GIAN Course: PMSM and BLDC Motor Drive Systems Exercise 1: Obtaining flux density for an electromagnetic system Open Ansys Electronics Desktop Open: New Project > Save as: in the Default folder, file name extension is .aedt (or .mxwl) ‘On Menu bar, click View > Docking Window Layouts > Default Adjust ‘Message Manager’ and ‘Progress’ windows such that the status is visible Use hide/unhide buttons in the right bottom to toggle the view In the third row of toolbar below menu bar, click on Insert Maxwell 2D design Available windows on the screen: Project Manager, Properties, Message Manager, Progress, History Tree, Geometry Window A rectangle has to be drawn using Draw ribbon. A rectangle is made by giving the initial comer co-ordinates and then by giving the specifications of dx and dy of the opposite corner from the initial comer. The values can be specified using mouse and gridpoints or by manually entering values. The procedure for manual entry is given below. For Exercise-I: (x,y,2)=(0,0,0) and (dx,dy,dz)=(100,100,0), default units are mm. (Note: In 2D z and dz. values will always be zero.) In the first row of toolbar, click on Draw Rectangle > Press Tab With this cursor is present in the x-coordinate box (at right bottom). After giving the x-value press Zab and enter y-value and press enter. Now the cursor will be asking for (dx,dy,dz). Use tab to switch between the boxes. Press enter after giving dx and dy. For creating core, a smaller square 60x60 mm has to be subtracted from the 100x100 mm square. Create another square using Draw Rectangle with (x.y) as (20,20) and (dx,dy) as (60,60). There should be two squares on the geometry window. Select both rectangles using chi, click Subtract in the second row of tociber. Keep Reetanglel as blank part and Rectangle? as tool part and click ok. Select the model, and using the properties window change its name to Core. A magnet is to be created with dimensions 20 mm (width) and 5 mm (height), on the left limb of the core, Create a rectangle with (x,y) as (0,47.5) and (dx,dy) as (20,5). Change the name this rectangle to Magnet. Select both Magnet and Core, Click Subtract, keep Core in Blank Parts and Magnet in Tool Parts. Check ‘Clone tool objects before operation’. Click OK. Draw a rectangle with (x,y) as (80,49.75) and (dx,dy) as (20,0.5). Name this rectangle as Airgap. Subtract Airgap from the core, Blank Parts: Core, Too! Parts: Airgap. Do not ‘Clone’ Note: Use History tree for changing the dimensions, if needed. Press Escape to bring the cursor into default mode. Creating Boundary A boundary has to be made such that it encloses the considered system and the field is solved within the boundary. Click Draw > Region. Percentage Offset can be assigned as 20%, OK ‘ In Geometry Window, right click. Choose Select Edges. Press Ctr! and select all the edges of Region. Right click, choose Assign Boundary > Vector Potential. Give Value = 0. OK. Assign Materials In Geometry window, right click, choose Select Objects. In the History tree, right click on Core > Assign Material. Search for Steel_1008 and select it. OK. ereRight click on Magnet > Assign Material. Select NdFe30. Click Clone Materials. Change Material Name to NdFe30_y. In Properties, edit XComponent = 0 and YComponent = 1. OK. OK. In Project Manager, right click Analysis, choose Add Solution Setup. Maximum Number of Passes = 10. Percent Error = 0.1. OK. In toolbar, use Validate to check for errors. Close. In Project Manager, right click on Setup! > Analyze. After it is solved, Normal completion message will appear in Message Manager. In Geometry window, press ctrl+A. Right click -> Fields > B > Mag_B. Click