2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

Transcription

1 ANSYS Solutions for Electromechanical Applications Scott Stanton Technical Director Advanced Technology Initiatives 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

2 ANSYS & Process Engineering System ANSYS - Simplorer Mixed--Signal Multi Mixed Multi--Domain System Simulator Sub-System Model Order Reduction Cosimulation Component ANSYS Workbench Electrical 2010 ANSYS, Inc. All rights reserved. Magnetic Fluid 2 Mechanical Thermal Acoustic ANSYS, Inc. Proprietary

3 From ANSYS to Process Model V Requirements & Specifications System Validation Sub-System Integ. & Verification System Functional Design Subsystem Design Component Integration & Verification Detailed Design & Optimization Time 2010 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary

4 Adaptive Mesh Technology Field in air gap Energy error convergence Force convergence (axial component) Adaptive mesh refinement 2010 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

5 Key Technology: Automatic Adaptive Meshing Algorithms Geometry (no mesh data) Create Initial Mesh Calculate Field Calculate Field Accuracy Error Acceptable? e? Yes No Refine Mesh Display Simulation Results 2010 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary

6 Example: Team Problem #7 Conductive Plate: σ = 3.8e7 S/m Line to measure B z Coil d = 19mm 2010 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary

7 Principle The eddy currents will penetrate the conductive plate according to the skin depth δ δ= 2 µ µ ωσ o r For the TEAM 7 project the plate is made of copper which is 19mm thick and the frequency is 200 Hz. δ=5.77mm δ is a little less than three skin depths 2010 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary

8 Automatic Adaptive Meshing Example: Team Workshop # ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary

9 Automatic Adaptive Meshing 2010 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary

10 Current Density in Plate The mesh is automatically refined in the area where the gradient of the field is the greatest 2010 ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary

11 Electromechanical Power Flow Power Power Electric Mechanical Source Electronics Machine Component Control 2010 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary

12 Industrial Automation Power Plant Power Electronics EM Component Mechanical Component ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary

13 Power Generation Power Plant Power Electronics EM Component Mechanical Component 2010 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary

14 HEV/EV Propulsion/Charging Power Plant Power Electronics EM Component Mechanical Component Battery Electronics Motor Shaft Safety EMC/EMI Efficiency Vibration Oakridge National Laboratory, ORNL/TM-2004/247, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System Interim Report ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary

15 Safety: Fire-Damaged PHEV 2010 ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary

16 Simulation Techniques Math Based Model Battery Circuits Inverter Motor Electromagnetics Thermal Controller EMC/EMI Drive Shaft Mechanics Mathematics +Mathematics Ansoft Road Show 2008 Inspiring Engineering - Simulating EMC/EMI Effects for High Power Inverter Systems - Emmanuel Batista Alstom Pearl 2010 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary

17 Traditional Simulation Framework 2010 ANSYS, Inc. All rights reserved. 17 ANSYS, Inc. Proprietary

18 Integrated Concurrent Design Circuit - System Analytical Automated Integration Magnetics Thermal Radiation L,R,C Extraction Structural 2010 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary

19 Power Source Power Electronics Electric Machine Mechanical Component Newman s 1D Electrochemistry Model Lithium Ion Batteries Li + Jump Li + Li + Li x C 6 e (εe ce ) 1 t = De c e + t F Li ( ) j + Li + e Li x -Metal Metal-oxide Simplorer Results Newman s Results 2010 ANSYS, Inc. All rights reserved. 19 ANSYS, Inc. Proprietary

20 Power Source Power Electronics Electric Machine Mechanical Component Battery Cell Electrical Model Ref: Chen et al* Accounts for non-linear opencircuit voltage Capable of predicting runtime Error less than 0.4% Capable of predicting transient I-V performance Error less than 30-mV Can be implemented easily in circuit simulator Implemented in Simplorer Results from Simplorer Results from Chen * Reference: M. Chen, G. A. Rincon-Mora, Accurate electrical battery model capable of predicting Runtime and I-V performance", IEEE Trans. On energy conversion, vol. 21, no. 2, June ANSYS, Inc. All rights reserved. 20 ANSYS, Inc. Proprietary

21 Power Source Power Electronics Electric Machine Mechanical Component Batteries Fluid Flow Region 2010 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary

22 Simplorer Architecture C/C++ User Defined Model Matlab Real Time Workshop Matlab Simulink Co-Simulation ANSYS MBD ANSYS Maxwell Simulation Data Bus/Simulator Coupling Technology Blocks: Circuits: States: Model Extraction: Equivalent Circuit, Impulse Response Extracted LTI, Stiffness Matrix Electromagnetic (FEA) Mechanical (FEA) Thermal (FEA) Fluidic (CFD) VHDL-AMS IF (domain = quiescent_domain) V0 == init_v; ELSE Current == cap*voltage'dot; END USE; 2010 ANSYS, Inc. All rights reserved. 22 ANSYS, Inc. Proprietary

