ElectromagneticForce

CouplinginElectricMachines

MarkSolveson,Cheta Rathod,MikeHebbes,
Gunjan Verma,Tushar Sambharam
ANSYS,Inc.
1

2011ANSYS,Inc.

September6,2011

Introduction
Lownoiseregulation
Aimedatreductioninnoisepollution

ComfortCriteria
Noisecausesdiscomfortandfatigue
Noisesuppressiondemonstrates
technological/marketingedge

ComponentFailure
Sensitivityofstructuretoacousticresonances

TheaboveAppliestomanyIndustrysectors:
Transportation,Power,Environmental,Buildingservices
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Introduction
Noiseandvibrationinelectricmachinescomefrom
manysources.
ANSYSprovidesexcellentcapabilitiesforthedesignand
analysisofelectricmachines:

Electromagneticperformance
ElectricDriveperformance
Structuralanalysis
Thermalanalysis
Acousticsanalysis

ANSYSfieldcouplingtechnologyallowsmappingof
electromagneticforcesforMechanicalanalysis
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MachineTypes
Differentmachinesmayhavedifferentconsiderations
dependingontheirarchitectureorcontrolstrategies.
PrimaryForcesareinplane(radialandtangential)
SingleandThreePhaseInductionMachines.
PMSynchronousMachines(SurfaceMount,IPM).
Switchedreluctancemachines
PrimaryforceareAxial
AxialFluxMachines

2011ANSYS,Inc.

September6,2011

NoiseSources[1]
Magnetic

Mechanical

Aerodynamic

Electronic

FluidCooling
Phenomena

Radial
Self

Switching
Harmonics

LoadInduced

Auxiliaries

Slot
Harmonics
Stator

Magnetic
Unbalance

Couplings

Rotor

Foundation

Modesof
Vibration
Bearings

Balancing

Static
Eccentricity

Dynamic
Eccentricity
Unbalanced
Rotor

Audible
Frequencies

20Hz
5

60Hz

2011ANSYS,Inc.

Elliptical
RotorSurface

261.63Hz
September6,2011

4.186kHz

5kHz

20kHz

[1]P.Vigayraghavan,R.Krishnan,NoiseinElectricMachines:AReview,IEEE,1998

ANSYSMachineModel

2011ANSYS,Inc.

September6,2011

ElectromagneticDesignandAnalysis
ANSYSMachineDesignMethodology
RMxprt:calculateratedperformanceformachine
Maxwell:CalculatedetailedmagneticFEAofmachineintime
domain
Simplorer:Calculatedetaileddrivedesignwithcoupled
cosimulation witheitherRMxprtorSimplorer.

SINE1

SINE2

SINE3

TRIANG1

IGBT1

D7

IGBT3

D9

IGBT5

D11

E1

RphaseA
PhaseA_in

PhaseA_out

PhaseB_in

PhaseB_out

PhaseC_in

PhaseC_out

RphaseB

RphaseC

VM1

MotionSetup1_in

MotionSetup1_out

E2
D8
IGBT2

D10
IGBT4

IGBT6

D12
0

V_ROTB1

2011ANSYS,Inc.

September6,2011

MachineModelinMaxwell Simplorer
2DIPM(InteriorPermanentMagnet)motormodelcreatedfromRMxprtand
MaxwellUDP(UserDefinedPrimitive)forrotor
Model

Model

DModel1
D40

+
-

D35

S_48

S_46

SModel1

D44

4pole,1500RPM,220VoltDCbus.
TwoControlStrategiesused:
6stepinverter InMaxwell
PWMcurrentregulated Cosimulation
MaxwellwithSimplorer

D42

D37

S_50

D39

110V
LabelID=V32

+
-

110V
LabelID=V33

D41

D43

D36

S_49

S_47

2.00694ohm
RA

LPhaseA

LabelID=VIB
0.000512893H*Kle
LB

2.00694ohm
RB

LPhaseB

LabelID=VIC
0.000512893H*Kle
LC

2.00694ohm
RC

LPhaseC

D45

D34

LabelID=VIA
0.000512893H*Kle
LA

D38

S_51

LabelID=IVc1
LabelID=IVc2
LabelID=IVc3
LabelID=IVc4
LabelID=IVc5
LabelID=IVc6
100ohm
100ohm
100ohm
100ohm
100ohm
100ohm
R20
R21
R22
R23
R24
R25

