ElectromagneticForce CouplinginElectricMachines

MarkSolveson,Cheta Rathod,MikeHebbes, Gunjan Verma,Tushar Sambharam ANSYS,Inc.

1 2011ANSYS,Inc. October24,2011

Introduction
Lownoiseregulation
Aimedatreductioninnoisepollution

ComfortCriteria
Noisecausesdiscomfortandfatigue Noisesuppressiondemonstrates technological/marketingedge

ComponentFailure
Sensitivityofstructuretoacousticresonances

TheaboveAppliestomanyIndustrysectors:
Transportation,Power,Environmental,Buildingservices
2 2011ANSYS,Inc. October24,2011

Introduction
Noiseandvibrationinelectricmachinescomefrom manysources. ANSYSprovidesexcellentcapabilitiesforthedesignand analysisofelectricmachines:
Electromagneticperformance ElectricDriveperformance Structuralanalysis Thermalanalysis Acousticsanalysis

ANSYSfieldcouplingtechnologyallowsmappingof
electromagneticforcesforMechanicalanalysis
3 2011ANSYS,Inc. October24,2011

MachineTypes
Differentmachinesmayhavedifferentconsiderations dependingontheirarchitectureorcontrolstrategies.
PrimaryForcesareinplane(radialandtangential) SingleandThreePhaseInductionMachines. PMSynchronousMachines(SurfaceMount,IPM). Switchedreluctancemachines PrimaryforceareAxial AxialFluxMachines

2011ANSYS,Inc.

October24,2011

NoiseSources[1]
Magnetic
Radial
Self Auxiliaries LoadInduced

Mechanical

Aerodynamic
FluidCooling Phenomena

Electronic
Switching Harmonics

Slot Harmonics Magnetic Unbalance

Stator Rotor Couplings

Modesof Vibration Bearings Balancing Static Eccentricity

Foundation

Dynamic Eccentricity

Audible Frequencies

Unbalanced Rotor Elliptical RotorSurface

20Hz
5

60Hz

261.63Hz
October24,2011

4.186kHz

5kHz

20kHz

2011ANSYS,Inc.

[1]P.Vigayraghavan,R.Krishnan,NoiseinElectricMachines:AReview,IEEE,1998

ANSYSMachineModel

2011ANSYS,Inc.

October24,2011

ElectromagneticDesignandAnalysis
ANSYSMachineDesignMethodology
RMxprt:calculateratedperformanceformachine Maxwell:CalculatedetailedmagneticFEAofmachineintime domain Simplorer:Calculatedetaileddrivedesignwithcoupled cosimulation witheitherRMxprtorMaxwell.

SINE1

SINE2

SINE3

TRIANG1

IGBT1 E1

D7

IGBT3

D9

IGBT5

D11

RphaseA PhaseA_in RphaseB PhaseB_in RphaseC PhaseC_in MotionSetup1_in E2 D8 IGBT2 IGBT4 D10 IGBT6 D12 0 PhaseC_out MotionSetup1_out PhaseB_out PhaseA_out

V
VM1

V_ROTB1

2011ANSYS,Inc.

October24,2011

MachineModelinMaxwell Simplorer
2DIPM(InteriorPermanentMagnet)motormodelcreatedfromRMxprtand MaxwellUDP(UserDefinedPrimitive)forrotor
Model
V Model DModel1 D40 D42 D44 SModel1

4pole,1500RPM,220VoltDCbus. TwoControlStrategiesused: 6stepinverter InMaxwell PWMcurrentregulated Cosimulation MaxwellwithSimplorer

S_46

V D35

S_48

V D37

S_50

V D39

+ -

110V LabelID=V32 LabelID=VIA 0.000512893H*Kle LA 2.00694ohm RA LPhaseA

LabelID=VIB 0.000512893H*Kle LB

2.00694ohm RB

LPhaseB

+ -

110V LabelID=V33

LabelID=VIC 0.000512893H*Kle LC

2.00694ohm RC

LPhaseC

D41

D43

D45

D34

S_47

D36

S_49

D38

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

SINE1

SINE2

SINE3

TRIANG1

IGBT1 E1

D7

IGBT3

D9

IGBT5

D11

RphaseA PhaseA_in RphaseB PhaseB_in RphaseC

1.10

PhaseA_out PhaseB_out
Sine Triangle
Basic_Inverter1
Curve Info SINE1.VAL SINE2.VAL SINE3.VAL TRIANG1.VAL
ANSOFT

V
VM1

PhaseC_in MotionSetup1_in

PhaseC_out
TR

0.88

TR TR TR

E2 D8 IGBT2 IGBT4 D10 IGBT6 D12 0

MotionSetup1_out

V_ROTB1

0.25

2011ANSYS,Inc.

