ANSYS Maxwell + CFD + structure 虎門科技股份有限公司 CAE 事業部 李奇錄 1
ANSYS 機電 系統解決方案 System Circuit Component ANSYS Workbench Electrical Magnetic Fluid Mechanical Thermal Acoustic 2
Maxwell 設計流程 場域耦合 ANSYS CFD Fluent RMxprt 馬達設計 HFSS Maxwell 2-D/3-D 電磁元件 ANSYS Mechanical 熱 / 應力 PExprt 磁力 場域求解 模型生成 3
ANSYS Multiphysics Workflow Analytical Motor Design Geometry Winding Materials Vibration Analysis Modal Harmonic Structural Analysis Stress Deformation Electromagnetic Force - FFT Electromagnetic Forces Temperature AutoSetup For FEA FE Motor Analysis Efficiency Inductance, Torque Optimization Temp. Feedback Thermal FE Analysis Temp Distribution EM Losses Losses Temp. CFD Analysis Temp Distribution External Cooling Convective Coefficients 4
ANSYS Multiphysics Simulation Example From electromagnetic fields to heat, cooling, and stress Electromagnetic field 5 Thermo-fluid Heat transfer Stress
Loss of Motors Classified by loss causes Classified by parts 6 Resistance loss Copper loss Eddy current loss Stray load loss Magnetic loss Hysteresis loss Mechanical loss Friction loss Windage loss Coil Copper Stranded loss Stray load loss Electrical steel sheet (core) Hysteresis loss Eddy current loss Permanent magnet Eddy current loss Other Friction loss Windage loss
Previous proposed workflow: one-way CFD Model Temperature Geometry 7 Maxwell Model Losses Mapped Losses
CFD Thermal Analysis: Results 8 Forced water cooling Forced air cooling Natural air cooling
Customers Requirements: Two Way Thermal Analysis No fluid mesh Use HTC Mechanic CFD Model al Temperature Deformation Temperature Geometry 9 Losses Maxwell Model Mapped Losses
Customers Requirements : Two Way CFD Thermal Analysis, R14 CFD Model Temperature Geometry 10 Losses Maxwell Model Mapped Losses
馬達噪音 11
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 12
簡介 在電機中噪聲和振動有許多來源. ANSYS 提供了優良的電機設計和分析能力 : : 電磁性能 電氣驅動性能 結構分析 熱分析 聲學分析 ANSYS 耦合技術允許映射電磁力於多物理場域分析 13
Noise Sources [1] Magnetic Mechanical Aerodynamic Electronic Radial Fluid Cooling Phenomena Switching Harmonics Slot Harmonics Self Auxiliaries Load Induced Magnetic Unbalance Stator Rotor Couplings Modes of Vibration Bearings Balancing Static Eccentricity Foundation Audible Frequencies Dynamic Eccentricity Elliptical Rotor Surface Unbalanced Rotor 20 Hz 60 Hz 261.63 Hz 4.186kHz 5 khz 20 khz 14 [1] P. Vigayraghavan, R. Krishnan, Noise in Electric Machines: A Review, IEEE, 1998
電磁設計與分析 ANSYS Machine Design Methodology RMxprt: 計算額定機械性能 Maxwell: 在時域計算磁有限元分析 Simplorer: 耦合 RMxprt 及 Maxwell 協同模擬驅動設計. SINE1 SINE2 SINE3 TRIANG1 E1 IGBT1 D7 IGBT3 D9 IGBT5 D11 RphaseA PhaseA_in PhaseA_out RphaseB + V VM1 RphaseC PhaseB_in PhaseC_in PhaseB_out PhaseC_out E2 IGBT2 D8 IGBT4 D10 IGBT6 D12 MotionSetup1_in 0 MotionSetup1_out w + V_ROTB1 15
V V V V V V ANSOFT Curve Info SINE1.VAL TR SINE2.VAL TR SINE3.VAL TR TRIANG1.VAL TR Maxwell Simplorer 模擬模型 2D IPM (Interior Permanent Magnet) motor model created from RMxprt and Maxwell UDP (User Defined Primitive) for rotor Model V Model DModel1 SModel1 4 pole, 1500 RPM, 220 Volt DC bus. Two Control Strategies used: 6 step inverter In Maxwell PWM current regulated Cosimulation Maxwell with Simplorer + 110V LabelID=V32-0 + 110V LabelID=V33 - D40 S_46 D34 D35 D41 S_47 D42 S_48 D36 D37 D43 S_49 D44 S_50 D38 D39 LabelID=VIA 0.000512893H*Kle 2.00694ohm LPhaseA LA RA LabelID=VIB 0.000512893H*Kle 2.00694ohm LPhaseB LB RB LabelID=VIC 0.000512893H*Kle 2.00694ohm LPhaseC LC RC D45 S_51 LabelID=IVc1 LabelID=IVc2 LabelID=IVc3 LabelID=IVc4 LabelID=IVc5 LabelID=IVc6 100ohm 100ohm 100ohm 100ohm 100ohm 100ohm R20 R21 R22 R23 R24 R25 + -1 + 1V LabelID=V14-1 + 1V LabelID=V15-1 + 1V LabelID=V16-1 + 1V LabelID=V17-1 + 1V LabelID=V18-1 1V LabelID=V19 0 SINE1 SINE2 SINE3 TRIANG1 E1 IGBT1 D7 IGBT3 D9 IGBT5 D11 E2 IGBT2 D8 V VM1 + IGBT4 D10 IGBT6 D12 RphaseA RphaseB RphaseC PhaseA_in PhaseB_in PhaseC_in MotionSetup1_in 0 PhaseA_out PhaseB_out PhaseC_out MotionSetup1_out 1.10 0.88 Sine Triangle Basic_Inverter1 w + 0.25 V_ROTB1 Y1-0.38 16-1.00-1.10 20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.50 40.00 Time [ms]
