Electrical Machines, Solenoids

and Sensors – The Art of

Electromechanical Component
and System Design

Scott Stanton
Application Engineering Manager
Ansoft Corporation
Pittsburgh, PA
 Integrated Design Flow
Model
Analytical Design Generation System Design
RMxprt SIMPLORER
Electrical Machines Circuits, Blocks, State
Transformers, Sensors Machines, VHDL.AMS

Link
nt
Model si e Model
n
Generation T ra Generation

Physics Based FEA

Maxwell Model Generation
Static, Harmonic, Transient,
Parametric
Maxwell
Motion Circuits
Solution
 EM Design

Actuators/Sensors Electric Machines

Macros/Wizards Analytical Solution

Parametrics/Optimization Parametrics/Optimization

FEA

System Simulation System Simulation

 EM Design – Electrical Machines
Parametrics/Optimization

FEA

Parametrics Transient
2D/3D

System Simulation State Space Model

Actuators and Sensors using
Maxwell 3D and Optimetrics
Maxwell 3D - Wizards
Create the Geometry
Assign Materials
Maxwell 3D - Problem
Setup Complete
Maxwell 3D - Macros / Wizards
Maxwell 3D - Macros / Wizards
 Maxwell 3D - Optimization
Goal: Obtain the maximum force for the minimum volume

Objective = - Force / Volume

Vary the Yoke and Armature dimensions:

5.5 < Yoke_Width < 9 mm
0.5 < Yoke_Height < 2.5mm
3.5 < Arm_Width_Front < 5.2 mm
5.5 < Yoke_Width_Back < 7.5 mm
Maxwell 3D - Optimization
 Maxwell 3D - Parametrics

Sweep coil current from 1 to 1200 Amp-Turns

Sweep armature position from 0.75 to -4 degrees
 Maxwell 3D - Parametrics

Create State Space Model for use in SIMPLORER

 System Simulation using
SIMPLORER
BJT1 BJT2 BJT3

E1

Mass Spring
EMSSLink1 Force
R2 R3 R4
+
A N_1 N_3 A
+ m

I_Coil Pressure S
STF

A
N_2
N_4 + GND
I1
Table
NL

Position
Position
control_A:=1 I_Coil.I > 3.5 control_A:=0 control_B:=0
t> 0.01
control_B:=0 control_B:=1 control_C:=1
control_C:=0 control_C:=0
SIMPLORER – Simulation Results
Current Position
I_Coil.I
4.0 0.60m

3.0

0.25m
2.0

1.0 0

0 -0.20m
0 10m 20m 30m t 0 10m 30m t

Pressure and Force Input Voltage

15.0
Force.I E1.V
50.00

0
10.0
-50.00

5.0
-100.00

-150.00 0
0 10m 20m 30m t 0 10m 20m 30m t
Electrical Machines
RMxprt
RMxprt - Results
RMxprt - Results
RMxprt - Results
RMxprt - Results
RMxprt - Results
RMxprt - Results
 RMxprt - Parametrics

2 mm < Magnet Thickness < 10 mm

20 mm < Magnet Width < 40 mm
0.3 mm < Pole Embrace < 0.9 mm

For Each variation, calculate Ld and Lq

A total 1323 solutions completed in ~20 minutes

RMxprt - Parametrics
 RMxprt - Optimization

Specify limits for input parameters:

¾ 2 mm < Magnet Thickness < 10 mm
¾ 20 mm < Magnet Width < 40 mm
¾ 0.3 mm < Pole Embrace < 0.9 mm
¾ 0 deg < Trigger Angle < 80 deg
¾ 120 deg < Trigger Pulse Width < 180 deg
¾ 8 mm < Tooth Width < 11 mm

Specify objective: -efficiency

 RMxprt - Optimization

-91
RMxprt – Create Model for System
Simulation using SIMPLORER
Analytical Based
_1MBI400N120_5
R5
_1MBI400N120_3
R3
_1MBI400N120_1

R1 V_AB
Model
V

+
E5 E3 E1 MOI
EMF_1 113.1 J

IA Torque
BLDC +
A A
+ A Torque
IB
A
+ B
Position
A
+ C + Speed
_1MBI400N120_4 IC
113.1 V

+
EMF_2 _1MBI400N120_2 _1MBI400N120_6
V
V
Position

+
R2 R6 R4 V_AC
V_BC

E2 E6 E4 ICA:
PP := 4
delta := 53.7
ON := 15
OFF := -15
ctrl_6:=ON ctrl_1:=ON ctrl_2:=ON
ctrl_1:=ON ctrl_2:=ON ctrl_3:=ON

theta>90 AND theta<150 theta>150 AND theta<210 theta>210 AND theta<270

ctrl_5:=ON ctrl_4:=ON ctrl_3:=ON

ctrl_6:=ON ctrl_5:=ON ctrl_4:=ON

theta>30 AND theta<90

theta>330 OR theta<30 theta>270 AND theta<330

Phase Current Torque Phase Voltage

1.00 IA 400.00 Tor 300.00 V_A
200.00
500.00 IB
IC 200.00
0 0

-500.00 0 -200.00
-1.00k -100.00 -300.00
0 10.00m 17.27m t 0 10.00m 17.27mt 0 10.00m 17.27mt
RMxprt – Create Maxwell 2D Model

Auto generation of
FE geometry
Parametric Analysis

Extract Sate Space Model

 System Simulation using
SIMPLORER
FEA Based Model
V
from Maxwell 2D
MOI

+
IGBT5 IGBT3 IGBT1
J
E1 113.1 Torque
IA
+
A A_Ph_p torque
A
+ IB A_Ph_m
A
+
Angle Speed
B_Ph_p
B_Ph_m
113.1

+
IGBT2 IGBT6 IGBT4 V A C_Ph_p
GAIN
E2 + IC C_Ph_m
V_AC
V

+
V_BC
PP := 4
ICA:
delta := 53.7

ctrl_6:=1 ctrl_1:=1 ctrl_2:=1

ctrl_1:=1 ctrl_2:=1 ctrl_3:=1

theta>90 AND theta<150 theta>150 AND theta<210 theta>210 AND theta<270

ctrl_5:=1 ctrl_4:=1 ctrl_3:=1

ctrl_6:=1 ctrl_5:=1 ctrl_4:=1

theta>30 AND theta<90

theta>330 OR theta<30 theta>270 AND theta<330
 Maxwell 2D -Transient FEA

Geometry takes advantage

of symmetry boundaries

Simultaneous Equations:
∂A
Field Equation: ∇ × υ∇ × A = J s − σ − σ∇ V + ∇ × H c + σ v × ∇ × A
∂t
N f l dA d if duc
Circuit Equation: d f ∫∫ dΩ + R if + L + uc = u s if − C =0
S f a dt dt dt

Motion Equation mα + λω = Tem + Texternal

 Maxwell 2D - Circuit Elements
Position Dependent Control Circuit

Phase Winding

Switch based on: time, speed, position, voltage, or current

Maxwell 2D - Mechanical Setup
 Maxwell 2D - Core Loss
Steel:
2 2 2 3/2
Loss density = Kh f B max + Kc f B max + Ke (f Bmax)
Loss will be a function of Lamination Thickness

Power Ferrite:
Loss density= Cm fx By_max
Fixed Finite Element Mesh

stationary part

master moving surface

7 6 5 4 3 2 1

7' 6' 4' 2' 1'

5' 3'

slave moving surface

moving part(s)
Maxwell 2D - Results
Maxwell 2D - Results
Maxwell 2D - Results
Conclusion
 Conclusion

Phase Winding