October24,2011

Y1 -0.38 -1.00 -1.10 20.00 22.50 25.00 27.50 30.00 Time [ms] 32.50 35.00 37.50 40.00

MachineModelinMaxwell Simplorer

SAS IP, Inc.

15.00

Torque

Basic_Inverter1
Curve Info
TR FEA1.TORQUE

ANSOFT

SAS IP, Inc.

20.00

Currents

Basic_Inverter1
Curve Info
TR TR RphaseA.I RphaseB.I RphaseC.I

ANSOFT

15.00
12.50

TR

10.00

10.00

5.00

FEA1.TORQUE

7.50

Y1 [A]
20.00 22.50 25.00 27.50 30.00 Time [ms] 32.50 35.00 37.50 40.00

0.00

-5.00
5.00

-10.00

2.50

-15.00

0.00

-20.00 20.00 22.50 25.00 27.50 30.00 Tim e [ms] 32.50 35.00 37.50 40.00

2011ANSYS,Inc.

October24,2011

ForceCalculations
Force calculationusingairgapfluxdensity Maxwell StressTensor
[9]

Forcecalculationatapointonthestator. Forceonalineintheairgap Forceonalinecolinearwiththestatortooth

Thisiscommonmethodinliterature.

EdgeForceDensity
DefaultfieldquantityavailableinMaxwell Canbeusedforcreatinglumpedforce
calculationsontoothtips

AutomaticForcemappingfromMaxwellto
ANSYSMechanical.(2D2D,2D3D,3D3D)
10 2011ANSYS,Inc. October24,2011

EdgeForceDensityinMaxwell
Tangential Force on Tooth Tips
10.00

02_DC-6step_IPM

ANSOFT

5.00

0.00

Force (Newtons)

-5.00

-10.00

-15.00
Curve Info ExprCache(ToothTipTangent_Full1)

-20.00

ExprCache(ToothTipTangent_2) ExprCache(ToothTipTangent_3) ExprCache(ToothTipTangent_4) ExprCache(ToothTipTangent_5) ExprCache(ToothTipTangent_6)

-25.00

-30.00 0.00 5.00 10.00 15.00 20.00 Time [ms] 25.00 30.00 35.00 40.00

Radial Force on Tooth Tips

50.00

02_DC-6step_IPM

ANSOFT

-0.00

-50.00 Force (Newtons)

-100.00

-150.00

Curve Info ExprCache(ToothTipRadial_Full1) ExprCache(ToothTipRadial_2) ExprCache(ToothTipRadial_3) ExprCache(ToothTipRadial_4) ExprCache(ToothTipRadial_5) ExprCache(ToothTipRadial_6)

-200.00

-250.00 0.00 5.00 10.00 15.00 20.00 Time [ms] 25.00 30.00 35.00 40.00

11

2011ANSYS,Inc.

October24,2011

EccentricityModel

LeftSide Tooth

RightSide Tooth

12

2011ANSYS,Inc.

October24,2011

ParametricStudyofEccentricity Electromagetic Force

Rotormissaligned 0%,25%,50% Solved simultaneouslyon multicorecomputer Shown:RadialForce onRightToothTip FFTofRadialForce

13

2011ANSYS,Inc.

October24,2011

EdgeForceDensity,50%Eccentricity

14

2011ANSYS,Inc.

October24,2011

50%Eccentricity:RadialandTangential ForceonRightSideandLeftSideTooth
0.00

Radial Tooth Tip Forces

ANSOFT

15.00

Tangential Tooth Tip Forces

ANSOFT

10.00 -50.00 5.00

-100.00

0.00

-150.00

-200.00

-250.00
Curve Info Radial Force Small Gap Radial Force Large Gap

Force (N)

Force (N)

-5.00

-10.00

-15.00

-20.00
Curve Info Tangential Force Small Gap Tangential Force Large Gap

-25.00

-300.00 20.00

22.50

25.00

27.50

30.00 Time [ms]

32.50

35.00

37.50

40.00

-30.00 20.00

22.50

25.00

27.50

30.00 Time [ms]

32.50

35.00

37.50

40.00

15

2011ANSYS,Inc.

October24,2011

ANSYSForceMapping

16

2011ANSYS,Inc.

