  SolidWorks + JMAG-Designer + JMAG-Studio + modeFRONTIER

CD-adapco JAPAN Co., LTD.

Integrated Simulation Technology Dept.
Yasushi Fujishima (yasushi.fujishima@cdaj.co.jp)

2008 modeFRONTIER® users' meeting 2008

October 14-15, Trieste Italy
2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Introduction

  Definition of Optimization Problem for Rotor Design

of Interior Permanent Magnet Synchronous Motor

  Analysis model and configuration

  Optimized Results

  Conclusion

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Design optimization of Interior Permanent Magnet

Synchronous Motor (IPMSM) was conducted applied for
railway traction systems of electric commuter train.
Electric Commuter Train�

IPMSM Configuration �
Electric Commuter Train�
Stator

Winding Coil

Rotor

Permanent Magnet

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Difficulties
  Rotor shape of IPMSM often becomes complicated structure involving
magnetic saturation and concentration of mechanical stress. Therefore it
is not easy to determine optimal rotor shape.

Torque Magnetic Analysis Structural Analysis

Characteristics Mass Reduction

Circuit Voltage
Characteristics
Reduce Mechanical
stress
High Efficiency

  Plural characteristics must be improved simultaneously under the several

constraints.

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

Torque Generation

IPMSM Configuration �
S N
Stator S

Winding Coil N
N

Rotor
S
Permanent Magnet N S

N Magnetic attraction force Torque

Magnetic Pole Generation
S Magnetic repulsion force

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

Torque of IPMSM is divided by magnet torque and reluctance torque.

Without permanent magnet Permanent Magnet only.

S
S N

N N

N S S
Reluctance torque is only generated by Magnet torque is only generated by
magnet poles established by the salient magnet poles established by permanent
shape of rotor core. Magnet.

To maximize the total torque, one has to try to maximize both the magnet torque and
reluctance torque simultani that are

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Maximization of Average Torque

  Minimization of open-circuit voltage

  To prevent unexpected regenerative brake at maximum speed during no
-load operation

  Minimization of Rotor Mass

  To reduce total mass

  Minimization of max value of Von Mises Stress

  For at max speed operation

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  What is JMAG ?
  Electromagnetic field analysis software based on FEM (or FEM-
BEM) developed by Japan Research I Solutions, Limited.

  Application Field
  Motor, Actuator, Transformer, Sensor, Magnetic Recording
Device, Antenna, other electro-magnetic devices and so on.

  Other topics
  2D/3D FEM analysis, FEM-BEM combined analysis, static field,
Quasi-Static Field, High frequency field, Frequency domain.
  Including electric circuit, thermal, structural analysis solver and
these can be coupled with magnetic field analysis.
  Can also be applied for a wide range of system design problems,
including drive circuits by the capability to link the analysis with a
power electronics simulator (Matlab, PSIM, etc).
  CAD direct interface (Solidworks, CATIA, Pro/E, and so on)

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Magnetic Analysis
  Analysis-1・・・Load Analysis (Appling Maximum Current Source)
  For evaluating Torque

  Analysis-2・・・No-Load Analysis ( Without appling Current Source)

  For evaluating open-circuit induced voltage

  Model Configuration
  Analysis Method : 2-dimentional FEM analysis
  Analysis Area : Quarter part of model considering periodic boundary condition
  Num. of Element: 10000 
  Num. of Node : 5000
  Magnetic Materials
  Stator/Rotor・・・non-oriented magnetic steel (50H400)
  Permanent Magnet ・・・Rare Earth Magnet (39SH)

30°
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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Configuration of Main Electric Circuit

No-Load Analysis Load Analysis
U-Phase

W-Phase

V-Phase

U-Phase

  Power Source : Three-phase symmetric alternating current

  Effective value of current :123.7[A]
  Connection : Star
  Num. of Turns : 18 turns per 1 slot

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Structural Analysis
  For evaluating maximum Von Mises Stress Value

  Model configuration
  Analysis Method : FEM Analysis
  Analysis Area : 1 / 8 Rotor considering symmetric
and periodic
  Num. of Element : 10000
  Num. of Node : 4000
  Material Value 

Young's
Material Poisson’s ratio Density[kg/m3]
modulus[Pa]
Iron Core 2.1*1011 0.3 7850
Perm. Magnet 1.2*1011 0.3 8400

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  The number of design variables :12

  11 for rotor shape design variables x1, x2, x3, x5, x6, x7, x8, x9 : [mm]
  1 for winding current phase [deg] Variable unit x4, x10, x12: [deg]
x11: [%]

x11 = L1/L2 * 100 [%]

x6
L2 x10
L1
x9

x8 x4
x3
x2 x5
x1
x7

Why the winding current phase must be added as design value ?

