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Workshop 7.1: PMSM Example

Introduction to ANSYS Maxwell

1 © 2016 ANSYS, Inc. November 8, 2016

 Overview
• PMSM Example
– This workshop will discuss how to use RMxprt in connection to Maxwell in order to develop a
complete analysis of a PMSM (Permanent Magnet Synchronous Machine).
– The following tasks will be performed:
• Create the RMxprt model
• RMxprt Results Analysis
• Create the Maxwell 2D Model from RMxprt
• Analyze the model
• Review/Post-process Maxwell 2D results
• Create the Maxwell 3D Model from RMxprt
• Analyze the model and modify excitations to save simulation time
• Analyze Maxwell 3D results

2 © 2016 ANSYS, Inc. November 8, 2016

 RMxprt Model Settings
• Open the Electronics Desktop 2016
• Open the RMxprt example assm1.aedt under File 
Open Examples RMxprt  assm assm1.aedt
• Save the File in a different folder, in order not to modify the default example

3 © 2016 ANSYS, Inc. November 8, 2016

 RMxprt Model Settings
• The model has small dimensions and 0.5 kW rated power
– In order to increase machine power, modify the settings as shown in the following pictures,
scrolling the machine items/menus from up to down

Mod. Index: 0.8 Outer Diam: 340 mm

N. of Poles: 6 Inner Diam: 225 mm
Ref. Speed: 1000 rpm Carrier Freq.: 100
Length: 100 mm
Control Type: PWM N. of Slots: 36

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 RMxprt Model Settings

Hs0: 1 mm
Hs1: 2 mm
Hs2: 30 mm
Bs0: 4 mm
Bs1: 10 mm
Bs2: 15 mm

Cond. Per Slot: 14 Limit. Fill. Fact.: 0.99

Coil Pitch: 2
N. of Strands: 11 Under Analysis Setup

Outer Diam: 224 mm Embrace: 0.85 Rated Output: 20000 W

Inner Diam: 35 mm Mag. Thickn.: 6 mm Rated Volt.: 138 mm
Length: 100 mm Rated speed: 1000 rpm

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 RMxprt Model Settings
– The final machine and the winding setup should look like the ones described in the following pictures

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 Analysis and Results
– In Project manager window RMB on Setup1  Analyze to run the simulation
– In Project manager window RMB on Setup1  Curve to analyze results

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 Analysis and Results
• In Project manager window RMB on Setup1  Performance to analyze results
• At Full Load Operation the most important data are:
– Peak Line Induced Voltage: 139.6 V
– RMS Phase Current: 226.2 A
– Iron-Core Loss: 114.2 W
– Armature Copper Loss: 4627 W
– Total Loss: 5973.4 W
– Output Power: 17421.9 W
– Input Power: 23395.3 W
– Efficiency 74.47 %
– Torque Angle: 78 deg
– Maximum Output Power: 17421.9 W

Note that efficiency considers also the losses in driving converter

RMxprt suggests that 17.4 kW is the maximum power possible to be
obtained with that machine

8 © 2016 ANSYS, Inc. November 8, 2016

 Maxwell Design Creation
• In Project manager window RMB on Setup1  Create Maxwell Design…
• Create both the 2D and the 3D Model

Note that every time a model is created, also the corresponding external circuit is automatically created

9 © 2016 ANSYS, Inc. November 8, 2016

 Maxwell 2D Design Inspection
• Independently from 2D or 3D, the settings are mostly identical
– Expand the tree for the 2D design and scroll it from up to down to inspect the settings
– Double click on MotionSetup1 and verify the speed is constant at 1000 rpm,
starting position is -10 deg and motion type is set to Rotation
– Inspect Boundaries: VectorPotential1 should be set on the external stator
side, while Master and Slave are set on the two cut sides.
– Slave must be Bs = -Bm

Master

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 Maxwell 2D Design Inspection
– Double click on PhaseA, PhaseB and PhaseC Windings and verify the sources are set to External
and conductors to Stranded
– The winding selection highlights the belonging conductors

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 Maxwell 2D Design Inspection
– Click on each Mesh operation an verify the settings are as shown in the
following pictures
– RMB on each mesh operation  Select Assignment highlights the
corresponding objects