October24,2011

TwoApproaches
DirectForceMapping
ElectromagneticforcesfromMaxwellto Mechanicalbylinkingsystemsin Workbench Maps2DEdgeForce,and 3DSurfaceforce TransientAnalysisforStressprediction

LumpedForceMapping
ToothTipobjectscreatedformapping calculatedlumpedforceusing EdgeForceDensityinMaxwell. Applytheselumpedforcesmanually orthroughAPDLMacro FurtherharmonicandNoiseAnalysis
17 2011ANSYS,Inc. October24,2011

Approach1 DirectForceMapping
Scenario:StudytheeffectofRotorEccentricity Case1:0%Eccentricity
Nomisalignment

Case2:50%Eccentricity
Eccentricityamountissetto 50%ofgapwidth Createsunbalanced electromagneticforces

PeakEdgeForceDensity1.5e6N/m2

18

2011ANSYS,Inc.

October24,2011

PeakEdgeForceDensity1.9e6N/m2

DirectionalDeformationRadial
This image cannot currently be display ed.

MaxDeformationvs time

Case10%Eccentricity
This image cannot currently be display ed.

19

2011ANSYS,Inc.

October24,2011

Case250%Eccentricity

This image cannot currently be display ed.

VonMissesStress
MaxStressesvs time

Case10%Eccentricity
This image cannot currently be display ed. This image cannot currently be display ed.

20

2011ANSYS,Inc.

October24,2011

Case250%Eccentricity

Results:Comparison
Highertheamountofeccentricity,higheristhevariationof electromagneticforces,causingdeformationofstator, vibrationandnoise

TotalDeformation
Deformationhigherforeccentric model

PeakStresses

Stressesattime=12ms

StatorStressesarenonsymmetricandhigherforeccentricmodelwheretheair gapisminimum

21

2011ANSYS,Inc.

October24,2011

Approach2LumpedForceMapping
ElectromagneticForces Exportforces ANSYS Maxwell LumpedForcesinTimeDomain PerformFFTinMaxwell Real/ImaginaryForces InFrequencyDomain APDLinWorkbench ANSYS Mechanical HarmonicResponse APDLinWorkbench ANSYS Acoustics
22 2011ANSYS,Inc. October24,2011

Workbench FlowChartfor NoisePrediction

ExtractAcousticPressures

ANSYSHarmonicAnalysis

23

2011ANSYS,Inc.

October24,2011

ModalAnalysis:GetResonantFrequencies

Mode#1,8502Hz

Mode#2,8708Hz

Mode#3,8708Hz

FirstfourNaturalFrequencyand correspondingmodeshapes

24

2011ANSYS,Inc.

October24,2011

Mode#4,9080Hz

WhyHarmonicAnalysis
Tomakesurethatagivendesigncanwithstandsinusoidalloadsat differentfrequencies Todetectresonantresponseandavoiditifnecessary(e.g.using mechanicaldampers,changingPWMfrequency,etc.) TodetermineAcousticresponse

BoundaryConditions

InputForces

Applingharmonicforcesfrom MaxwellintoANSYSMechanical
25 2011ANSYS,Inc. October24,2011

HarmonicResponse Bodeplot
Frequencyresponseataselectednodelocationofthemodel.

Helpsdeterminethat MaxAmplitude(1.7mm) occursat8710Hzonthe selectedvertex

26 2011ANSYS,Inc. October24,2011

HarmonicResponse Contourplot
Amplitudedistributionofthedisplacementsataspecificfrequency,

Deformationplotat8710Hz

27

2011ANSYS,Inc.

October24,2011

ANSYSAcoustics

28

2011ANSYS,Inc.

October24,2011

AcousticsCapabilitiesinANSYS
Acousticsisthestudyofthegeneration,propagation,absorption,
andreflectionofsoundpressurewavesinanacousticmedium.

Acousticproblemscanbeidentifiedas
VibroAcoustics:Soundgeneratedstructurally(ANSYSMechanical) AeroAcoustics :Soundgeneratedaerodynamically(ANSYSCFD)

29

2011ANSYS,Inc.

October24,2011

ModelingAeroAcoustics(ANSYSCFD)
FreeSpaceProblemwithnosolidsurfaces:
soundgeneratedfromturbulence,jetnoise

FreeSpaceProblemwithsolidsurfaces:
Fannoise,airframenoise,rotornoise,boundarylayernoise, cavitynoise

Interiorproblem:
Ductnoise,mufflers,ductedfannoise

Soundpressurefluctuations
30 2011ANSYS,Inc. October24,2011

VibroAcoustics(ANSYSMechanical)
Computingtheacousticfieldradiatedbyavibratingstructure StructuremodeledinANSYSMechanicalwherevibration patternsarecalculated(Modal,HarmonicAnalysis).Applied loadsareobtainedfromMaxwell. Vibrationpatternsusedasboundaryconditionstocompute acousticfieldradiatedbystructure(ANSYSMAPDL,ANSYS AcousticStructures)

31

2011ANSYS,Inc.

