# METHODOLOGICAL CONSIDERATIONS OF DRIVE SYSTEM SIMULATION, WHEN COUPLING FINITE ELEMENT MACHINE MODELS WITH THE CIRCUIT SIMULATOR MODELS OF CONVERTERS.

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1 SEDM 24 June 16th - 18th, CPRI (Italy) METHODOLOGICL CONSIDERTIONS OF DRIVE SYSTEM SIMULTION, WHEN COUPLING FINITE ELEMENT MCHINE MODELS WITH THE CIRCUIT SIMULTOR MODELS OF CONVERTERS. Áron Szûcs BB Electrical Machines P.O. Box 186, FIN-81 Helsinki, Strömbergin tie 1B, FINLND bstract The paper discusses the issues with - and provides an overview of - the available methods for drive system simulation when the electrical machine is modeled by the finite element method () and the converter with the control is modeled by a circuit simulator. The main emphasis is placed on the necessity and accuracy of the simulation of the interaction between the subsystems: the electrical machine, the power electronics and the control logic. 1. INTRODUCTION typical drive system consists of an electrical machine, power electronics and a control intelligence, usually integrated into the converter. Fig 1 shows a simplified structure of a drive system with the interacting components. Converter Power Electronics Electrical machine Control intelligence Fig.1 Schematic structure of a drive system. Interaction between the sub systems is represented by arrows. the converter terminal, provides all the information needed for the control: currents for e.g.: power/torque feedback voltage output from the converter e.g. flux/speed feedback From this schematic figure one can conclude, that there is a mutual influence between the electrical machine and the converter, and the outcome of this mutual is the input for the control intelligence. 1.1 Conventional design of components The conventional design of the components involves accurate modeling of the component, which is the object of the design and optimization, while utilizing reduced models for the other components. Traditionally it has been an acceptable approach. However in modern drive systems it is becoming increasingly difficult to define the error made by reduced modeling and usually it is only after an in depth analysis, when such conclusion can be made. It is becoming a paradigm of system simulation, that in order to be able to determine whether one needs accurate system simulation or not, accurate system simulation is required. The direction of the arrows indicates, which system has a direct effect on the other. In this schematic diagram it is supposed that measuring the voltages and currents at the connecting terminals between the electrical machine and TRDITIONL DRIVE SYSTEM MODELS Electrical machines fed from frequency converters are commonly analyzed by providing proper voltage waveform for the 2D model of an electrical

2 SEDM 24 June 16th - 18th, CPRI (Italy) machine, while ignoring the effect what the machine has on the drive circuit. Control systems are also often analyzed in connection with only partially accurate analytical machine models. Fig2. shows these common ways of simulation, from the electrical machine point of view Fig.2. a, and from the converter point of view: Fig. 2. b. Converter voltage waveform Electrical Machine? Converter, in circuit simulator. nalytical Machine model a, b, Fig 2. a, Drive system from the machine point of view. b, Drive system from the converter point of view. In these methods the mutual interaction is not Both of the above mentioned approaches ignore or heavily simplify the interaction between the electrical machine and the converter circuit. The separate study of the subsystems seriously limits the analysis of the interactions in the whole system. There are a few guidelines to decide, when such separate analysis is justified. 1. 2D modeling of the electrical machine with the converter supply voltage wave is justified if the voltage waveform can be considered as predefined. Usually this is the case if: The control does not change the switching pattern. In the studied operation point the converter behaves linearly. (Voltage can be considered independent from the motor current.) The control parameters do not change. 2. Circuit simulator modeling of the converter, connected with analytical machine model is justified if the machine parameters remain constant and well definable. This is the case if: The machine runs in a well-known operation point. The machine parameters can be calculated or measured with desired accuracy for the simulated operation point. For the experts of modern drive systems it is obvious that these conditions cannot always be met. With increased frequency the very reason for drive simulation is to study what happens when the drive is running in an operation point where such restrictions do not apply. It can be stated that accurate analysis of the drive system for such cases requires a coupled simulation of the components.. COMBINED SOLUTION OF THE MGNETIC FIELD ND CIRCUIT EQUTIONS The combined solution of the magnetic field equations in electrical machines and the circuit equations of the windings and the external components is more than a decade old research topic [1,2,. The first papers were dealing with the inclusion of the circuits of the electrical machine itself into the field equations, but the combination of power electronic components of inverters soon followed..1 Strong - weak, direct - indirect The terminology of weak strong, direct indirect is continuously developing and it is quite freely defined by individual authors. Some regard strong and direct, weak and indirect as synonyms. This is a simplified but very sober approach, which helps to avoid misunderstandings about the properties of the. It is however harder to define special methods by this definition. Others relate the strength of the to the accuracy of the physical model used and the directness of the is viewed in light of the numerical technique applied. The explanation presented in this paper is adjusted for the better description of the specific problem of the in drive systems, using machine models and circuit simulator models of converters. Table 1. represents the different possibilities for the methods by the terminology used in this paper: 579