Done. Press Esc. Right click > Fields > Marker > Add Marker. Use Mouse scroll to zoom the Magnet. Click to see the Field value. Similarly check the Field value in Airgap. Observe the Flux density at different points in the system. Follow the similar procedure for observing other field quantities. For controlling the visibility of plotted ficlds use Field Overlays in Project Manager. Right click on particular field and check/uncheck Plot Visibility. Press Esc. Right click > Fields > Marker > Clear All Click Hide/Show (tool bar third row) > FieldsReporter. Uncheck All. (this is to clear the geometry window from field plots) Click on Draw line (tool bar first row), give first point (x,y) as (0,50). Enter. Second point (%y) as (20,50). Press Enter two times to exit from drawing mode. Rename this line as Line_Magnet (in History tree). Click on Draw line, give First point (x,y) as (80,50). Enter. Second point (x,y) as (100,50). Press Enter two times to exit from drawing mode, Rename this line as Line_Airgap. Tn Mem bar, Maxwell 2D > Fields > Calculator Input > Quantity > B Vector > Scal? > ScalarY In Geometry > Line > Line_Magnet, OK Scalar > Integrate Library > Add. Name the expression as Flux_Magnet. OK. Scroll down and select Flux Magnet. Library > Copy to stack. Output > Eval, The evaluated value appears. Itis flux through the magnet. In 2D static solver, default depth of the model is 1 m. Therefore the evaluated value, that is, line integral of By is same as the surface integral of By, ie. Flux. Similarly flux in the Airgap can be computed. Compare the values. Note: In NdFe30 material properties, default value for relative permeability is 1.0446. While doing analytical calculation, use the same value. Introducing coil Use Draw circle (Tool bar first row), type (x.y) = (78,40), and (dx,dy) = (1,0). This corresponds to a circle of 1 mm radius drawn at the centre (78 mm, 40 mm). Use Duplicate Along Line (Tool bar second row) for creating return conductor of the coil. (.y) = (78,40) and (dx,dy) = (24,0). In the Pop-up window, enter 2. Select circle-1, change its name as Conductor. Name the circle-2 as Retum_conductor. For considering these conductors as Models (that are influencing analysis), those are to be declared as Models. For this purpose, select Conductor and Return_conductor. Go to Properties window, check Model Assign copper material to both the conductors. Click on Conductor, right click > Assign Excitation > Current. Enter the value of current. For outward current, Reference direction is to be positive (for inward current, Reference direction is to be chosen as negative). Now Validate and Analyze All (Too! bar first row)GIAN Course: PMSM and BLDC Moter Drive Systems Exercise 2: Using RMxprt, create a complete model of 4 pole, 36 slot BLDC machine and perform FE analysis in Maxwell 2D Open Ansys Electronics Desktop Open: New Project > Save as: in the Default folder, file name extension is .aedt (or zmxw!) On Memu bar, click View > Docking Window Layouts > Default Adjust ‘Message Manager’ and ‘Progress’ windows such that the status is visible Use hide/unhide buttons in the right bottom to toggle the view In Toolbar third row, click on Insert RMxprt design Available windows on the screen: Project Manager, Properties, Message Manager, Progress, History Tree, Geometry Window Choose Machine Type: Brushless Permanent Magnet DC Motor Change the design name as 4pole36slots Project Manager > Double click Machine > Enter the following values, Number of poles: 4 Reference speed: 1500 Control Type: DC OK Project Manager > Double click Stator > Enter the following values Outer Diameter: 165 mm Inner Diameter: 