Vibroacoustic Simulation

of
Claw Pole Generator
Dr. Martin Hanke
Jens Otto
Daniel Bachinski Pinhal

PRACE Autumn School 2013 - Industry Oriented HPC Simulations, September

21-27, University of Ljubljana, Faculty of Mechanical Engineering, Ljubljana,
Slovenia
ANSYS Maxwell: Motor Simulation Overview
 Motor performance analysis by
Maxwell, RMxprt
 Coupled with Simplorer for Motor
Control 出力，効率特性 (Vdc=1.5V)
800 80

 DC Motor
600 60

Efficiency [%]
Output [mW]
 Induction Motor 400 40

 PM Motor 200 Output

Efficiency
20

 SR Motor 0
0.0 1.0 2.0 3.0 4.0
0

Torque [mN-m]

 Claw Pole Alternator

 Linear Motor

-1- © 2013 CADFEM GmbH

 ANSYS Maxwell: PM Motor
 dq axis Inductance vs Torque

T  Tm  Tr
 Pn a I a cos 
Pn
 ( Lq  Ld ) I a sin 2
2

2
Ld, Lq vs iq (id=0, Thet=0) Ld, Lq vs Thet (id=0, Ie=40)
7 7

6 6

5 5
Ld, Lq [mH]

Ld, Lq [mH]

4 4

3
Ld 3
Ld
Lq Lq
2 2

1 1

0 0
0 20 40 60 80 100 0 10 20 30 40 50 60 70 80 90

Ie [A] (=iq/sqrt(3)) Thet [deg]

-2- © 2013 CADFEM GmbH

ANSYS Maxwell: Claw-Pole Alternator

Core Loss
Torque Characteristic tra_motor_1440rpm ANSOFT
16.00
Curve Info
avg(Moving1.Torque)
14.00 Setup1 : Transient
I_f='1A'
avg(Moving1.Torque)
Setup1 : Transient
12.00 I_f='2A' Name X Y
avg(Moving1.Torque) m1 60.0000 10.0624
Setup1 : Transient m1

avg(Moving1.Torque)
10.00 I_f='3A'
avg(Moving1.Torque)
Setup1 : Transient
I_f='4A'
8.00
avg(Moving1.Torque)
Setup1 : Transient
I_f='5A'
6.00

4.00

2.00

0.00
0.00 20.00 40.00 60.00 80.00 100.00
I_a [A]

Torque
Shota Takayama, Takashi Abe, Tsuyoshi Higuchi (Nagasaki University),
'22 Institute of Electrical Engineers Industry Applications large Heisei, Vol.1
No.Y-101
-3- © 2013 CADFEM GmbH
Object of Interest
 Claw pole alternator
 Used widely in automotive sector
 Low cost
 Starter generator/ power for electronics

 Some machine parameters

 5 phase Source: CADFEM Source: Wikipedia
 16 poles
 80 slots
 Integer-slot winding (single layered)

 5-phase rectifier (full wave)

 Connects generator to supply system
 13.5V voltage level

Source: CADFEM

-4- © 2013 CADFEM GmbH

HANDS-ON

HANDS-ON-Starter-Generator-Simulation-with-Maxwell3D.docx

5 © 2013 CADFEM GmbH

Goal of Analysis
Supports
 Predict vibration at the outer housing
during operation

 Vibration behavior depends heavily

on assembled condition
 Housing is modeled
 2 fixed supports

Source: CADFEM

-6- © 2013 CADFEM GmbH

Insight in Theory of Linear Dynamics
 Output depends on two quantities
 Excitation (input)
 System characteristics (transfer
function)
 Calculation in frequency domain Source: CADFEM
(obtained from Fourier transform)
Tacoma Narrows Bridge (07.11.1940)
 Output obtained from multiplication
of excitation spectrum and transfer
function spectrum

 High output values results of:

 High value of input spectrum
 High value of transfer function
 Highest values when both
(e.g. resonance)
-7- © 2013 CADFEM GmbH
Simulation Approach (3 Step-Workflow)
 Transient electromechanical
simulation
 Extraction of excitation forces on
stator‘s teeth Resonance
Excitation
Frequencies
Forces
Shapes
 Modal analysis of stator and housing
 Corresponds to transfer function
extraction

Harmonic
 Harmonic analysis Analysis
 Mode superposition (Vibration)
 Using Extracted excitation forces

-8- © 2013 CADFEM GmbH

Workflow Implementation in Workbench
 Workflow steps are implemented in Workbench environment
 Visualization
 Easy geometry share
 Consistent parameterization

 ANSYS Design Modeler (B) is used to add housing to geometry from Maxwell

Source: CADFEM

-9- © 2013 CADFEM GmbH

Transient Electromagnetic Simulation inside Maxwell
 3D geometry of machine

 axis of rotation: global Z-axis

 Simulation setup should include 1

stationary period for force evaluation
Source: CADFEM
 Period not necessarily always electric
period (e.g. fractional slot winding)