12 © 2016 ANSYS, Inc. November 8, 2016

 Maxwell 2D Design Inspection
– Double Click on Setup1 an verify the settings are as shown in the following pictures. In Solver Tab
modify the Non linear Residual to 1e-6

– Maxwell 2D Excitations – Maxwell 2D Excitations

 Set Core Loss  Set Eddy Effects
– Activate Core Loss – Make sure no object is
calculation for Stator and checked
Rotor Objects

13 © 2016 ANSYS, Inc. November 8, 2016

 External circuit Inspection
– Double Click on MaxCir1 to show the schematic used for 2D design

3-phase Inverter
Diodes and
switches models

Phase Resistance and

Leakage Inductance

Link to
Maxwell
Windings

PWM
Control

14 © 2016 ANSYS, Inc. November 8, 2016

 Maxwell 3D Design Inspection
– Expand the tree for the 3D design

– MotionSetup1 is identical to 2D design

– VectorPotential BC is not anymore present, due to default 3D settings
– Master and Slave are set on the two cut Surfaces.
– Slave must be Hs = -Hm

Slave

Master

15 © 2016 ANSYS, Inc. November 8, 2016

 Maxwell 3D Design Inspection – modify Excitation
– Double click on PhaseA, PhaseB and PhaseC windings and modify the sources from External to Voltage
– Resistance: 0.0301525 W
– Inductance: 6.289e-5 H
– Voltage PhaseA : 55*sin(2*pi*50*time+78deg)
– Voltage PhaseB : 55*sin(2*pi*50*time+78deg-120deg)
– Voltage PhaseC : 55*sin(2*pi*50*time+78deg-240deg)

Note that 78 deg is the torque angle calculated in RMxprt

16 © 2016 ANSYS, Inc. November 8, 2016

 Maxwell 3D Design Inspection
– Mesh operations are similar to 2D (even if values are different) and in addiction there is a
Cylindrical Gap treatment for the Band and a SurfPriority for the Coils

17 © 2016 ANSYS, Inc. November 8, 2016

 Maxwell 3D Design Inspection
– Setup1 is similar to 2D Design. In General Tag modify Stop time to 0.12 sec and Time step to
0.0005 sec. In Solver Tab modify the Nonlinear Residual to 1e-4

– RMB on Excitations  – RMB on Excitations

Set Core Loss  Set Eddy Effects
– Activate Core Loss – Make sure no object
calculation for Stator and is checked
Rotor Objects

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 2D Model Results Analysis – Output mechanical power

Output mechanical Power (19.1 kW)

Note: to obtain the Output mechanical power it is enough to insert the following expression:
Moving1.Torque*Moving1.Speed

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 2D Model Results Analysis – losses

Stranded losses (2.6 kW) and Core losses (91 W)

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 2D Model Results Analysis – Currents and Fluxes

Phase Currents (221 A RMS) Flux linkages

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 3D Model Results Analysis – Output mechanical power

Output mechanical Power (18.1 kW)

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 3D Model Results Analysis – losses

Stranded losses (4.1 kW) and Core loss (64 W)

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 3D Model Results Analysis – Currents and Fluxes

Phase Currents (202 A RMS) Flux linkages

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 Analysis Results and comments
• The results are in agreement each other, taking into account the two different
calculation methods (analytical for RMxprt, FEM for Maxwell)
• Main apparent discrepancy are the winding losses: 4.6 kW in RMxprt (where the
losses are calculated on 30 mW winding resistance), 2.6 kW in Maxwell 2D (the
winding resistance is only about 17 mW).
• That discrepancy is only apparent: in fact applying a scaling factor 30/17 to the
Maxwell losses we get 2.6 kW*30/17 = 4.59 kW, i.e. the RMxprt result.
• The winding losses calculated with Maxwell 2D are 4.1 kW, near to RMxprt
calculated value. Also the output mechanical power comparison shows good
agreement: 17.4 kW for RMxprt and 18.1 kW for Maxwell 3D.
• The huge discrepancy in losses between 2D and 3D model is due to the fact that the
depth of the machine is small compared to diameter. This causes the end-winding
contribution to be important and not negligible.
25 © 2016 ANSYS, Inc. November 8, 2016
 Saving the Project
• This completes the workshop
• Save the file with the name Workshop_7_1 in the working folder

26 © 2016 ANSYS, Inc. November 8, 2016