PExprt v71 L01 Introduction

PExprt
7.1
Design Software for Magnetic Components
Users Guide
Page 01-1
PExprt v7.1 Users Guide
Agenda
9:00am Introduction to PExprt (01,02,03,03a) Example Problem #1 Inductor design with fixed gap Example Problem #2 Winding Loss Recalculation (Eq,1D,2D) BREAK Example Problem #3 Core Loss Modeling Example Problem #4 PExprt to Maxwell 2D Coupling (flux,J,E,C) Example Problem #5 Influence of core gap on the winding losses Lunch 12 noon 1pm 1:00 pm PExprt Additional Features (04,05) Example Problem #6 Influence of the interleaving on the winding losses Example Problem #7 Integrated Magnetics BREAK Example Problem #8 Buck Converter with Simplorer Example Problem #9 Forward Converter with Simplorer Example Problem #10 3ph to 6ph transformer with Simplorer 4:00 pm adjourn
Page 01-2
PExprt
Design Software for Magnetic Components
7.1
Users Guide
PExprt Introduction
Page 01-3
Quick Overview of PExprt

Design Software for transformers and inductors Includes standard libraries for cores, wires, bobbins, insulators, and material Creates potential designs automatically that can be analyzed and Modeled
Types Inductors Multi-winding transformers Coupled inductors Flyback components
Page 01-4
Magnetic Design, Modeling & Analysis
C1 R2 C2 C3 R3 R1 vs
vref vref
vctrl
ctr
FEA
PID_Cont1
ET1
Inductor_2
SMPS Library
ctr a c
BUCK_Converter
p
MEAN VALUE
42
Inductor_LossesC2 50u Diode_Characteristic
Load
240m
Page 01-5
Power System Design Suite

ANSYS offers the most complete solution for power systems design in the industry through its Power System Design Suite of tools What is the Power System Design Suite of tools? Four combinable tools which assist engineers in designing and analyzing power systems, power supplies, and drives Integrates electromagnetic, circuit, and system engineering using a common desktop environment The Power System Design Suite includes: PExprt for transformer and inductor design Simplorer for complete system/circuit analysis Maxwell 2D/3D for finite element analysis Q3D Extractor for parasitic extraction of interconnects, busbars, and cables
Page 01-6
Power System Design Suite

System
Circuit / Subsystem Simplorer XPrt Tools Component FEA Field Solvers ANSYS: Multiphysics Solvers
Thermal Fluidic Mechanical
Electromagnetic
Page 01-7
HF/SI
HFSS, Q3D, SIWave
ANSYS Simplorer
System Design
IA
A
SCADE Suite
Control Systems
RLCG Parasitics
PMSYNC IB
A ICA:
Torque
A
D2D
IC
A
PP := 6
GAIN
ANSYS CFD
Thermal
PExprt Optimetrics
LS-DSO
RMxprt
Machine Design
Magnetics
ANSYS Mechanical
Thermal/Stress
ANSYS Maxwell
2D/3D FEA Analysis
Embedded Design Model order Reduction Co-simulation Field Solution FE Model Generation Push Back Excitations
Page 01-8
FEA Model Extraction
Machines RMxprt - Broad library of machine topologies (Generators, Motors) Fully Parameterizable
Mechanical Source Generator
RMxprt
Evaluate Machine Performance Export to Maxwell 3D Export Circuit Model Simplorer

engine_ss
Engine
ROT1
FML_INIT1
ICA:
PWR_Probe1
PWR Probe
DigViewSel1 Name PWR_Probe1.VE [V] Total_Power Value 114.18 5.43k
RLoad:=7.2
FML1
EQU
RMxprtLink11
Total_Power := PWR_Probe1.S[0] *3
Ra R := RLoad Ohm
A
n := 3000*1.0 rpm Rb R := RLoad Ohm