-1
+
1V
LabelID=V14

-1
+
1V
LabelID=V15

-1
+
1V
LabelID=V16

-1
+
1V
LabelID=V17

-1
+
1V
LabelID=V18

-1
1V
LabelID=V19

SINE1

SINE2

SINE3

TRIANG1

IGBT1

D7

IGBT3

D9

IGBT5

D11

E1

RphaseA
PhaseA_in

PhaseA_out

PhaseB_in

PhaseB_out

PhaseC_in

PhaseC_out

RphaseB

Basic_Inverter1

VM1

TR

0.88

MotionSetup1_in
D8

D10

IGBT6

IGBT4

TR
TR

MotionSetup1_out

E2
IGBT2

Sine Triangle

1.10

TR

ANSOFT

Curve Info
SINE1.VAL
SINE2.VAL
SINE3.VAL
TRIANG1.VAL

D12
0

0.25

Y1

RphaseC

V_ROTB1
-0.38

2011ANSYS,Inc.

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-1.00
-1.10
20.00

22.50

25.00

27.50

30.00
Time [ms]

32.50

35.00

37.50

40.00

MachineModelinMaxwell Simplorer

Torque

SAS IP, Inc.

15.00

Basic_Inverter1

ANSOFT

Currents

SAS IP, Inc.

20.00

Basic_Inverter1

Curve Info
TR

ANSOFT

Curve Info

FEA1.TORQUE

TR
TR

15.00

TR

RphaseA.I
RphaseB.I
RphaseC.I

12.50

10.00

10.00

Y1 [A]

FEA1.TORQUE

5.00

7.50

0.00

-5.00
5.00

-10.00

2.50

-15.00

0.00
20.00

22.50

2011ANSYS,Inc.

25.00

27.50

30.00
Time [ms]

September6,2011

32.50

35.00

37.50

40.00

-20.00
20.00

22.50

25.00

27.50

30.00
Tim e [ms]

32.50

35.00

37.50

40.00

ForceCalculations
Force calculationusingairgapfluxdensity
Maxwell StressTensor

Forcecalculationatapointonthestator.
Forceonalineintheairgap
Forceonalinecolinearwiththestatortooth
EdgeForceDensity
DefaultfieldquantityavailableinMaxwell
Canbeusedforcreatinglumpedforce
calculationsontoothtips

AutomaticForcemappingfromMaxwellto
ANSYSMechanical.(2D2D,2D3D,3D3D)
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EdgeForceDensityinMaxwell
Tangential Force on Tooth Tips

02_DC-6step_IPM

ANSOFT

10.00

5.00

Force (Newtons)

0.00

-5.00

-10.00

-15.00
Curve Info
ExprCache(ToothTipTangent_Full1)

-20.00

ExprCache(ToothTipTangent_2)
ExprCache(ToothTipTangent_3)
ExprCache(ToothTipTangent_4)

-25.00

ExprCache(ToothTipTangent_5)
ExprCache(ToothTipTangent_6)

-30.00
0.00

5.00

10.00

15.00

20.00
Time [ms]

25.00

30.00

Radial Force on Tooth Tips

35.00

02_DC-6step_IPM

40.00

ANSOFT

50.00

-0.00

Force (Newtons)

-50.00

-100.00

-150.00

Curve Info
ExprCache(ToothTipRadial_Full1)
ExprCache(ToothTipRadial_2)
ExprCache(ToothTipRadial_3)

-200.00

ExprCache(ToothTipRadial_4)
ExprCache(ToothTipRadial_5)
ExprCache(ToothTipRadial_6)

-250.00
0.00

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2011ANSYS,Inc.

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5.00

10.00

15.00

20.00
Time [ms]

25.00

30.00

35.00

40.00

EccentricityModel

LeftSide
Tooth

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2011ANSYS,Inc.

RightSide
Tooth

September6,2011

ParametricStudyofEccentricity
Electromagetic Force
Rotormissaligned
0%,25%,50%
Solved
simultaneouslyon
multicorecomputer
Shown:RadialForce
onRightToothTip
FFTofRadialForce

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EdgeForceDensity,50%Eccentricity

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2011ANSYS,Inc.

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50%Eccentricity:RadialandTangential
ForceonRightSideandLeftSideTooth
Radial Tooth Tip Forces

0.00

ANSOFT

Tangential Tooth Tip Forces

15.00

ANSOFT

10.00
-50.00
5.00

0.00

Force (N)

Force (N)

-100.00

-150.00

-5.00

-10.00

-200.00

-15.00

-20.00
-250.00
Curve Info
Radial Force Small Gap
Radial Force Large Gap

-300.00
20.00

15

22.50

25.00

2011ANSYS,Inc.