October24,2011

AcousticAnalysis PressurePlot
This image cannot currently be display ed.

This image cannot currently be display ed.

32

2011ANSYS,Inc.

October24,2011

AcousticAnalysis PressurePlot

0.5m

Pres_1

Pres_2

Pres_3

Pressurevs Freq

Pressure(Pa)

33

2011ANSYS,Inc.

October24,2011

Freq(Hz)

Summary
Investigateddifferentnoisesourcesforelectricmachines DemonstratedanintegratedapproachfromElectromagnetics
toStructuraltoAcoustics. Showedtheeffectsofstaticeccentricityonstatortoothforces, deformationandstresses. Performedmodalanalysistofindtheacousticresonances

FutureWork: Investigationofdifferentnoisescenarios(machinetypes,drives) Includemoremechanicaldetails(windings,housing,etc) Expandharmonicanalysistoincludehigherfrequencycontentofforces FurtherinvestigationofAeroacousticswithANSYSCFD

34

2011ANSYS,Inc.

October24,2011

References
[1] P.Vijayraghavan,R.Krishnan,Noiseinelectricmachines:AReview,IEEE,1998 [2] K.Shiohata,R.Kusama,S.Ohtsu,T.Iwatsubo,TheStudyonElectromagneticForceInducedVibrationandNoisefroma NormalandEccentricUniversalMotors,PIERSProceedings,2011. [3] S.Fink,S.Peters,AnsoftNoisePredictionforElectricalMotors,CADFEM/ANSYSPresentation,2011. [4] WeiWang,QuanfengLi,ZhihuanSong,ShenboYu,JianChen,RenyuanTang,ThreeDimensionalFieldCalculationand AnalysisofElectromagneticVibrationandNoiseforDiskPermanentMagnetSynchronousMachines,ShenyangUniversityof Technology,China. [5] R.Belmans,D.Verdyck,W.Geysen,R.Findlay,ElectroMechanicalAnalysisoftheAudibleNoiseofanInverterFedSquirrel CageInductionMotor,IEEE,2008. [6] M.Anwar,I.Husain,DesignPerspectivesofaLowAcousticNoiseSwitchedReluctanceMachine,IEEE,2000. [7] S.Huang,M.Aydin,T.A.Lipo,ElectronmagneticVibrationandNoiseAssessmentforSurfaceMountedPMMachines,IEEE, 2001. [8] RakibIslam,IqbalHussain,AnalyticalModelforPredictingNoiseandVibrationinPermanentMagnetSynchronousMotors, IEEE2009. [9] PragasenPillay,William(Wei)Cai,AnInvestigationintoVibrationinSwitchedReluctanceMotors,IEEETransactionson IndustryApplications,Vol.35,NO.3,May/June,1999.

35

2011ANSYS,Inc.

October24,2011

ThankYou

36

2011ANSYS,Inc.

October24,2011

ANSYSAcousticsStructure
ANSYSAcoustics Structurescomputes noiseradiatedby vibratingstructures. FromHarmonic Vibrations toNoise Estimates. ANSYSAcoustics Structuresintegrateswith yourcurrentsimulation tools.

37

2011ANSYS,Inc.

October24,2011

TitleandAbstract
ElectromagneticForceCouplinginElectricMachines IncludingStress,Deformation,andAcousticAnalysis. Understandingtheimpactofelectromagneticforceson noisegenerationforelectricmachinescanincludemany factors. Thispresentationwillreviewtheseissuesand illustrateelectromagneticforces,stress,deformation,and acousticcouplinginANSYSWorkbench. Anexample showingautomaticmappingofmagnetictimedomain forces,andacomparisonofstressesfordifferentrotor eccentricitieswillbeshown.
38 2011ANSYS,Inc. October24,2011

PresentationOutline(Goal30totalSlides)
1. 2. Introduction Literaturereview whatarethenoisecomonents forelectricmachines
a. b. NoiseSources,examples AcousticDefinition,examples RMxprttoMaxwell,Simplorer Forcecalculations EccentricityModel

3.

EMMotorMethodology
a. b. c.

4.