3 SEDM 24 June 16th - 18th, CPRI (Italy) Direct Indirect Strong Weak Mutual interaction together in one system. Eq.1. Mutual interaction separately. Usually in the form of numerical de, or iterative process. Eq.2, NO mutual interaction together in one system, but the between components is missing. Eq.4 NO mutual interaction Table 1. Representation of methods separately. Eq Strong, direct The combination of the equations leads to the assembly of one unified system of equations, which has been solved together, thus leading to a strong between the magnetic field and electrical circuit domains. Several high quality publications are available to describe the methods for strong. Eq.1 shows the basic philosophy of the strong in one possible formulation. (1) c c5 c1 c6 c2 c4 The variables in Eq.1 stand for: - stiffness matrix of the equations - the matrix for the power electronics circuit - Matrix for the control logic c1-c6 - matrices - variable vectors, e.g.: vector potential - Right hand side vectors.1.2 Strong, indirect When using indirect strong, the same equation system - as presented in Eq.1 - is solved in a subdivided manner. The subdivision can be implemented at several 1 2 stages of the solution process, e.g.: subdivision in every nonlinear iteration step [1, subdivision at the solver level, subdivision at mixed levels [5, etc.. Eq.2 and Eq. show a possible separation of Eq.1 into two systems of equations. One part includes all nonlinear variables, which are needed to be iterated. This is created by the gauss elimination of the linear variables. The elimination can be easily repeated in consecutive time steps by storing the "eliminating matrices" [1,5. The other system of equations contains the linear variables, which can be calculated in one step after the iterative solution of the other system has converged. Such formulation reduces the size of the system of equations for the duration of the nonlinear iteration process. (2) () [ NL [ NL [ NL [ L [ L [ L NL is the non-linear system matrix including all subsystems. NL stands for the non-linear variables and NL is the corresponding right hand side vector after the gauss elimination of the linear equations. ccordingly L, L, L stand for the linear system matrix, variable vector and right hand side vector respectively..1. Weak, direct In this case the physical interaction between the electrical machine and the converter is not modeled, or only a semi empirical model is used. In the weak coupled formulation the matrices in Eq.1 are not present or all are "zero matrices". Eq.4 presents the weak - direct formulation: (4).1. Weak, indirect s the terms are all zeros in Eq.4 it can be cut into independent equations, row by row. Eq.5 presents the separated equations: (5) [ [ [ [ [ [ [ 1 [ 2 [