27.50

30.00
Time [ms]

32.50

September6,2011

35.00

37.50

Curve Info
Tangential Force Small Gap
Tangential Force Large Gap

-25.00

40.00

-30.00
20.00

22.50

25.00

27.50

30.00
Time [ms]

32.50

35.00

37.50

40.00

ANSYSForceMapping

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TwoApproaches
DirectForceMapping
ElectromagneticforcesfromMaxwellto
Mechanicalbylinkingsystemsin
Workbench
TransientAnalysisforStressprediction

LumpedForceMapping
ToothTipobjectscreatedformapping
calculatedlumpedforceusing
EdgeForceDensityinMaxwell.
Applytheselumpedforcesmanually
orthroughAPDLMacro
FurtherharmonicandNoiseAnalysis

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Approach1 DirectForceMapping
Scenario:StudytheeffectofRotorEccentricity
Case1:0%Eccentricity
Nomisalignment

Case2:50%Eccentricity

PeakEdgeForceDensity1.5e6N/m2

Eccentricityamountissetto
50%ofgapwidth
Createsunbalanced
electromagneticforces

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PeakEdgeForceDensity1.9e6N/m2

DirectionalDeformationRadial
This image cannot currently be display ed.

MaxDeformationvs time

Case10%Eccentricity
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2011ANSYS,Inc.

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Case250%Eccentricity

This image cannot currently be display ed.

VonMissesStress
MaxStressesvs time

Case10%Eccentricity
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This image cannot currently be display ed.

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2011ANSYS,Inc.

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Case250%Eccentricity

Results:Comparison
Highertheamountofeccentricity,higheristhevariationof
electromagneticforces,causingdeformationofstator,
vibrationandnoise

TotalDeformation
Deformationhigherforeccentric model

PeakStresses

Stressesattime=12ms

StatorStressesarenonsymmetricandhigherforeccentricmodelwheretheair
gapisminimum

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2011ANSYS,Inc.

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Approach2LumpedForceMapping
ElectromagneticForces
Exportforces
ANSYS
Maxwell

Workbench
FlowChartfor
NoisePrediction

LumpedForcesinTimeDomain
PerformFFTinMaxwell
Real/ImaginaryForces
InFrequencyDomain
APDLinWorkbench

ANSYS
Mechanical

HarmonicResponse
APDLinWorkbench

ANSYS
Acoustics
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ExtractAcousticPressures

ANSYSHarmonicAnalysis

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ModalAnalysis:GetResonantFrequencies

Mode#1,8502Hz

Mode#2,8708Hz

Mode#3,8708Hz

FirstfourNaturalFrequencyand
correspondingmodeshapes

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2011ANSYS,Inc.

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Mode#4,9080Hz

WhyHarmonicAnalysis

Tomakesurethatagivendesigncanwithstandsinusoidalloadsat
differentfrequencies

Todetectresonantresponseandavoiditifnecessary(byusingdampers,
forexample)

TodetermineAcousticresponse

BoundaryConditions

InputForces

Applingharmonicforcesfrom
MaxwellintoANSYSMechanical
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2011ANSYS,Inc.

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HarmonicResponse Bodeplot
Frequencyresponseataselectednodelocationofthemodel.

Helpsdeterminethat
MaxAmplitude(1.7mm)
occursat8710Hzonthe
selectedvertex
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2011ANSYS,Inc.

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HarmonicResponse Contourplot
Amplitudedistributionofthedisplacementsataspecificfrequency,

Deformationplotat8710Hz

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ANSYSAcoustics

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AcousticsCapabilitiesinANSYS
Acousticsisthestudyofthegeneration,propagation,absorption,
andreflectionofsoundpressurewavesinanacousticmedium.

Acousticproblemscanbeidentifiedas
VibroAcoustics:Soundgeneratedstructurally(ANSYSMechanical)
AeroAcoustics :Soundgeneratedaerodynamically(ANSYSCFD)

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2011ANSYS,Inc.