ROT2 B
R1
F1
Rc R := RLoad Ohm
C
66.5
E1
2.0
RMX
F2
+ VMphaseA
V
+ VMphaseB
V
+ VMphaseC
2DGraphSel1 179.07 V
100.00 2DGraphSel2 VMp... VMp... VMp... 4.10
-100.00
Maxwell
145.00m 146.00m 148.00m 150.00m
2.00
E1.I [A]
-180.23
0 0 100.00m 250.00m
Simplorer
Page 01-9 PExprt v7.1 Users Guide

Magnetics PExprt - (Inductors/Transformers) Design Cores, Materials, Wires Modeling Toroid, Planar, Integrated,winding Nonlinear core, Skin and proximity effects, interwinding capacitance, leakage L Analysis Gap energy, leakage Inductance, flux paths, current density, temperature Circuit Extraction Simplorer

Parasitics Q3D - 2D / 3D Geometry Circuit Boards, Busbar, Cables, connectors Package Parasitics Creates Z matrix with coupling Circuit Extraction Simplorer EMI/EMC analysis CM, DM noise
Page 01-11
Modeling with Maxwell 2D, 3D

2D and 3D Finite Element Analysis of Electrical Machines Sensors Actuators Transformers RFID Systems Wireless Power Transfer
and other electromagnetic and electromechanical components
Page 01-12
FEA Model Extraction Into Simplorer

Electo-Mechanical Motors, Generators Actuators Power Magnetics Inductors, Transformers Electrical Parasitics PCB, Cables, bus bars Thermal IGBT package, CFD Mechanical Example Motor shafts
High Power Inverter System

MappingSimplorer Power Loss
Mapping Electromagnetic Force ANSYS Icepak Model Simplorer

Current profile
Thermal-Structural
Battery5 Battery4 Battery3
Battery2 Battery1
Simplorer
Battery0
Maxwell coupled with ANSYS Mechanical

ANSYS Thermal Model - CFD Maxwell /RMxprt Model
Fluid Flow Region
Temperature profile
ANSYS Mechanical Model
Co-Simulation Maxwell
Ansoft Corporation
500.00
TR
Torque
Basic_Inverter1
Curve Info FEA1.TORQUE
400.00
300.00 FEA1.TORQUE
200.00
100.00
0.00
-100.00
-200.00 0.00 2.50 5.00 7.50 10.00 Time [ms] 12.50 15.00 17.50 20.00
Ansoft Corporation
100.00 75.00 50.00
BackEMF
Basic_Inverter1
Curve Info FEA1.EIT1 TR FEA1.EIT2 TR FEA1.EIT3 TR
25.00 0.00 -25.00 -50.00 -75.00 -100.00 -125.00 0.00 2.50 5.00 7.50 10.00 Time [ms ] 12.50 15.00 17.50 20.00
Page 01-15
Y1 [V]
Co-Simulation (3rd parties)

M otor C urrent
22.60 20.00
AM.I ... 10.00
0 0 50.00m 100.00m
Matlab/Simulink Mathcad ModelSim and QuestaSim - This also allows Simplorer and its VHDL-AMS capability to now include Verilog digital modeling.
Simplorers Integrated Environment

INREG
Equation Modeling Block

EQU
+
EQUBL
VBUS>=VSET VBUS<VSET OUTREG vset GAIN2

GAIN
vbus VM1
I_main
D1
EQU
vbus := VM1.V NL1

NL
a:= (t^(1.0/x)*rating)/(726.3^(1.0/x)) x:= -4.7306 rating:= 10

tY
sp
XY1 engine2generator VSET

CONST XY
I1 GAIN1
GAIN
GAIN3
GAIN
VBUS
CONST
GAIN4
GAIN
ERR
INTG1
I
SUM1
LIMIT1
LIM IT
DATAPAIRS1 RTH1 RTH2
Magnetics
therm
Circuit, Block, State
T1
R2 CTH1
G(s)
GS1
VHDLAMS FEA C code

1k 10*node.V*t*f*L.I
(S1.AC_Sim)? 1k: (S1.DC_Sim)? 1k: rload2_ctrl
rload21
TR Probe
TR_Probe1
#
pin
i=f(v)
Co-Sim (ie Simulink) Spice Import
Page 01-17
Power of VHDL-AMS (Compatibility, Capability)