Maximum torque depends on the winding current phase. So it must be optimized
simultaneously to obtain maximal torque.
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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Max. Von Mises Stress・・・Less than 200[MPa]

  Torque・・・More than 600[Nm]
  Can realize Rotor Configuration (Avoid unfeasible shape
design)

Cannot generate FEM meshes for field analysis !

Must be avoided to Compute.

The bridge part is broken due to unfeasible set of

design parameters.

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

Change CAD parameters

and detect geometry error
by ExcelVBA.

SolidWorks has API so that user can

control it from outside.

SolidWorks has VBA macro recorder then

user can be somewhat easy to make VBA macros.

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

CAD Parameter Detection of geometry error before

JythonScript executing SolidWorks.

Change of parametric shape design

SolidWorks detection of geometry error .

CAD data
VBScript
JMAG-Designer

Return Output Variables

Torque/Voltage data.csv Magnetic Analysis

DOS batch JMAG-Script CAD data

JMAG-Studio

JMAG-studio output file(.plot) Structural Analysis

Return Output Variables

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

SolidWorks
Detection of JMAG-Designer
Geometry Error JMAG-Studio

Output Variables
Subsytem
(includes Determination of Geometry Error)

Objectives / Constraints
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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

 Step 1
  Optimization Algorithm : MOGA ( Multi-Objective GA)
  Primal individuals : Created Rondomly
  Num. of individuals : 24
  Num. of generations: 20

 Step 2
  Optimization Algorithm : Fast-MOGA (Using Adaptive Response Surface)
  Primal individuals: Copied a part of Pereto-Frontier obtained from Step 1
  Num. of individuals : 24
  Num. of generations: 20
  Probability of using Adaptive Response Surface : 50 %

 Step 3
  Optimization Algorithm : Fast-MOGA (Using Adaptive Response Surface)
  Primal individuals: Copied a part of Pereto-Frontier obtained from Step 2
  Num. of individuals : 24
  Num. of generations: 20
  Probability of using Adaptive Response Surface : 50 %

 Total Num. of Calculation : 747 case

 Total CPU-time : 60 hours (5min per 1 case) (Pentium-4 3.2GHz)

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Pareto-Frontier
Open Circuit Voltage [V]

Rotor Mass [Kg]

Average Torque [Nm] Minimize Average Torque [Nm] Minimize

Maximize Maximize

Trade-Off relationship between the Open Trade-Off relationship betweeen the Average Torque
Circuit Voltage and Average Torque and Rotor Mass

Need to degrade Open Circuit Voltage to Need to degrade Rotor Mass to inclease Average
inclease Average Torque beyond 600 [Nm] Torque beyond 600 [Nm]

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Rotor design on Pareto-Frontier (Average Torque vs Open Circuit

Voltage)

Hierarchical Clustering
(using Shape Design Parameters)

Rotor shape design among the Torque v.s. Voltage Pareto-Frontier were very similar !�

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Rotor design on Pareto-Frontier (Average Torque vs Open Circuit

Voltage)

Open Circuit Voltage [V]

Design of Rotor iron core is
almost the same except the
permanent magnet size.

Average Torque [Nm]

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  Investigation of Pareto-Frontier (Torque v.s. Voltage) from

the viewpint of Magnet Torque and Reluctance Torque
on Torque = Magnet Torque + Reluctance Torque

Magnet Torque Reluctance Torque

Magnet Torque Value is incleased along the Pareto-Frontier,

while Reluctance Torque Value is kept almost maximum value at the Pareto-Frontier.
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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy

  In this study, multidisciplinary optimization of IPMSM rotor shape

applied for railway traction system was conducted by
modeFRONTIER.

  Automating the optimization process, design engineers can be

assigned to more creative project.

  The following Trade-off relation was found:

  Maximizing Torque v.s. Minimizing Open Circuit Voltage
  Maximizing Torque v.s. Minimizing Rotor Mass

  Analyzing obtained Pareto-Optimal deeply by the multivariate

analysis (such as Clustering Analysis), underlying design principles
could be revealed.
  Rotor iron core designs were very similar on the Torque v.s. Voltage Pareto-Frontier. And
the reluctance torque of those designs was almost maximized.

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2008 modeFRONTIER® users' meeting 2008
October 14-15, Trieste Italy