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ModelingAeroAcoustics(ANSYSCFD)
FreeSpaceProblemwithnosolidsurfaces:
soundgeneratedfromturbulence,jetnoise

FreeSpaceProblemwithsolidsurfaces:
Fannoise,airframenoise,rotornoise,boundarylayernoise,
cavitynoise

Interiorproblem:
Ductnoise,mufflers,ductedfannoise

Soundpressurefluctuations
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VibroAcoustics(ANSYSMechanical)
Computingtheacousticfieldradiatedbyavibratingstructure

31

StructuremodeledinANSYSMechanicalwherevibration
patternsarecalculated(Modal,HarmonicAnalysis).Applied
loadsareobtainedfromMaxwell.

Vibrationpatternsusedasboundaryconditionstocompute
acousticfieldradiatedbystructure(ANSYSMAPDL,ANSYS
AcousticStructuresACTRAN)

2011ANSYS,Inc.

September6,2011

ANSYSAcousticsStructure
ANSYSAcoustics
Structurescomputes
noiseradiatedby
vibratingstructures.
FromHarmonic
Vibrations toNoise
Estimates.
ANSYSAcoustics
Structuresintegrateswith
yourcurrentsimulation
tools.

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AcousticAnalysis PressurePlot
This image cannot currently be display ed.

This image cannot currently be display ed.

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AcousticAnalysis PressurePlot

0.5m

Pres_2

Pres_3

Pressurevs Freq

Pressure(Pa)

Pres_1

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2011ANSYS,Inc.

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Freq(Hz)

Summary
Investigateddifferentnoisesourcesforelectricmachines
DemonstratedanintegratedapproachfromElectromagnetics

toStructuraltoAcoustics.
Showedtheeffectsofstaticeccentricityonstatortoothforces,
deformationandstresses.
Performedmodalanalysistofindtheacousticresonances

FutureWork:
Investigationofdifferentnoisescenarios(machinetypes,drives)
Includemoremechanicaldetails(windings,housing,etc)
Expandharmonicanalysistoincludehigherfrequencycontentofforces
FurtherinvestigationofAeroacousticswithANSYSCFD

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References
P.Vijayraghavan,R.Krishnan,Noiseinelectricmachines:AReview,IEEE,1998
K.Shiohata,R.Kusama,S.Ohtsu,T.Iwatsubo,TheStudyonElectromagneticForce
InducedVibrationandNoisefromaNormalandEccentricUniversalMotors,PIERS
Proceedings,2011.
S.Fink,S.Peters,Anosft NoisePredictionforElectricalMotors,CADFEM/ANSYS
Presentation,2011.
WeiWang,Quanfeng Li,Zhihuan Song,Shenbo Yu,Jian Chen,Renyuan Tang,Three
DimensionalFieldCalculationandAnalysisofElectromagneticVibrationandNoiseforDisk
PermanentMagnetSynchronousMachines,ShenyangUniversityofTechnology,China.
R.Belmans,D.Verdyck,W.Geysen,R.Findlay,ElectroMechanicalAnalysisoftheAudible
NoiseofanInverterFedSquirrelCageInductionMotor,IEEE,2008.
M.Anwar,I.Husain,DesignPerspectivesofaLowAcousticNoiseSwitchedReluctance
Machine,IEEE,2000.
S.Huang,M.Aydin,T.A.Lipo,Electronmagnetic VibrationandNoiseAssessmentfor
SurfaceMountedPMMachines,IEEE,2001.
Rakib Islam,Iqbal Hussain,AnalyticalModelforPredictingNoiseandVibrationin
PermanentMagnetSynchronousMotors,IEEE2009.
Pragasen Pillay,William(Wei)Cai,AnInvestigationintoVibrationinSwitchedReluctance
Motors,IEEETransactionsonIndustryApplications,Vol.35,NO.3,May/June/1999.
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ThankYou

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TitleandAbstract
ElectromagneticForceCouplinginElectricMachines
IncludingStress,Deformation,andAcousticAnalysis.
Understandingtheimpactofelectromagneticforceson
noisegenerationforelectricmachinescanincludemany
factors. Thispresentationwillreviewtheseissuesand
illustrateelectromagneticforces,stress,deformation,and
acousticcouplinginANSYSWorkbench. Anexample
showingautomaticmappingofmagnetictimedomain
forces,andacomparisonofstressesfordifferentrotor
eccentricitieswillbeshown.
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PresentationOutline(Goal30totalSlides)
1.

Introduction

2.

Literaturereview whatarethenoisecomonents forelectricmachines

a.
b.

3.

EMMotorMethodology
a.
b.
c.

4.

