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Damping Factor Maxwell
Damping Factor Maxwell
Application Note
AP064-9911
General Data
Use the General window to specify the motor characteristics.
Rotor Data
Use the Rotor1 and Rotor2 windows to define the rotor data.
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12. Enter 5 in the Coil Pitch field. Even though RMxprt assumes there are two layers of conductors,
a rotor that uses only one layer can still be modeled by making the coil pitch full instead of
fractional. A full pitch for this motor would be 6 slots (12 slots/2 poles); instead of a full pitch,
this motor is wound one slot short, or 5 slots, and is a lap-type winding.
13. Enter 2 in the number of Wires per Conductor field.
14. Enter 0.09 mm in the Wire Wrap field as the thickness of the insulations. This refers to the
width of the insulation on both sides of the wire.
15. Enter 0.95 in the Wire Diameter field. This number is not a standard AWG value, so you must
enter it in the field, rather than selecting an available value from the pull-down menu. When
you enter this value, the Gauge field automatically changes to USER. If you do not have a wire
standard defined, choose Tools/Options, select either American or Chinese as the Wire Setting,
and choose OK. Once this is done, you can choose Materials/Wire to view the wire table. In this
table, under Round Wire Data, there is a column for Wrap where all values are 0. Depending on
your manufacturer, the value for the wire wrap can be entered here, and then, when you select
the wire gauge, RMxprt looks up the value of wire wrap in this table. Any value greater than 0
entered in the Wire Wrap field in the Rotor2 window overrides the value in this wire table.
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Stator Data
Use the Stator Pole window to define the stator data.
7. Enter 0.726 mm in the Pole Embrace field. The stator pole embrace represents a percentage of
the maximum physical dimension of the permanent magnet stator pole. A pole embrace of 1
for a two-pole machine means that the physical rotor pole covers exactly 180 mechanical
degrees; likewise, a pole arc radius of 0.667 (2/3) means that the stator pole covers 120
mechanical degrees.
8. Select TEM as the Magnet Type. TEM is a permanent magnet with a retentivity (or residual flux
density (Br)) of 0.4 tesla, a coercivity of -318 kiloamps/meter, a maximum energy density of
31.82 kilojoules/meter3, and a relative recovery (or recoil permeability) of 1.0.
9. Enter 9.0 mm in the Magnet Thickness field.
10. Enter 40.0 mm in the Magnet Length field.
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Design Output
The Design Output window is divided into nine sections: General Data, Rotor Data, Stator Data, Permanent Magnet Data, Commutator & Brush Data, No-Load Magnetic Data, Full-Load Data, Commutating
Data, and Transient FEA Input Data. The second line of the Design Output file tells you where the results
file is located; this file has the same name as the project, with the extension .res (stndj-1.res for this example).
GENERAL DATA
This information is the same as the data you entered in the General window, except for the value of Frictional Loss. Since you entered 0 in this field, RMxprt calculated a value from the brush pressure value of
approximately 2 watts.
ROTOR DATA
This information is the same as the data you entered in the Rotor1 and Rotor2 windows, except that the
width of the top and the width of the bottom of the rotor tooth are also calculated, along with the slot fill
factor.
The slot fill factor represents the percentage of the available slot area, which is the total slot area minus the
slot insulation, that is filled with the wire (copper plus insulation). The area of the copper is calculated by
A=d2, not A=r2, where d is the diameter and r is the radius of the wire. For this example, the slot is completely filled to a value of 100%.
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STATOR DATA
Most of this information is the same as the data you entered in the Stator Pole window. The polar arc
radius is given instead of the pole arc offset value. Pole embrace is given in mechanical and electrical
degrees. You defined the mechanical pole embrace in the Stator Pole window. The electrical pole embrace
is based on the air gap flux density distribution and is the ratio of the average flux density to the maximum flux density over one pole. Please see the following figure:
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FULL-LOAD DATA
The following motor performance parameters are calculated at a rated output power of 75 watts:
Input Current (A)
8.2 The DC line current value.
Armature Current (A)
4.1 The input current divided by the number of parallel paths.
Armature Thermal Load
16.3 Specific Electric Loading (A/mm) multiplied by Armature Cur2
3
(A /mm )
rent Density (A/mm2).
Specific Electric Loading
5.7 The Specific Electric Loading value (A/mm).
(A/mm)
Armature Current Density
2.9 The current density of the armature winding.
(A/mm2)
Friction and Wind Loss (W) 2.0 The value calculated from the brush pressure.
Iron-Core Loss (W)
1.4 The total core loss in the stator and rotor based on the loss curve.
Armature Copper Loss (W) 7.2 The power loss due to the resistance of the armature winding.
This is the total copper loss.
Brush Loss (W)
12.2 The power loss due to the drop across the brushes.
Total Loss (W)
22.8 Friction and Wind Loss + Iron-Core Loss + Armature Copper
Loss + Brush Loss.