23 Power Source Power Electronics Electric Machine Mechanical Component Power Temperature Simplorer Battery Model Co-simulation CFD Battery Model 2010 ANSYS, Inc. All rights reserved. 23 ANSYS, Inc. Proprietary

24 Model V - Verification Model libraries Subsystem Design Modeling techniques Combined 3D components Reduced-order LTI ROM MOR Parameter extraction L, R, C, G, S Lookup table Knowle edge Base Validate Nonlinear Component Integration & Verification Co-simulation Detailed Design & Optimization 2010 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary

25 Power Source Power Electronics Electric Machine Mechanical Component Dynamic IGBT accurately captures the switching waveforms Static IGBT for fast system simulations 2010 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary

26 Power Source Electric Machine Power Electronics Mechanical Component EMI/EMC: Automatic L,R,C Extraction and Network Model Current Distribution The structure is meshed using automatic and adaptive meshing 2010 ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary

27 Power Source Power Electronics Electric Machine Mechanical Component + W ECELink1 IA A EQU sourcea1 Magnet01 + ω EA Ixa := Ixb := IB.I * c Ixc := IC.I * c sourcea2 Magnet02 IB A Ix := Ixa + I Iya := Iyb := IB.I * sourceb1 EB Iyc := IC.I * Iy := Iya + I Im := sqrt(ix^2 + sourceb2 IC delta := atan2 (Ix, Iy) A D sourcec1 ECE - LINK EC D D sourcec2 FEA ICA: DGraphSel1 NIGBT71.IC m m EQUBL 2DGraphCon1 GAIN 57.3 CONST ANGRAD + Φ -30+PWM_PER EQUBL FFT m EQUBL EQUBL CONST CONST -60+PWM_PER -90+PWM_PER GS_I m m Extract Power Loss EQUBL 1.00k 3.00k 10.00k k 1.00Meg 2010 ANSYS, Inc. All rights reserved. 27 ANSYS, Inc. Proprietary 0 EQUBL CONST CONST -120+PWM_PER -150+PWM_PER

28 Power Source Power Electronics Electric Machine Mechanical Component m m 2DGraphCon1 Ansoft HFSS m GS_I k 3.00k 10.00k k 1.00Meg Multiplied mage plots by Simplorer Freq. res. Emission Test MagE@10m by specified inputs Normalized S para ANSYS, Inc. All rights reserved. 28 ANSYS, Inc. Proprietary

29 Power Source Power Electronics Electric Machine Mechanical Component The E field is very localized close to the module even at 100 MHz However, the very high power can lead to large values of E field even far from the module This design is fine at 110MHz. mag 100 MHz, Power = W Spectrum (MHz) Power (W) E field at 1m (V/m) ANSYS, Inc. All rights reserved. 29 ANSYS, Inc. Proprietary

30 Power Source Power Electronics Electric Machine Mechanical Component IGBT Inverter Design Mechanical Stress Analysis Mapping Power Loss Thermal-Structural Plus Electromagnetic-Structural 2010 ANSYS, Inc. All rights reserved. 30 ANSYS, Inc. Proprietary

31 IGBT Package Thermal Model Simple 4-node system Air at a constant speed of 1 m/s ANSYS, Inc. All rights reserved. 31 ANSYS, Inc. Proprietary

32 IGBT Package Thermal Model: Technical Background T(t) 1 θ11(t) ϕ12(t) L ϕ1n(t) T2(t) 21(t) 22(t) L 2n(t) M M M O M ϕ θ ϕ = Tn (t) ϕn1(t) ϕn2(t) L θnn(t) Each matrix element is a complete thermal transient response curve [ h(t) h (t) L h (t)] T 1 2 n Foster network 2010 ANSYS, Inc. All rights reserved. 32 ANSYS, Inc. Proprietary

33 IGBT Package Thermal Model Implementation 2010 ANSYS, Inc. All rights reserved. 33 ANSYS, Inc. Proprietary

34 IGBT Package Thermal Model Validation Temperature at Node 1 with constant heat flux applied at all 4 nodes Temperature at Node 1 with time-variant heat flux 2010 ANSYS, Inc. All rights reserved. 34 ANSYS, Inc. Proprietary

35 Power Source Electric Machine Power Electronics Mechanical Component Host manager 2010 ANSYS, Inc. All rights reserved. 35 ANSYS, Inc. Proprietary