4 SEDM 24 June 16th - 18th, CPRI (Italy) 4. SELECTION OF THE COUPLING METHOD Utilizing Eq.1, Fig.1 and the general knowledge on drive systems, certain guidelines for the selection of the method can be defined. The following variables will be used to choose the method: T EM Time constants of the electrical machine. (depending on machine properties, including all inductances, e.g.: end windings, etc.) T CC Time constants of the converter and the cabling. T C Time constant, (describing the speed) of the control algorithm. The following variables describe the outcome of the method selection. These will be defined as the functions of the variables above: t MX Maximum time steps size allowed for the analysis. It will be defined as a function of the dominant variables above. From the matrices c1-c6, those which can be set to zero - meaning weak between corresponding sub-domains - will be named. The following simple guidelines can be used to define the type of the physical model: The smallest time constant is the dominant and the one, which defines the maximum allowable time step size: t MX. Large difference between time constants, indicates that the modeling of the interaction can be ignored between those sub systems and the can be defined as weak. If the control is slow the effect of it to the whole system should be considered one (or more) time steps later than the effect of the interaction between the converter electronics and the electrical machine. Some examples for the selection are presented in Table 2. The relationship of the variables are presented as the conditions on the left-hand side and the proposed model is given by introducing the proposed "zeroed" coefficients. Eq.1 is used to define the matrices, which can be set to zero. They indicate, that only a weak is required for those related subsystems. Condition Small machine at the end of long cabling, with slow control. T EM << T CC and T EM << T C Speed of the control, is significantly slower than the speed of the electrical transients. T EM ~ T CC and (T EM, T CC) << T C Proposed "zeroed" coefficients c1, c2, c, c5 t MX f (T EM ) c2, c4, c5, c6 (The control effects the system, but only in a later time step.) Table2. Example cases for method selection. 4. NUMERICL ISSUES When the 2D models of electrical machines for magnetic field calculation with the circuit equation models of converters the following numerical problems have to be addressed: 5.1 Time step size Transient time stepping simulation requires the choice of time steps both in the magnetic domain and in the circuit simulator domain. The time steps size can be significantly different in these domains - depending on the time constants - but the co-simulation requires adjusting the different time steps sizes. The simplest solution is to choose the smaller time step for both domains, although this could lead to unacceptably long calculations. nother option is to use variable time step size but the choice of such variable time stepping method requires also careful strategy. If eddy currents are present at the magnetic system, the variable time step size must be defined considering the correct modeling of those time dependent embedded sources of the magnetic field. 5.2 D effects modeled in 2D The exact end winding reactance values for a 2D machine model are inputs from the calculation point of view. These inaccuracies due to the missing D effects in the 2D model can have an important effect because the end winding reactances act as smoothing filters. 581

5 SEDM 24 June 16th - 18th, CPRI (Italy) 5. Realization of strong When the magnetic field model is solved with a solver and the power electronic circuits and the control logic is modeled in a circuit simulator the realization of the strong represents a great challenge. It has been discussed in section.1.2 that strong indirect is possible, but it requires special formulations (e.g.: unification in each iteration step [1 ) Using commercial products those special solver techniques must be supported commercially. This requires very close cooperation between the calculation tool developers. 6. CONCLUSIONS The paper highlighted some of the major issues with cosimulation of the magnetic field in electrical machines and the circuit simulation of the power electronic circuits and the control logic for the modeling of drive systems. It is obvious, that while thorough knowledge of both domains - electrical machines and converters - is a must, expertise in these areas alone might not be anymore sufficient in all cases of modern drive system analysis. It is likely that the development of a new "science of " will be required to build efficient calculation tools for drive system modeling in the future. Equations, cta Polytechnica Scandinavica Electrical Engineering Series, No. 59, Helsinki 1987, 97 p. [ Csendes Z. J. and Konrad., "Electric machine modeling and power system constraints," Presented at the Conf. on Electric Power Problems: The Mathematical Challenge, 18-2 March 198, Seattle, W [4 rkkio.,., Finite element analysis of cage induction motors fed by static frequency converters. IEEE Transaction on Magnetics Vol. 26 (199) 2, pp [5 Áron Szûcs, "Macro Elements In the Finite Element nalysis of Multi-Conductor Eddy-Current Problems", IEEE Transactions on Magnetics, Volume 6, Number 4, July 2 [6 Väänänen, J. "Combination of Two-Dimensional Finite Element nalysis Electrical Machines with Circuit Simulation Techniques.", Helsinki 1995, cta Polytechnica Scandinavica, Electrical Engineering Series No. 8, Doctor of Technology thesis, 14 p. The emerging fields of applications for the coupled modelling could include: - Controlled drive working separately (e.g.: double fed wind generators) - Controlled drive working in a network - Other multi-physics phenomena involving electro-magnetic field calculation and converter circuit simulation - in sub-domains. REFERENCES [1 Väänänen, J. Circuit Theoretical pproach to Couple Two-Dimensional Finite Element Models with External Circuit Equations. IEEE Transactions on Magnetics, March 1996, Vol. 2, No. 2, 11 p. [2 rkkio., nalysis of Induction Motors Based on the Numerical Solution of the Magnetic Field and Circuit 582

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