ANSOFT ANSOFT Maxwell Simplorer 模擬模型 SAS IP, Inc. 15.00 Torque Basic_Inverter1 SAS IP, Inc. 20.00 Currents Basic_Inverter1 Curve Info FEA1.TORQUE TR Curve Info RphaseA.I TR 15.00 RphaseB.I TR RphaseC.I TR 12.50 10.00 10.00 5.00 FEA1.TORQUE 7.50 Y1 [A] 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 Time [ms] -20.00 20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.50 40.00 Time [ms] 17
力的計算 用氣隙磁通密度計算力 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) 18
Edge Force Density in Maxwell 10.00 Tangential Force on Tooth Tips 02_DC-6step_IPM ANSOFT 5.00 0.00 Force (Newtons) -5.00-10.00-15.00-20.00-25.00 50.00 Curve Info ExprCache(ToothTipTangent_Full1) ExprCache(ToothTipTangent_2) ExprCache(ToothTipTangent_3) ExprCache(ToothTipTangent_4) ExprCache(ToothTipTangent_5) ExprCache(ToothTipTangent_6) -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 -0.00-50.00 Force (Newtons) -100.00-150.00-200.00 Curve Info ExprCache(ToothTipRadial_Full1) ExprCache(ToothTipRadial_2) ExprCache(ToothTipRadial_3) ExprCache(ToothTipRadial_4) ExprCache(ToothTipRadial_5) ExprCache(ToothTipRadial_6) -250.00 0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 Time [ms] 19
偏心模型 Left Side Tooth Right Side Tooth 20
轉子偏移 0%, 25%, 50% 偏心之電磁力的參數研究 可用多核心求解模型 呈現 : 於右方齒型上之徑向力 FFT of 徑向力 21
邊端受力密度, 50% 偏心 22
50% 偏心 : 徑向和切線力在左邊及右邊 0.00 Radial Tooth Tip Forces ANSOFT 15.00 Tangential Tooth Tip Forces ANSOFT 10.00-50.00 5.00-100.00 0.00 Force (N) -150.00 Force (N) -5.00-10.00-200.00-15.00-250.00 Curve Info Radial Force Small Gap Radial Force Large Gap -300.00 20.00 22.50 25.00 27.50 30.00 Time [ms] 32.50 35.00 37.50 40.00-20.00-25.00 Curve Info Tangential Force Small Gap Tangential Force Large Gap -30.00 20.00 22.50 25.00 27.50 30.00 Time [ms] 32.50 35.00 37.50 40.00 23
ANSYS Force Mapping 24
Force Mapping Direct Force Mapping Electromagnetic forces from Maxwell to Mechanical by linking systems in Workbench Transient Analysis for Stress prediction 25
Direct Force Mapping Scenario: Study the effect of Rotor Eccentricity Case 1: 0% Eccentricity No misalignment Case 2: 50 % Eccentricity Eccentricity amount is set to 50% of gap width Creates unbalanced electromagnetic forces Peak Edge Force Density 1.5e6 N/m 2 26 Peak Edge Force Density 1.9e6 N/m 2
Directional Deformation Radial Max Deformation vs time Case 1 0% Eccentricity 27 Case 2 50 % Eccentricity
Von Misses Stress Max Stresses vs time Case 1 0% Eccentricity 28 Case 2 50 % Eccentricity
ANSYS Harmonic Analysis 29
模態分析 : 共振頻率 Mode #1, 8502 Hz Mode #2, 8708 Hz Mode #3, 8708 Hz 前四個自然頻率, 相應的模式形狀 30 Mode #4, 9080 Hz
Why Harmonic Analysis 確保可以在不同頻率的正弦負載設計 必須要可避免共振響應 確認聲音響應 Boundary Conditions Input Forces Appling harmonic forces from Maxwell into ANSYS Mechanical 31
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 32
Harmonic Response Contour plot Amplitude distribution of the displacements at a specific frequency, Deformation plot at 8710 Hz 33
ANSYS Acoustics 34
ANSYS 中的聲學功能 聲學研究為聲波在介質中的產生 傳播 吸收 反射. 聲學問題可以認定義為 : Vibro-Acoustics: 結構產生的聲音 (ANSYS Mechanical) Aero-Acoustics : 空氣動力學產生的聲音 (ANSYS CFD) 35
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 36
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) 37
Acoustic Analysis Pressure Plot 38
Acoustic Analysis Pressure Plot 0.5 m Pres_1 Pres_2 Pres_3 Pressure vs Freq Pressure (Pa) 39 Freq(Hz)
Appendix: ANSYS 14 版場域映射能力 Maxwell 2D/3D Electrostatic Magnetostatic Eddy Current Magnetic Transient Electric Transient ANSYS Static/Transient Structural(Two-Way Link) ANSYS Static/Transient Structural One-Way Link (Maxwell upstream) Maxwell 2D/3D Electrostatic Magnetostatic Eddy Current Magnetic Transient Electric Transient 40 ANSYS Static/Transient Thermal Two-Way Link ANSYS Static/Transient Thermal One-Way Link (Maxwell upstream)
Appendix: ANSYS 14 版場域映射能力 Maxwell 2D/3D Electrostatic Magnetostatic Eddy Current Magnetic Transient Electric Transient Fluent Steady State (Thermal link) Two-Way Link Fluent Transient (Thermal link) One-Way Link (Maxwell upstream) 41
Thank You 42