36 Power Source Power Electronics Electric Machine Mechanical Component Create a behavioral model from the results of the DSO run 2010 ANSYS, Inc. All rights reserved. 36 ANSYS, Inc. Proprietary

37 Power Source Power Electronics Electric Machine Mechanical Component 2010 ANSYS, Inc. All rights reserved. 37 ANSYS, Inc. Proprietary

38 Power Source Power Electronics Electric Machine Mechanical Component Co-simulation between Field Solver and System Simulator Maxwell Co-simulate Core Loss: K h, K c, K e, K dc Solid Loss: J 2 /σ Copper Loss: I 2 *R Lamination Stacking Factor Adaptive Time Stepping 2010 ANSYS, Inc. All rights reserved. 38 ANSYS, Inc. Proprietary

39 Power Source Power Electronics Electric Machine Mechanical Component Co-simulate Maxwell Co-simulate 2010 ANSYS, Inc. All rights reserved. 39 ANSYS, Inc. Proprietary

40 Power Source Power Electronics Electric Machine Mechanical Component Electromagnetic Field Includes Harmonics Slot & Carrier: 1 khz 10 s khz 100 s khz Contributors to Loss Rotor Stator Magnet Winding Winding Insulation Failure due to high dv/ dt 2010 ANSYS, Inc. All rights reserved. 40 ANSYS, Inc. Proprietary

41 Power Source Power Electronics Electric Machine Mechanical Component Coupled Electromagnetic - Thermal Analysis EM Field Calculation Including: Core Loss: K h, K c, K e Solid Loss: J 2 /σ Copper Loss: I 2 *R Seamless Automatic Mapping of Losses for Thermal 2010 ANSYS, Inc. All rights reserved. 41 ANSYS, Inc. Proprietary

42 Power Source Power Electronics Electric Machine Mechanical Component Forced Water Cooling Losses Mapped to CFD Forced Air Cooling 2010 ANSYS, Inc. All rights reserved. 42 ANSYS, Inc. Proprietary

43 Model Order Reduction Mechanical FEA Link to System Simulator From ~45,000 equations to 18 states and 6 terminals (Rotational and translational for each DOF) Mechanical FEA Reduced Order Model System Representation 2010 ANSYS, Inc. All rights reserved. 43 ANSYS, Inc. Proprietary

44 System Integration Simplorer - ANSYS Mechanical Link through WB Desired displacement value for DOF2 = 0.1 radians 2010 ANSYS, Inc. All rights reserved. 44 ANSYS, Inc. Proprietary

45 Workbench Schematic 2010 ANSYS, Inc. All rights reserved. 45 ANSYS, Inc. Proprietary

46 Simplorer Schematic 2010 ANSYS, Inc. All rights reserved. 46 ANSYS, Inc. Proprietary

47 Device Level System Analysis Automotive Antilock Braking System - + Battery Delay COIL_N1 TRB1 F Delay COIL_N2 TRB2 COIL_N1 TRB1 F accumulator ECE C2NC COIL_N2 TRB2 ECE RHYD3 + PM13 + PM14 BS=>Q BS=>Q C2NC VALVE_NR_SPR4 v Electrical Control Unit omega Vehicle Speed Estimator fx t + PM6 + PM11 RHYD1 + PM10 PIPE2 Level1 + PM9 pedalpressure + V RLoad + ω ECE 2010 ANSYS, Inc. All rights reserved. 47 ANSYS, Inc. Proprietary

48 Component Design 1 Ideal 0 Actual - Nonlinear 1 Coil Current and Position 500m 0 20m 30m 40m 50m 2010 ANSYS, Inc. All rights reserved. 48 ANSYS, Inc. Proprietary

49 Behavioral vs. Device Results Vehicle Speed (m/s) Behavioral Device Difference in results: >15% 2010 ANSYS, Inc. All rights reserved. 49 ANSYS, Inc. Proprietary

50 ANSYS Multiphysics System Integration Thermal CFD EMC/EMI FEA Magnetic FEA Mechanical FEA Electrochemistry/ Thermal Temperature profile Current profile 2010 ANSYS, Inc. All rights reserved. 50 ANSYS, Inc. Proprietary

51 Engineering Simulations for Realizing SDPD Circuit/System System Core Optimization Activity Order: 0D CAD/FEA Depth Link kt to 0D-1D Component Process Compression HPC 2010 ANSYS, Inc. All rights reserved. 51 ANSYS, Inc. Proprietary Knowledge Man nagement Order: 2D/3D Electrical Magnetic Fluid Mechanical Thermal WB Adoption: Multi-Domain Breadth CAD, PLM, etc. Order: 1D

52 2010 ANSYS, Inc. All rights reserved. 52 ANSYS, Inc. Proprietary