 Objective: Extract periodic

excitation of stator’s teeth during
stationary period
 Available data from simulation:
electromagnetic field distribution

- 10 - © 2013 CADFEM GmbH

Maxwell Stress Tensor
 Calculation of forces from EM fields M atrix Notation
 Simple situations: Lorentz force law  BH 
 ( H x  Bx  ) H x  By H x  Bz 
 In continua, (2D/3D) becomes more  2 
B H
complex   H y  Bx ( H y  By  ) H y  Bz 
 2 
 Maxwell stress tensor is a powerful tool  H z  Bx H z  By ( H z  Bz 
BH
) 
 2
 2nd order tensor  
 Makes use of tensor calculus
Index Notation
B H
 Tensor product of σ and surface  ij  H i  B j   ij  k k 2
normal is force density

 Straight forward procedure: d F    d A (3 equations)

 Compute B/H fields
 Program expressions for σ
 Multiplication of σ with normal vector at
each point of surface
 Result: surface force density

- 11 - © 2013 CADFEM GmbH

Force Calculation
 Calculation of surface force densities
not in real iron to air interface µ=µ0 µ>>µ0
 µ is not defined
 B and H have to be known for σ
Source: CADFEM

 Force densities on virtual surfaces in

the air gap
 Air gap is usually small
 Good engineering precision
 Surfaces should be segmented to
obtain more accurate results

- 12 - © 2013 CADFEM GmbH

Force Calculation
 Using force densities
 compute moments of rising order with
respect to rotational axis
M k   z k  d F (3  k equations)

 e.g. for k=0 Mk correspond to forces in z- coordinate of dF

x, y and z directions

 Goal is to represent force densities

through discrete forces
(later in Mechanical)
 Resulting in the same moments until
kth order

 In Maxwell we just calculate the Source: CADFEM

Moments until kth order for x,y and z

for teeth

- 13 - © 2013 CADFEM GmbH

Force Calculation
 kth order moments are needed for
each stator tooth
 Simulation during rotation over all
relevant teeth
 Number of files: (x, y, z)

N files  nteeth  k  3

Max. moment order

 Smart approach:
 Each tooth experiences same fields
(in this example)
Source: CADFEM
 Leads to same force densities
 Time i.e. phase shifted
 See animation to the right
 Moment calculation for 1 single tooth
- 14 - © 2013 CADFEM GmbH
Demonstration

Emvib.wbpz
15 © 2013 CADFEM GmbH
Implementation in ANSYS Maxwell
 Steps Recap
 Define simulation model
 Define integration surface in air gap
 Compute B and H fields
 Use expressions to calculate σ
 Compute surface force densities
 Evaluate moments until kth order

 This results will be exported to be

used as excitation
 Fourier Transform still needed
 done in Mechanical to apply phase shift
manually
 Use forces of one tooth phase shifted
for all (for cyclic cases)

- 16 - © 2013 CADFEM GmbH

Implementation in ANSYS Maxwell
 Simulation Process is controlled by
one Python script
 Emag_Vibration_FIX.wbjn

 Some adaption can be performed at

the header (e.g. file paths)
 Name of project
("Klauenpolmaschine_DEMO_V16_1")
 Name design
("Sektor_Transient_No_Eddy")
 Name of analysis setup
(“EMVIB")
 Path of 2 calculator files
 Expressions for (σ, dF, Mk)
Source: CADFEM
 Required: rotation around global z

- 17 - © 2013 CADFEM GmbH

Implementation in ANSYS Maxwell
 Define segmented integration
surface(s) at air gap
 Sheet
 Here: only for one tooth

 Add sheets corresponding to

integration surface to object list
 Required name: EVAL_FORCE Source: CADFEM

 Specify middle angle of integration

surface in script’s header
 Here: 22.5°

φ
- 18 - © 2013 CADFEM GmbH
Handling and Export of Moments
EMVIB 1_1_Teilmodell_Test1

 Moments (up to kth order) are 6

plotted in report 5

 Units differ (N, Nm, Nm²…) 4

 In this case

Y1
2
 Moments in z direction unchanged
1
 Moments in x and y direction converted
0
 Using sin / cos of 22.5°
-1
4.00 5.00 6.00 7.00 8.00 9.00 10.00
Time [ms]
 Results in Moments in radial,
tangential and axial direction for
tooth used for force evaluation

 Report content exported as csv file

Source: CADFEM

- 19 - © 2013 CADFEM GmbH

Vibration Simulation
 Description of nodal displacements
 Two possibilities
 For each node (magnitude, phase)
 For each modal shape (magnitude, Source: CADFEM
phase) max mode
sn   u m , n  sm
sn: nodal displacement
sm: modal displacement
m 1 um,n: participation (projection) factor
 Vibration analysis with mode
superposition 1st normal mode 4th normal mode
 Modal analysis to extract eigenmodes
 Arbitrary periodic displacements
summation of weighted eigenshapes