MechanicalAnalysis
a. 2D(3D?)transientforcemappingresults b. DiscussionofFFTapproaches(byinspectionor3rd partytools/scripts) c. 2D(3D?)harmonicAnalysis

5.

Acousticanalysis
a. Generalcapabilities(acousticelements,Actran coupling?) b. Resultsforstatorlamination

39

2011ANSYS,Inc.

October24,2011

NoiseSources
Magnetic
Theinteractionofmagneticfieldsandcurrentsinthemachinecause electromagnetictorque andthusrotationoftherotor. Evaluationoftheradialandtangentialforcesonthetoothtipsareimportant. Thiscanbeaccomplishedthroughevaluationoftheairgapfluxdensity,orusing ForceDensityfieldcalculationsavailablewithinMaxwell. Ifoneoftheradialforcefrequenciescoincideswiththenaturalfrequency ofthe machine,resonanceoccursleadingtoacousticnoise. Mixedproductofstatorandrotorwindingspaceharmonics. SlotHarmonics RotorEccentricity:improperrotoralignmentcausingunbalancedmagnetic forcesonthestator. Laminationvibrationduetomagnetorestrictiveforces(worstwhennotstacked properly)

Electronic
40

Switchingnoise InverterPWMfrequenciescanbeinaudiblerange. ANSYS,Inc. October 24,2011 2011 Current through the winding Lorentzforces

NoiseSources
Mechanical
Selfresonance naturalresonancefrequencies Closedformequations FEA Loadinduced Couplingofmachinetoload,andmounting. Auxiliaries BearingVibration Brushcommutators Chattering Intralamination FunctionofBoltforce Involves3DMechanicaltransientvibrationanalysis Manufacturingasymmetriesoftherotorandstator nonuniformairgap Statorwindingwhicharenotinstalledproperly

AeroDynamics
41 2011ANSYS,Inc. October24,2011 ANSYSCFD

MachineModelinMaxwell
VBscriptFieldsCalculatortocreateRadialand TangentialForceExpressionsfrom EdgeForceDensity VBscriptCalculatesRadialandTangential ForceonToothTips Allowsonlyforceonedgethatneighborsnon ferrousobjects Halfteethforcecomponentsaddedtogether AddtoExpressionCache

42

2011ANSYS,Inc.

October24,2011

HarmonicAnalysisOverview
Atechniquetodeterminethesteadystateresponseofastructureto sinusoidal(harmonic)loadsofknownfrequency. Input: Harmonicloads(forces,pressures,andimposeddisplacements)ofknown magnitudeandfrequency. (ObtainedfromMaxwell) Maybemultipleloadsallatthesamefrequency. Output: HarmonicdisplacementsateachDOF,usuallyoutofphasewiththeapplied loads. Otherderivedquantities,suchasstressesandstrains.

43

2011ANSYS,Inc.

October24,2011

ANSYSAcoustics
Structuralbornenoise(onewayVibroAcoustics)
ANSYSAcousticsStructures(FFTsACTRANSolver)

VibroAcoustics
ANSYSMechanical(APDLSolver)

AeroAcoustics
ANSYSCFD

Nonlinearfluidstructureinteraction
ANSYSCFD+ANSYSMechanical

44

2011ANSYS,Inc.

October24,2011

AeroAcousticsANSYSCFDApproaches
Directcalculation:
ResolvetheacousticpressurefluctuationsaspartoftheCFD solution CoupleCFDwithspecializedacousticscodes,Boundary ElementMethods(BEM),Hybridzonalmethods AcousticwavesarenottrackedwithCDFsolution Calculatewavepropagationusingspecializedcodes(ACTRAN, SYSNOISE)

45

2011ANSYS,Inc.

October24,2011

AeroAcousticsimulationofAutomotive FrontEndModulecoolingfans
byusingFLUENTsAcousticmodule
CourtesyofHyundaiMOBIS,Korea

Computationaldomain GeometryofCoolingFans

PressureContours
46 2011ANSYS,Inc. October24,2011

Soundpressure fluctuations FlowPathlines through calculatedatthe receiverposition

SubwooferExample(ANSYSCFD) (nonlinearfluidwithstructure)

FluidStructureInteractionSolution

TransientPressures

47

2011ANSYS,Inc.

October24,2011

Acoustic StructuralExample Coupled

AcousticEnergy Source TargetObject: NestedCylindrical Cans

ScatteredAcoustic Radiation

FEAModel quarterSymmetry Hemispherical Domain

AnimationofAcoustic Pressure(Pa)

48

2011ANSYS,Inc.

October24,2011