Electromechanical Integration using Simplorer

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Hubert Merritt
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2 Process V Requirements & Specifications System System Acceptance System Topology & Layout Circuit Sub-System Integ. & Verification Sub-System Options & Design Physics Component Integration & Verification Component Optimization 2010 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

3 Process V Requirements & Specifications System Topology & Layout System Circuits and Systems: Simplorer, RMxprt, PExprt Circuit System Acceptance Sub-System Integ. & Verification Sub-System Options & Design Physics Component Integration & Verification Physics Based Component Modeling: Maxwell, Q3D, Optimization ANSYS Mechanical, Fluent, CFX 2010 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary

D2D GAIN J Electromechanical Design Flow ANSYS Icepack

IB ICA: A A IC PP := 6 A Q3D Parasitics PExprt Magnetics ANSYS

Components Model order Reduction Co-simulation Field Solution

4 D2D GAIN J Electromechanical Design Flow ANSYS Icepack Simplorer System Design RMxprt Motor Design IA PMSYNC Torque A IB ICA: A A IC PP := 6 A Q3D Parasitics PExprt Magnetics ANSYS Mechanical Thermal/Stress Maxwell 2-D/3-D Electromagnetic Components Model order Reduction Co-simulation Field Solution Model Generation 2010 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

7 Simplorer s Versatile Modeling Open Data ExchangeSpice Equation Import Modeling Block VHDL-AMS Couplings Co-simulation with FEA with Physical-Based External Simulators Models Mentor Graphics ModelSim C-Code Interface Simulink Circuit, Block, State Mathcad Model parameters can be * f(project, Design and Simulator variables) * Made pins 2010 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary

8 Fitted curve vs. measured data Transfer characteristic curve from datasheet IGBT Device Generation Characterization Tool Extraction of the IGBT Electro-Thermal Parameters Measured Data Fitted Curve Extracted parameter values 2010 ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary

9 Typical Power Electronics Design Flow PExprt Maxwell vctrl ctr C1 R2 C2 PID_Cont1 - + C3 R3 R1 vs FEA vref ctr SMPS Library a c BUCK_Converter p 42 Inductor_2 ET1 MEAN VALUE Inductor_Losses C2 50u Load 240m Diode_Characteristic Simplorer 2010 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary

10 Forward Converter Design PExprt Transformer Model Over-Voltage at the Switch because of the leakage Inductance Converter Losses: 1.7 W 2010 ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary

11 t t t Inverter Drive System TH 11 TH 12 TH 13 E TR UR E TS US E TT UT TH 24 TH 25 TH 26 v_soll EXT 60 vsoll un_ist EXT omg"mastacho" uni6 n_soll P 100 v_soll1 P 100 un_soll P 5m um_sollb LIMI TER N E G1 NEG un GR np P 4.67 GR ni I ui_ist ui_soll ui_sollb LIMI TER N E G2 ui GR ip P GR ii I ust ICA 1 ICA : V A 1_1 VA1 : Control loop N E 10 TH 14 TH 15 TH 16 ERS UR US UT E R S U S ynr U S yns U S ynt J M TH 21 TH 22 TH 23 J EXT omg"mastisch" n_ist v_ist EXT P m omg"mastacho" n6 v6 EXT P m omg"mastisch" J s_ist I 1 s6 I 1 J EXT 0.2 i_a"dcmpmotor" J NEG t Y dssi N E 2 ltt2 S tart N E 41 Sp N E 1 ltt1 N E 8 P1 N E 9 N E 7 S R 1 N E 3 N E 6 P2 N E 5 N E 4 S R 2 MasTacho J := 0.15m STF DCMP STF STF STF STF S tftachow elle D cmpmotor S tfmotorw elle S tfk pplg S tfs pindel S tfs pdla xial c := 20k c := 35k MasK upplgli MasK pplgr es pdlli MasS pindelr e MasTisch R _a := 1.28 c := 186k c := 18k c := 190 J := 0.9m J := 1.55m J := 1.94m k_v sc := 66.7m k_v sc := 0.24 k_v sc := 0.39 k_v sc := k_v sc := J := 0.57m L_a := 4.749m k_v sc := 1 k_e := 971m I_a0 := 0 Mechanical Elements J := 2.1m k_v sc := 0.25 V S oll State Machine V 01 V 02 V i_a"dc u_a"dcmpmotor" N E 11 N E 12 N E 15 N E 16 N E 21 N E m 812.9m T m 812.9m T Z11 Z21 Z12 Z22 Z13 Z23 N E 13 N E 14 N E 17 N E 18 N E 19 N E m 5.000m ssoll sist sschl 7.500m 5.000m s_ist s6 N E 23 N E 24 N E 25 W 01 W 02 W m m 812.9m T m 812.9m m m 812.9m T m_dff"stftachowelle" 20.00m m_dff"stfmotorwelle" m_dff"stfkpplg" m_dff"stfspindel" m_dff"stfspdlaxial" 0 T m m 812.9m T v6 v_ist V 04 V 05 V 06 N E 26 N E 27 N E 28 N E 29 N E 30 N E 31 Z14 Z24 Z15 Z25 Z16 Z26 N E 32 N E 33 N E 34 N E 35 N E 36 N E 37 N E 38 N E 39 N E 40 W 04 W 05 W ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary

Suspension and Stability System Design ECU

Break with Suspension - FM 2010 ANSYS, Inc.

17 New Cosimulation with RBD Automotive Drive train Throttle Control Control Inverter/Converter PM Motor ANSYS Mech. Motor Shaft ROM Transient Structural (MBD) Crankshaft Model 2010 ANSYS, Inc. All rights reserved. 17 ANSYS, Inc. Proprietary

forces out of phase Small starting torque 2010

18 Simplorer Design Details Measure rotation (used in force calculation) Forces applied every cycle Two forces out of phase Small starting torque 2010 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary

20 Multi-Domain State-Space Model Simplorer state-space model Description: New capability to simulate multi-domain state-space models Thermal Mechanical Electrical 2010 ANSYS, Inc. All rights reserved. 20 ANSYS, Inc. Proprietary

23 Summary Simplorer is the multi-domain, mixed-signal system simulator providing with a versatile modeling capabilities Simplorer is a simulation environment coupling high fidelity physics with circuit/system design Simplorer is rapidly advancing on multi-physics system integration modeling to couple with ANSYS portfolio 2010 ANSYS, Inc. All rights reserved. 23 ANSYS, Inc. Proprietary

Low Frequency Electromagnetic Applications:

Low Frequency Electromagnetic Applications: Power Systems Design Methodology Mark Christini, P.E. Lead Application Engineer ANSYS, Inc. 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary Overview