Standard Format Allows Model Portability (IEEE standard) Different engineering groups within same company With Sub-Contractors Between different simulators Multi-level Modeling Different levels of abstraction of model behavior Multi-domain Modeling Electrical, Thermal, Magnetic, Mechanical, etc Mixed-signal Modeling Supports analog and digital modeling
Motor Drive Example

DSP Program Model
vf_full
FPGA Program Model

VHDL-AMS
mu mv st1 st2 st3 st4
TMS320C6701
u_phase.i
w_phase.i
C code
mw
DC_link.v
PWM signal
st5 st6
dead time
ctrl_1 ctrl_2 ctrl_3 ctrl_4 ctrl_5 ctrl_6 u_phase
p u
ICA:
c_freq:=650 c_rpm:=60*c_freq
DC_link
p a a
+
b b
Conv.
n m V
PWM Inv.
Q 3 D
+
V
fan
rot1 rot1
w_phase
A
c
Motor
heatout thermalin
) ) V . v u V ( S B A ( G E T N I * m 0 . 0 2 / 0 . 1 * ) ) 0 . 2 ( t r q s * 0 . 2 ( / I P = : n m _ v u V ) ) V . w v V ( S B A ( G E T N I * m 0 . 0 2 / 0 . 1 * ) ) 0 . 2 ( t r q s * 0 . 2 ( / I P = : n m _ w v V
PWM inverter Model Simplorer

Page 01-19
EQU
PM Motor Model RMxprt/Maxwell
) ) V . u w V ( S B A ( G E T N I * m 0 . 0 2 / 0 . 1 * ) ) 0 . 2 ( t r q s * 0 . 2 ( / I P = : n m _ u w V 0 . 3 / ) n m _ u w V + n m _ w v V + n m _ v u V ( = : n m V
Power of ANSYS
2DGraphSel7 200.00
VHDL-AMS
PExprtLink1
PEX
Probe2 13.00 10.00
DC/DC Converter
Probe1 28.00 20.00
dutym in 0.01 dutym ax 1.0

buck_vhdlams_dxn_ng
vout.V 5.00
v loadp v gp v gm v loadm
l 0.53m fs 200k
d1m
eoutp eoutm v m ode
-68.00u 0 200.00m
d1p
WM2
N025...
Maxwell
V Mph... V Mph... V Mph...
+
V
Simplorer
5m H
10.00
2.5u R1
C4
VM3 rload
0 0 200.00m
7.5 (1/2.5)*vopam p.V AC_MAG 0.0
Louttop
AC/DC Conversion
D1 D2 D3
+
1479p
50k 166k r2 r1
-
c2 E2 AC_MAG 0 EMF 2.0 V vopam p
7.45k r3
-200.00 158.41m 160.00m 162.00m 163.83m
OPV54
440p 87k r4 VOMAX 10 VOMIN -10 c1
A
engine_ss
Engine
ROT 1 A
VM1
M1
AC_MAG 1 E6
E5
RMxprtLink1
F_TR := 5m eg Hz R7 100m eg AD := 50k V/V 4 RO := 0 Ohm vref
Lina 50u H Rina10m Ohm Linb 50u H Rinb10m Ohm

B
B A C B
+ VMphaseA
V
D4
D5
D6
K := 0
n := 3000*1.0 rpm
ROT 2
PExprt
PWR_Probe1
PW R Probe
F1
Linc 50u H Rinc10m Ohm

