐ nonuniform air gap
– Stator winding which are not installed properly
• Aero‐Dynamics
41 © 2011 ANSYS, Inc.
September 6, 2011
– ANSYS CFD
Machine Model in Maxwell
• VB script Fields Calculator to create Radial and
Tangential Force Expressions from
EdgeForceDensity
• VB script Calculates Radial and Tangential
Force on Tooth Tips
• Allows only force on edge that neighbors non
ferrous objects
• ‘Half’ teeth force components added together
• Add to Expression Cache
Harmonic Analysis Overview
A technique to determine the steady state response of a structure to
sinusoidal (harmonic) loads of known frequency.
Input:
• Harmonic loads (forces, pressures, and imposed displacements) of known
magnitude and frequency. (Obtained from Maxwell)
• May be multiple loads all at the same frequency.
Output:
• Harmonic displacements at each DOF, usually out of phase with the applied
loads.
• Other derived quantities, such as stresses and strains.
ANSYS Acoustics
• Structural‐borne noise (one way Vibro‐Acoustics)
– ANSYS Acoustics Structures (FFT’s ACTRAN Solver)
• Vibro‐Acoustics
– ANSYS Mechanical (APDL Solver)
• Aero‐Acoustics
– ANSYS CFD
• Nonlinear fluid‐structure interaction
– ANSYS CFD + ANSYS Mechanical
Aero‐Acoustics ANSYS CFD Approaches
• Direct calculation:
– Resolve the acoustic pressure fluctuations as part of the CFD
solution
• Couple CFD with specialized acoustics codes, Boundary
Element Methods (BEM), Hybrid zonal methods
– Acoustic waves are not tracked with CDF solution
– Calculate wave propagation using specialized codes (ACTRAN,
SYSNOISE)
Aero‐Acoustic simulation of Automotive
Front End Module cooling fans
by using FLUENT’s Acoustic module
Courtesy of Hyundai MOBIS, Korea
Computational domain
Geometry of Cooling Fans
Sound pressure
fluctuations
Pressure Contours Flow Pathlines through calculated at the
receiver position
Subwoofer Example (ANSYS CFD)
(non‐linear fluid with structure)
Fluid‐Structure Interaction Solution Transient Pressures
Acoustic ‐ Structural Example ‐ Coupled
Target Object:
Nested Cylindrical
Acoustic Energy Cans
Source
Scattered Acoustic
Radiation
Animation of Acoustic
FEA Model
quarter Symmetry
Pressure (Pa)
Hemispherical
Domain

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Electromagnetic Force

Magnetic Mechanical Aerodynamic Electronic

20 Hz 60 Hz 261.63 Hz 4.186kHz 5 kHz 20 kHz

SINE1 SINE2 SINE3

IGBT1 D7 IGBT3 D9 IGBT5 D11

D40 D42 D44

D41 D43 D45

Maxwell with Simplorer LabelID=IVc1 LabelID=IVc2 LabelID=IVc3 LabelID=IVc4 LabelID=IVc5 LabelID=IVc6

SINE1 SINE2 SINE3

IGBT1 D7 IGBT3 D9 IGBT5 D11

RphaseC Sine Triangle Basic_Inverter1 ANSOFT

PhaseC_in PhaseC_out Curve Info

8 © 2011 ANSYS, Inc. September 6, 2011 -1.00

Radial Force on Tooth Tips 02_DC-6step_IPM ANSOFT

18 © 2011 ANSYS, Inc. September 6, 2011 Peak Edge Force Density 1.9e6 N/m2

19 © 2011 ANSYS, Inc. September 6, 2011 • Case 2 50 % Eccentricity

This image cannot currently be display ed.

This image cannot currently be display ed.

This image cannot currently be display ed.

34 © 2011 ANSYS, Inc. September 6, 2011 Freq(Hz)

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