110 mm Length: 80 mm & Su ‘Number of Slots: 36 Slot type: 3 OK Stator > Double click Slot > Uncheck Auto Design. Click OK. Open Slot again. Enter the following values Hs0: 1, Hs!: 1, Hs2: 8, Bs0: 4, Bsl: 6, Bs2: 7, Rs: | (all values are in mm). OK Stator > Double click Winding Winding Layers: 2, Parallel Branch: 1, Coil Pitch: 9. OK (Some entries are left zero. Those will be estimated automatically by RMxprt) Double click Rotor > Enter the following values Outer Diameter: 109 mm, Inner Diameter: 35 mm, Length: 80 mm, Steel Type: Steel_1008 Pole Type: 1. OK Rotor >Double click Pole > Enter the following values Embrace: embrace (variable), Enter. In Pop-up window, enter value as 0.7. OK. ‘Magnet Type: NdFe30, Magnet Thickness: 5 mm Double click Shaft > Uncheck Magnetic Shaft. OK. Analysis > right click > Add Solution Setup Load Type: Constant Power, Rated Output Power: 2 kW, Rated Voltage: 220 V, Rated Speed: 1500 rpm. OK Validate and Analyze. Address the errors if any. Save,Right click on Setup1, Create Maxwell Design. OK. Wait for the generation of 2D design. Quarter section of the motor with Master and Slave boundaries is created. Rename the design as 4pole36slots_ 2D Project Manager -> 4pole36slots_2D > Excitation > Phase A — double click Type: Current Current: current*sin(2*pi*50*Time — Alpha). Enter. (Note: current and Alpha are user defined variables. Time is intrinsic variable) In Pop-up window, for the variable current, give value as 10 A. OK, In Pop-up window, for the variable Alpha, Unit Type: Angle, Unit: rad, Value: 0. OK. Project Manager > 4pole36slots_2D > Excitation > Phase B — double click Type: Current, Current: current*sin(2*pi*50*Time — Alpha — 2*pi/3). Enter. Project Manager > 4pole36slots_2D > Excitation > Phase C — double click Type: Current, Current: current*sin(2*pi*50*Time ~ Alpha — 4*pi/3), Enter. Model > MotionSetup] (double click) Mechanical tab, Angular Velocity: 1500 rpm Analysis > Setup (double click) Stop time: 40 ms, Time step: 0.1 ms, OK Validate Ignore the warning of Boundaries and Excitations. Analyze All Voltage and Current waveforms Results (right click) > Create Transient Report > Rectangular Plot Category: Winding, Quantity: InducedVoltage(PhaseA). Click New Report. Category: Winding, Quantity: InputCurrent(PhaseA)- Clici-Atid Trace. Observe that Voltage and Current are in phase. Similarly verify for other phases. Torque: EMF method and Virtual Energy method Results (right click) > Create Transient Report > Rectangular Plot Y: Type the following (Induced Voltage(PhaseA)*InputCurrent(PhaseA) Induced Voltage(PhaseB)*InputCurrent(Pa aseB)+InducedVoltage(PhaseC)* InputCurrent(PhaseC))/(2*pi* 1500/60) (Let this waveform be referred as T_emf) Primary Sweep: Time, Range: Specify range as 0’ ms to 10 ms. Click New Report Category: Torque, Quantity: Moving]. Torque. Click Add Trace. (Let this waveform be referred as T_ve) Right click on the graph, Export Save as >ve_emf.esv SOK Right click on 4pole36slots_2D, Copy, right click on Exercise2, Paste Leff click on 4pole36slots_2D_cogging, In Properties window, enter current Analysis > Setup] > Analyze Results > Torque > Primary Sweep: Time, Range: Specify range as 0 ms to 10 ms. Apply Trace. (Let this waveform be referred as T_cogging) Right click on the graph, Export Save as >cogging.csv OK ve_emf.esv file has T_ve and T_emf in column B and C respectively cogging.csv file has T_cogging in column B Verify that T_ve = T_emf +T_coggingExercise 3: Finding flux linkage using line integral of Vector Potential 1. Open Ansys Electronics Desktop 2. Load Exercise? Project file. By default, this project can be found in C:\Documents\Ansoft 3. OnMenu bar, click View > Docking Window Layouts > Default 4, Click anywhere in geometry window and press Ctrl +D, Double click on 4pole36slots_2D_cogging > Excitations -> Click Phased. 