NoiseSources,examples
AcousticDefinition,examples
RMxprttoMaxwell,Simplorer
Forcecalculations
EccentricityModel

MechanicalAnalysis
a. 2D(3D?)transientforcemappingresults
b. DiscussionofFFTapproaches(byinspectionor3rd partytools/scripts)
c. 2D(3D?)harmonicAnalysis

5.

Acousticanalysis
a. Generalcapabilities(acousticelements,Actran coupling?)
b. Resultsforstatorlamination

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NoiseSources
Magnetic
Theinteractionofmagneticfieldsandcurrentsinthemachinecause
electromagnetictorque andthusrotationoftherotor.
Evaluationoftheradialandtangentialforcesonthetoothtipsareimportant.
Thiscanbeaccomplishedthroughevaluationoftheairgapfluxdensity,orusing
ForceDensityfieldcalculationsavailablewithinMaxwell.
Ifoneoftheradialforcefrequenciescoincideswiththenaturalfrequency ofthe
machine,resonanceoccursleadingtoacousticnoise.
Mixedproductofstatorandrotorwindingspaceharmonics.
SlotHarmonics
RotorEccentricity:improperrotoralignmentcausingunbalancedmagnetic
forcesonthestator.
Laminationvibrationduetomagnetorestrictiveforces(worstwhennotstacked
properly)

Electronic
40

Switchingnoise
InverterPWMfrequenciescanbeinaudiblerange.
2011ANSYS,Inc.
September6,2011
Currentthroughthewinding
Lorentzforces

NoiseSources
Mechanical
Selfresonance naturalresonancefrequencies
Closedformequations
FEA
Loadinduced
Couplingofmachinetoload,andmounting.
Auxiliaries
BearingVibration
Brushcommutators
Chattering
Intralamination
FunctionofBoltforce
Involves3DMechanicaltransientvibrationanalysis
Manufacturingasymmetriesoftherotorandstator nonuniformairgap
Statorwindingwhicharenotinstalledproperly

AeroDynamics
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ANSYSCFD

MachineModelinMaxwell
VBscriptFieldsCalculatortocreateRadialand
TangentialForceExpressionsfrom
EdgeForceDensity
VBscriptCalculatesRadialandTangential
ForceonToothTips
Allowsonlyforceonedgethatneighborsnon
ferrousobjects
Halfteethforcecomponentsaddedtogether
AddtoExpressionCache

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HarmonicAnalysisOverview
Atechniquetodeterminethesteadystateresponseofastructureto
sinusoidal(harmonic)loadsofknownfrequency.
Input:
Harmonicloads(forces,pressures,andimposeddisplacements)ofknown
magnitudeandfrequency. (ObtainedfromMaxwell)
Maybemultipleloadsallatthesamefrequency.
Output:
HarmonicdisplacementsateachDOF,usuallyoutofphasewiththeapplied
loads.
Otherderivedquantities,suchasstressesandstrains.

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ANSYSAcoustics

Structuralbornenoise(onewayVibroAcoustics)
ANSYSAcousticsStructures(FFTsACTRANSolver)

VibroAcoustics
ANSYSMechanical(APDLSolver)

AeroAcoustics
ANSYSCFD

Nonlinearfluidstructureinteraction
ANSYSCFD+ANSYSMechanical

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AeroAcousticsANSYSCFDApproaches
Directcalculation:

45

ResolvetheacousticpressurefluctuationsaspartoftheCFD
solution
CoupleCFDwithspecializedacousticscodes,Boundary
ElementMethods(BEM),Hybridzonalmethods
AcousticwavesarenottrackedwithCDFsolution
Calculatewavepropagationusingspecializedcodes(ACTRAN,
SYSNOISE)

2011ANSYS,Inc.

September6,2011

AeroAcousticsimulationofAutomotive
FrontEndModulecoolingfans
byusingFLUENTsAcousticmodule
CourtesyofHyundaiMOBIS,Korea

Computationaldomain
GeometryofCoolingFans

PressureContours
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2011ANSYS,Inc.

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Soundpressure
fluctuations
FlowPathlines through calculatedatthe
receiverposition

SubwooferExample(ANSYSCFD)
(nonlinearfluidwithstructure)

FluidStructureInteractionSolution

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TransientPressures

Acoustic StructuralExample Coupled

AcousticEnergy
Source

TargetObject:
NestedCylindrical
Cans

ScatteredAcoustic
Radiation

AnimationofAcoustic
Pressure(Pa)

FEAModel
quarterSymmetry
Hemispherical
Domain

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