C
E1
TFR3P21
28v Bus
Loutbot
5m H
2DGraphSel6 28.00 5.50k 4.00k
RMX
F2
C
+ VMphaseB
V
A
TFR3P11
2DGraphSel4
D7 B
D8
D9
+
V
+ VMphaseC
20.00
Generator
Cout VM2
3000u F
10.00 V Mou...
R_Load
1.4*100m
VMout
2.00k
PWR_...
RMxprt
Q3D
Probe5 16.00m 10.00m 0 0 100.00m 200.00m icoil1...
D10
TFR3P22
D11
D12
0 0 100.00m 200.00m
0 0 100.00m 200.00m
12v Bus
Probe6 0 -5.00 -14.00 0 100.00m 200.00m
Electrical Loads
f orce...
SSPC
R5
R := 365 Ohm
Vcc
EMF := 12 V
R4
R := 13.7E+006 Ohm
VHDL-AMS
TR Probe
RC
R := 1k Ohm
Winding current
CTRL := t>=0.15
A
Amature force
E3
force1
A
BJT1
C3
C1
C := 10n F C := 1u F FREQ := 1k Hz
VM4
R := 1500/1.8 Ohm
D2D2
D2D
MASS_TRB2
LIMIT_TRB2
Amplifier Input Voltage
R2
Amplifier Input, Output
R := 140 Ohm
TR_Probe1
TPERIO := Tend+1 s AMPL := 10m V
R3
R := 4k Ohm
S2
icoil1 R6 igrav1
RE
R := 375 Ohm
C2
C := 500u F
Mechanical Actuator
ECELink2
Probe4 1.00m 500.00u -5.00u 142.23m
N_1
N_3
IS := 0.00545*9.807 A
N_4
Amplif ier Input Voltage vs. Time 50.00m 25.00m 0 E3.V [V] -25.00m -50.00m 195.00m Time t 200.00m
Amplif ier Input, Output vs. Time 6.00 VM4.V [V]
N_2
ECE
E3.V [V]
5.00 VM4.... 4.00 195.00m 198.00m 200.00m Time t
E4
N034...
196.50m
Gap vs. time
Simplorer PExprt v7.1 Users Guide
Maxwell Page 01-20
Flyback Example
Simplorer Q3D
PExprt
Simplorer Simplorer
Page 01-21
PExprt - Introduction
PExprt is an interactive, performance based design tool that produces initial designs of magnetic components, such as transformers and inductors.
Designs can then be Modeled and Analyzed with the highest level of fidelity using FEA tools. Design Models can then be evaluated in the circuit using Simplorer
Standard libraries of magnetic cores, bobbins, insulators, and conductors allow you to define the model to your exact specifications. Using PExprt, you can design: inductors, multi-winding transformers, coupled inductors, and flyback components. Optimize constructive parameters, such as core size, core material, number of turns, air gap length, wire gauge, and winding stratagy.
PExprt - Introduction
Calculate performance parameters, such as winding losses, core losses, flux density, DC and AC resistance, Irms currents, magnetizing inductance, leakage inductance, and temperature rise. Consider complex effects, such as skin and proximity effects, fringing flux near the air-gap for energy calculations Calculate winding losses based on FEA field solution and core losses. PExprt also includes the PEmag modeling module, a powerful magnetic analysis module based on finite element analysis. This module conducts a detailed analysis of geometry, frequency, and material Generate model netlists for SIMPLORER, electrical simulator to perform a complete system simulation of the entire device.
Maxwell - Introduction
Solves 2D and 3D electromagnetic field problems using FEA Five Solution Types: Electrostatic, Magnetostatic, Eddy Current, Transient Electric, Transient Magnetic Determines R,L,C, forces, torques, losses, saturation, time-induced effects Parameter extraction for: Power Magnetics: Inductors, Transformers Machines: Motors, Generators, Actuators Electrical Parasitic: Cables, vias, bus bars
Q3D Extractor - Introduction