Output Power (W)
75
The given Rated Output Power from the General window. If the
motor cannot output this value of power, RMxprt calculates the
maximum output power and displays that value here.
Input Power (W)
98
The rated DC voltage multiplied by the Average Input Current.
Efficiency (%)
76.6 The output power divided by the input power.
Rated Speed (rpm)
2497 The running speed at the specified rated output power.
.
0.3
The shaft torque available at the rated output power.
Rated Torque (N m)
Locked-Rotor Torque (N.m)
Locked-Rotor Current (A)
3.6
96.8 The total current that the stator will draw when starting this
motor.
COMMUTATING DATA
In this example, the total induced voltage of -0.3 volts is calculated from the inductance, the armature
reaction, and the main fields.
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120
2
0.11
6.0e-5
40
2.5
0.92
0.4
318.3
0.00028 This value for inertia does not include any loading,
bearings, and so forth.
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Performance Curves
Examine the performance curves for the model.
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4. When you have finished viewing the performance curves, choose File/Exit to exit PlotData.
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This completes the RMxprt design of the 75-watt two-pole permanent magnet DC motor. You can continue the analysis of this design using the time transient FEA software program, EMpulse.
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orig SF
eff = ----------------------2
N
where:
eff is the effective conductivity.
orig is the original conductivity.
SF is the stacking factor.
N is the number of laminations.
For this example:
orig is 2x106 siemens/meter.
The stacking factor, SF, is 0.92.
The object has 80 laminations.
The effective conductivity is calculated to be 288 siemens/meter. From the above formula,
you can easily see that the effective conductivity decreases by a factor of the number of
laminations squared; thus, the more laminations, the smaller this effect.
8. Choose Enter to enter this material into your local database. The new material M36_29G_Rotor
is now available in the database for this project.
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Assign copper to all windings (PhA0 through PhA5, PhReA0, and PhReA7 through PhReA11).
Exclude the background from the model. The problem will have boundary conditions assigned
to every outside edge; therefore, the background is excluded from the solution.
Choose Exit, and save the changes made in the Material Manager.
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11. In the Winding Setup window, select PhA0, and then select Function. Enter the function name
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PhA0_PI, and then choose Assign. Repeat this for each armature coil.
12. Once all the assignments have been completed, choose OK to close the Winding Setup window.
13. Enter 10.5 volts in the Value field. This value is the terminal voltage, which includes the brush
drop.
14. Choose Assign to complete the definition.
15. Choose File/Save, and then choose File/Exit to save the changes and exit the 2D Boundary/
Source Manager.
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Manual Mesh
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Motion Setup
With the solution parameters defined, now define the motion parameters for the transient model.
2.0W
D = ------------------------------2 251.3 rad
---------
s
or D = 31.7 x10-6 N-m-s/rad.
10. Enter -0.3 N-m in the Load Torque field. This value was calculated by RMxprt. Since the
rotation of the motor is going to be counterclockwise, then the electromagnetic torque is
positive; therefore, the load torque needs to be negative.
11. Choose OK to close the Mechanical Setup window.
12. Choose Exit to exit the Motion Setup window. Save the changes as you exit.
13. Choose Solve/Nominal Problem from the Executive Commands menu, to generate the solutions.
The progress bar reports the solution status.
To display the transient data, such as voltages, currents, torque, and power loss, choose Solutions/Transient Data. Choose Refresh during the solution process, and the plots will be redrawn after the software
completes the current time step.
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Post Processing
The following figures show four of the transient plots for the sample problem:
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Comparison to RMxprt
Compare the results between EMpulse and RMxprt. To post process the transient plots, choose Post Process/Transient Data; this launches PlotData and asks you to open a plot.
Because RMxprt calculates all of its values based of the rated output power, in order to compare the two
results, we need to calculate the output power from EMpulse and then use this value as an input to RMxprt. We can then compare other quantities such as torque, line current, and copper loss.
P out = P airgap FW
where FW is the Friction & Wind Loss.
The average air gap power is calculated by taking the average torque in N-m multiplied by the speed in
rad/sec.
This calculation gives a value of 88.2 watts for the air gap power. The friction and windage loss used in
the RMxprt program at 2400 rpm is 2.0; thus, at a speed of 2627 rpm:
F.W. loss = 2 * (2627/2400) = 2.2 watts
Calculate the rated output power:
Pout = 88.2 2.2 = 86 watts
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Copper Loss
The copper loss consists of the I2R losses. Remain in the Signal Calculator, and perform the following calculation.
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Cogging Torque
Calculating the cogging torque is straightforward: turn off all excitation, open the windings, and solve at
a slow constant speed.
Return to the 2D Boundary/Source window, change the voltage on the field winding from 10.5 volts to
zero, and increase the resistance on the windings to simulate an open circuit. If you do not change the
resistance, you will model a short circuit winding instead of an open circuit.
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