5. In Geometry window, the highlighted conductors belong to Phase A. Make a note of all the coils that belong to Phased. 6. When full model of the machine is exported from RMxprt, the winding layout is as follows. 7. Top layer of slots has conductors: Coil_0, Coil_1, L: 8, Bottom layer of slots has conductors: CoilRe_0, CoilRe_I, ...., CoilRe_ 35 9. First coil of Phase A corresponds to PhA_0 and PhARe_0 (displaced by pole pitch). (PhA_0 can be seen in 4pole36slots 2D cogging > Project Manager > Excitations) 10. When quarter model of the machine is exported, as done in this exercise, only Coil_0 to Coil_8 will be visible, similarly CoilRe_0 to CoilRe 8 are visible, Flux linkage corresponding to the remaining quarters will be obtained by multiplying the symmetry factor. For example: Here, for a 4 Pole machine, symmetry factor is 4. Flux linkage computed from the solved quarter section will be multiplied by 4 to get complete flux linkage of Phase A. Obi flux linkage of PhaseA y 11. In Menu bar, Maxwell2D> Fields Ca 12, Input->Quantity> select A 13. Vector>Scal? >ScalarZ_ 14, Input->Geometry check Surface >Coil_0 ow 15. Scalar>Integrate at) 16. Input>Number>Scalar> Value=37209, OK N a culator 17. General > * (multiply) 18. Library: Add > Name: Flux_0 19. Click OK 20. Note: 37209 is obtained from the following: Number of tums, N=8 Stack Length L=80 mm, Area of Coil (Nex L)(Area of Coil)= 37209 17.2 mm? 21. For Coil_I 22. Input->Quantity-> select A 23. Vector->Scal? >ScalarZ 24. Input->Geometry > check Surface>Coil_1 25, Scalar Integrate 26. Input->Number->Scalar-> Value=37209, OK. 27. General> * (multiply) 28. Library: Add-> Name: Flux_1 29. Click OK30. For Coil_2 31. Input > Quantity > select A 32. Vector > Scal? >ScalarZ, 33. Input > Geometry > check Surface > Coil 2 34. Scalar Integrate 35. Input > Number > Scalar > Value=37209, OK 36. General * (multiply) 37. Library: Add > Name: Flux 2 38. Click OK 39. Now Flux_0 to 2 will be added and multiplied by symmetry factors to get total flux linkage of A. 40. Named Expressions, scroll down to select Flux_0 41. Library > Copy to stack 42, Named Expressions, scroll down to select Flux_1 43. Library > Copy to stack 44. General > + 45, Named Expressions, scroll down to select Flux_2 46. Library > Copy to stack 47. General > + 48. Input > Number > Scalar -> Value=8 49. (Note: Symmetry factor*Number of layers=4*2=8) 50. General->* (product) 3 51. Library > Add > Name=FluxLinkage_A. Click OK, Done. 52. Analysis Setup 1 Right Click>Reset to Time Zero 53. Analysis>Double Click Setup1> General >Stop time =20ms->Time step=.1 ms 54, SaveFiclds->Stop-20 ms-> Step Size-0.1> Click Replace List >OK 55. (The above step is done to save fields information at every time step) 56. Analysis->Right Click Setup! Analyze 57. (This takes more time than in Exercise 2 as the fields solutions are being saved at every time step) 58. Results > Right Click > Create Fields Report > Rectangular Plot 59. (Note: Do not use transient report) 60. Category >> Calculator Expressions > FluxLinkage A > NewReport 61. Results-> Right Click-> Create Transient Report->Rectangular Plot 62. Category>Select Winding-> Quantity->Select FluxLinkage(PhaseA)->NewReport 63. ( Verify that flux linkage waveform from inbuilt code FluxLinkage(PhaseA) and obtained using calculator (FluxLinkage_A) are same) Induced EME 64, Right click > Create Fields Report > Rectangular Plot > 65. Category: Calculator Expressions, Quantity: FluxLinkage_A, Function: derive 66. New Report 67. Plot induced emf using Transient Report as explained in Exercise 2 in the same report. Verify that both are same.GIAN COURSE: PMSM and BLDC Motor Drive Systems Exercise 4: Radial flux density component in Surface Mounted PM Machine Objectives (A)Plotting radial flux density in space (B) Identifying the effect of armature reaction on radial flux density 1, Open Ansys Electronics Desktop Load Exercise? Project file. By default, this project can be found in C:ADocuments\Ansoft 3. On Menu bar, click View > Docking Window Layouts > Default 4, Project Manager > Right Click on Maxwell 2D Design “4pole36slots_ 2D” > Copy 3. Project Manager > Right Click on Exercise2 > Paste 6. Change the name of this pasted Maxwell 2D Design to “4pole36slots_2D Fields” 7. In this design, Analysis > Setup (double click) 8. Stop time: 10 ms 9. Time step: 0.1 ms 10. Save Fields > Stop = 10 ms > Step Size=0.1 > Click Replace List > OK 11. Setup! > Analyse 12. Toolbar (First Row) > Click Draw centre point arc (Note: after this, if pop-up window appears with que Sol you want to create a Non-Model object?”, click on: Yes, otherwise proceed further) 13. Press Tab 14. X: 0, Press Tab, Y: 0, Press Tab, Z: 0, Enter 15. X: $4.75, Press Tab, Y: 0, Press Tab, Z:0, Enter 16. X: 0, Press Tab, ¥:54.75, Press Tab, Z:0, Enter, Enter 17. After this, click on Polylinel > Create Polyline > Create AngularAre Check in Properties, the following Start Point: 54.75,0,0 (mm) Center Point: 0,0,0 (mm) Angle: 90 deg 18, Rename Polylinel in the History Tree as Line_gap 19, Menubar > Maxweti 2D > Fields > Calculator 20. Input->Quantity> select B 21. Vector > Unit Vec > Normal 22. Vector > Dot 23. Library: Add, Name: Br_armature, OK 24. Click Done 25. Validate 26. Analyze27. Results -> Right Click > Create Fields Report > Rectangular Plot 28. Geometry > Select Line_gap 29. Category ~> Calculator Expressions > Br_armature 30, Families, Time, Fait 31. Enable Select values 32. Choose 8400000 ns and then Close 33. New Report, Close this window 34, In Project Manager->Exercise2> Double Click on Maxwell 2D Design ‘4pole36slots_2D_Ficlds’ 35. History tree > Right click Line_gap > Bdit > Copy 36, Project Manager > Double Click on Maxwell 2D Design ‘4pole36slot_2D_cogging’ > right click in Geometry window > Edit > Paste 37. Menubar -> Maxwell 2D > Fields > Calculator 38, Input->Quantity> select B 39. Vector > Unit Veo > Normal 49, Vector > Dot 41. Library: Add, Name: Br, OK 42. Click Done 43, Validate 44, Analyze 45, Results > Right Click > Create Fields Report > Rectangular Plot 46. Geometry > Select Linc_gap 47, Category > Calculator Expressions > Br 48. Families, Time, Edit 49, Enable Select values 50. Choose 8400000 ns and then Close 51. New Report, Close this window 52. Project Manager > Results-> Click on the plus sign besides the above plot containing Br > Right click on plot symbol of ‘Br'> Edit>Copy data 53, In Project Manager-> Exercise2-> Double click on 4pole36slot_2D_fields 54. Results->Go to the plot on which Br armature is plotted 55, Right click on the plot in Geometry Window > Edit Paste ‘56. Question: Armature excitation effect on airgap field can be scen by comparing Br and Br armature. Observe and describe the effect. 