Electrical Parasitic Extraction
2D / 3D Geometry Circuit Boards, Busbars Cables, Connectors Interfaces with popular layout tools Cadence Mentor Circuit Extraction Numerical Analysis (MoM)
Page 01-25
Simplorer - Introduction
Multi-domain, system simulator for designing high performance systems Three Basic Simulation Engines: Circuits, Block Diagrams, State Machines Mixed Signal Mixed Mode Modeling Digital / Analog Magnetic, Mechanical, Thermal Integrated analysis with electromagnetic simulation tools (Maxwell, PExprt, RMxprt, Q3D) Analysis Types: AC, DC, Transient Co-simulation with Maxwell and Simulink Statistical Analysis and Optimization VHDL-AMS Capability
Page 01-26 PExprt v7.1 Users Guide Circuits
R1
N0002
50 C1
R2
1k
R3
1k C2 3.3u
R4
50
12
3.3u V0 := 5
N0004 N0003
V0 := 0
N0005
Block Diagrams
I_PART_id
I CONST
UL := 9 LL := -9
LIMIT
P_PART_id
GAIN
id_ref id
G(s) GAIN
yd
KP := 0.76 SUM2_6
GS2
State Machines
SET: CS1:=-1 SET: CS2:=-1 SET: CS3:=-1 SET: CS4:=-1
IMP = 0 and RLine.I <= ILOW SET: CS1:=-1 SET: CS2:=1 SET: CS3:=-1 SET: CS4:=-1
IMP = 0 and RLine.I >= IUP
IMP = 1 IMP = 0 IMP = 1
IMP = 0
SET: CS1:=1 SET: CS2:=-1 SET: CS3:=-1 SET: CS4:=-1
IMP = 1 and RLine.I <= ILOW
SET: CS1:=-1 SET: CS2:=-1 SET: CS3:=-1 SET: CS4:=-1
IMP = 1 and RLine.I >= IUP

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PExprt

Design Software for Magnetic Components

PExprt v7.1 Users Guide

PExprt v7.1 Users Guide

PExprt v7.1 Users Guide

Quick Overview of PExprt

Types Inductors Multi-winding transformers Coupled inductors Flyback components

PExprt v7.1 Users Guide

Magnetic Design, Modeling & Analysis

Inductor_LossesC2 50u Diode_Characteristic

PExprt v7.1 Users Guide

Power System Design Suite

PExprt v7.1 Users Guide

Power System Design Suite

PExprt v7.1 Users Guide

PExprt v7.1 Users Guide

FEA Model Extraction

Evaluate Machine Performance Export to Maxwell 3D Export Circuit Model Simplorer

DigViewSel1 Name PWR_Probe1.VE [V] Total_Power Value 114.18 5.43k

n := 3000*1.0 rpm Rb R := RLoad Ohm

100.00 2DGraphSel2 VMp... VMp... VMp... 4.10

FEA Model Extraction

FEA Model Extraction

PExprt v7.1 Users Guide

Modeling with Maxwell 2D, 3D

PExprt v7.1 Users Guide

FEA Model Extraction Into Simplorer

High Power Inverter System

Mapping Electromagnetic Force ANSYS Icepak Model Simplorer

Battery5 Battery4 Battery3

Maxwell coupled with ANSYS Mechanical

Fluid Flow Region

ANSYS Mechanical Model

PExprt v7.1 Users Guide

Co-Simulation (3rd parties)

AM.I ... 10.00

Simplorers Integrated Environment

Equation Modeling Block

VBUS>=VSET VBUS<VSET OUTREG vset GAIN2

vbus := VM1.V NL1

a:= (t^(1.0/x)*rating)/(726.3^(1.0/x)) x:= -4.7306 rating:= 10

XY1 engine2generator VSET

DATAPAIRS1 RTH1 RTH2

Circuit, Block, State

VHDLAMS FEA C code

(S1.AC_Sim)? 1k: (S1.DC_Sim)? 1k: rload2_ctrl

Co-Sim (ie Simulink) Spice Import

PExprt v7.1 Users Guide

Power of VHDL-AMS (Compatibility, Capability)

Motor Drive Example

FPGA Program Model

PWM inverter Model Simplorer

PM Motor Model RMxprt/Maxwell

PExprt v7.1 Users Guide

Probe2 13.00 10.00

dutym in 0.01 dutym ax 1.0

eoutp eoutm v m ode

7.5 (1/2.5)*vopam p.V AC_MAG 0.0

c2 E2 AC_MAG 0 EMF 2.0 V vopam p

-200.00 158.41m 160.00m 162.00m 163.83m

440p 87k r4 VOMAX 10 VOMIN -10 c1

F_TR := 5m eg Hz R7 100m eg AD := 50k V/V 4 RO := 0 Ohm vref

Lina 50u H Rina10m Ohm Linb 50u H Rinb10m Ohm