 First step: Modal analysis

 Calculation of frequencies/shapes
Source: CADFEM

- 20 - © 2013 CADFEM GmbH

Vibration Simulation
max mode
 Velocities squared (mean value)
better than displacements sn  u
m 1
m,n  sm
 Sound power (density)

p  c    vn2,normal, RMS max mode

2
vn ,normal, RMS    u m,n  sm
v m 1
P  c     n , normal
 dA
2 v 2 n ,normal, RMS   2   um,n  um ',n  sm '  sm
m m'
 All equations already
c    2
 s  sm   um,n um ',n  dA
programmed in scripts
 Um,m’ matrix will be
P m'
computed in modal analysis for
2 m m'
radiating surfaces c    2
P
2
 s
m m'
m'  sm  U mm '

- 21 - © 2013 CADFEM GmbH

Modal Analysis 3rd normal mode

 Additionally to eigenmode extraction

 Creation of remote points
 Used later for excitation of teeth
 Calculation of projection factors
 Only for surface interface with air
 Here: outer cylindrical surfaces

6th normal mode

 3 APDL snippets
 Order of scripts is important
 Surface Areas Source: CADFEM
 Remote Points
 Modal_vsqr_Mean

- 22 - © 2013 CADFEM GmbH

Modal Analysis (Snippets Functionality)
 Surface Areas
 Needs surface named selection of Face nx ny nz
radiating surfaces
1 … … …
 Calculates normal vectors for surfaces
2 … … …
 Magnitude is area
… … … …
 Saves data in matrix
Source: CADFEM

 Remote Points
 Creates excitation points on teeth
 Here: 4 point/tooth in axial direction
 Requires number of stator’s teeth as
argument 1

 Modal_vsqr_Mean
 Calculates participation factors c    2
(for velocities squared)
 No global expansion pass needed
P
2
 s
m m'
m'  sm U mm '

- 23 - © 2013 CADFEM GmbH

Harmonic Response Analysis
 Mode superposition
 Supports are inherited from modal

 5 APDL snippets
 Order of scripts is important

 4 for setup
 Read_Force_Moments
 Diskrete_Fourier_Transformation
Source: CADFEM
 Vandermonde_Matrix
 Rotational_Speed_Loop

 1 for post processing

 SBS_Waterfall

- 24 - © 2013 CADFEM GmbH

Calculating Excitation for all Teeth
 Kth order Moments are periodic
functions (period = T)
 Fourier series (complex notation)
 
f (t )   ar  cos(rt ) br  sin(rt )  r
c  e ir ( 2 / p )t

r 0 r  

 Different teeth exposed to shifted

function
  
f (t  s)   c' e
r  
r
ir ( 2 / T )t
 c
r  
r e
ir ( 2 / T )( t  s )
 c
r  
r  e ir ( 2 / T ) s
 e ir ( 2 / T )t

c'r  cr  e ir ( 2 / p ) s
 a'r   cos( j  (2  s / T ))  sin( j  (2  s / T ))   ar 
       
 b'r   sin( j  (2  s / T )) cos( j  (2  s / T ))   br 

- 25 - © 2013 CADFEM GmbH

Harmonic Response Analysis (Snippets Functionality)
 Read_Force_Moments  Arguments
 Reads kth order Moments files from  arg1: relative Ω step size for scaling
Maxwell  arg4: rotational speed steps for scaling
 Diskrete_Fourier_Transformation  arg5: nominal rotational speed (Ω) in
 Performs Fourier Transform rpm
 Vandermonde_Matrix  arg2: # of header lines of csv (here: 2)
 Solves equation system to the right  arg3: # pole pair of machine
 Create forces on remote points  M xk 
 k
S z d F  S z  d A   M yk 
k k
 Discrete forces lead to same
moments as distributed surface force
Mz 
densities from Maxwell (until order k)
n 1 T
 Rotational_Speed_Loop 1 z1
z2
.. z   F1, x   M x0 
 1 1 1
n 1
    1 
 Varies rotational speed 1 z1
2 z3
2 .. z   F2, x   M x 
2
1 1 2
z    F3, x    M x2 
n 1
 Scaling of time while Fourier  z3 z3 .. 3
transforming  .. .. .. .. ..   ..   .. 
     
1 z1n zn2 .. z nn 1   Fn , x   M xn 1 
- 26 - © 2013 CADFEM GmbH
Resulting Carpet Plot
 Simulated Result:
 Harmonic response for single angular
speed Ω defined in Maxwell
2400 rpm
 Ω sweep:
 Through time axis scaling in Fourier Ω
transform
 Using arguments of
Read_Force_Moments script

 Carpet plot:
 Locate critical modes at specific
rotational speeds
f

Source: CADFEM

- 27 - © 2013 CADFEM GmbH