57. Question2: How tangential component of flux density can be plotted for this motor? BlocGIAN COURSE: PMSM and BLDC Motor Drive Systems Exercise 5: Reluctance terque and Reactance torque 1. Project Manager > Right click on the Maxwell 2D Design “4pole36slots_2D", Copy 2. Right click on Fxercise2, Paste 3. Rename the pasted design as 4pole36slots_Torquel VsAngle 4. Click on plus sign besides this design “4pole36slots_Torquel VsAngle’ > Model > double click on MotionSetup] > Mechanical Angular Velocit ORPM 5. Analysis > Setup! > Double Click > General > Stop time= 10 ms, Time step = 6. Save Fields tab > Click on: Clear All, Click OK .0lms 7. Validate 8. Analyze 9. Result > Torque (observe this waveform) 10. Right click on the Maxwell 2D Design “4pole36stots_Torquel VsAngle” in Project Manager, Copy 11, Right click on Exercise2, Paste 12. Rename the pasted Maxwell 2D Design as “4pole36slots_Torque2VsAngle? 13. History tree, Model > Sheets > steel_1008.... Right Click on Rotor > Edit > Delete 14. History tree, Vacuum, Right Click on InnerRegion, Edit, Copy 15, Right click in Geometry Window; Edie; Paste: a (Anew region named InnerRegion! should appear in History tree, in Vacuum tree) 16. History tree > Click on InnerRegion1, Rename InnerRegion! to Rotor from Properties Window 17. History tree > NDFE30..... -> Mag_0 > Click on CreateUserDefinedPart 18. In Properties window, change value of DiaGzp to 109.2 mm 19. Sclect both Rotor and Mag_0 using Cirl, Substract Mag_0 from Rotor (Use Substract, second row of toolbar, Uncheck the clone option) 20. Assign stee!_1008 to Rotor through AssignMaterial option Since the rotor is deleted (to introduce saliency), the existing motion definition gets invalid Therefore, the motion sctup needs to be reassigned. 21. Project Manager >‘4pole36slots_Torque2VsAngle’-> Model >Rightelick on MotionSetup>Delete 22, In History tree>Vacuum->Right click on Band Assign Band 23. $Check Rotation, Moving Vecotr->(lobal Z, Check Positive 24. In Data, Initial Position, 15 deg. 25, In Mechanical, Angular velocity: 0 rpm 26. Validate 27. Analyzeae Field weakening Create a new project using ‘New project’ in toolbar. Rename this project as ExerciseS_FW I. Project Manager > Exercise2-> Right click on the 2D Design ‘4pole36slots_2D', Copy 2. Project Manager-> Right click on ExerciseS_FW, Paste 3. Rename the pasted design as 4pole36slots_FW1 4. Project Manager Right click on ExerciseS_FW, Paste 5. Rename the pasted design as 4pole36slots_ FW2 6. Validate and Analyse the 2D design “4pole36slots_FW1* 7. Right click on Results Crate Transient reportRectangular plot-> Category:winding, 8. Quantity Induced voltage Phase A>New report, 9. Right click on the plot window-> Trace Characteristics-> All Check ‘rms’ 10. Add Trace Characteristics 11. Left click on ‘4pole36slots_FW2’, In the properties window, Enter Alpha= -pi/6 12, Validate and analyse 13. Right click on Results->Crate Transient report> Rectangular plot->Category:winding, 14. Quantity Induced voltage Phase A>New report 15. Right click on the plot window Trace Characteristics-> All->Check ‘rms? 16. Add Trace Characteristies Ql) In 2D design “4pole36slots FW1" Alpha is zero and eT ne 2) From the rms values of induced emf in both waveforms, comment oa the effect of changing Alpha to -pi/6 from 0 'b) By changing rpm in Motion setup and Alpha in properties window observe the effect on Field weakening 2) Plot Br flux density waveforms in both “4pole36slots_FW1’ and “4pole36slots_ FW2° ‘Comment on the effect Alpha on Br. (Refer previous exercise for help on plotting Br) ‘Animation Use *4Pole36slot_2D_Fields’ in “Exercise?” to get an animation of Fluxlines. If there is no solution present, Validate and Analyze. In the geometry window, Cir+A, Right click, Ficlds->A>Flux Lines, Done In the geometry window, near left bottom, double click on “Time--1s? In Set view context, Select Time~ms. In Project Manager->4Polc36slot_2D_ Fields->Field Overlays>A~ Right click on Flux lines > Animate >Ok eos Bfiwel Deb 9 Fruchion apace Ph (ae ashy Med