JMAG User Training RWH Künzelsau

Transcription

2 Training Outline Session I - Introduction Introduction to JMAG Product line Motor design using JMAG Express Quick Mode Power Mode Modifying existing templates Session II JMAG Designer Introduction to JMAG designer Interface Import models from Express (2D) Analysis Setup and Meshing Results & Post Processing Session III JMAG Tools Inductance Calculation Iron Loss Scripting JMAG-RT Parametric Analysis Coupled Analysis Session IV Examples PM Analysis: No Load Load case NT curves IPM MG-TH analysis IM Analysis Copyright 2012 JSOL Corp. All Rights Reserved 2

4 JMAG is FEA software for electromechanical design Created in 1983 Over 600 active customer sites A standard tool in EV/HV development Applications Analysis Modules Motors/Generators Magnetic Actuators Electric Transformers Structural Induction heating Thermal Sensors Multi-physics EM Shields etc. Copyright 2012 JSOL Corp. All Rights Reserved 4

7 JMAG Family Model Design Multi Physics JMAG-Express JMAG-Express Power Mode Abaqus, Virtual.Lab, AcuSolve End User JMAG-Designer Control System JMAG-Bus JMAG-VTB JMAG-RT JMAG-RT Viewer Copyright 2012 JSOL Corp. All Rights Reserved 7

8 JMAG Express JMAG-Express enables extremely fast evaluation of basic motor performance characteristics Does not require setting analysis conditions or details of model set up (time step size, mesh size, etc) Serves as a starting point for model validation Sizing function can be used to quickly estimate model geometry based on scaling an initial design Copyright 2012 JSOL Corp. All Rights Reserved 8

9 JMAG-Express Power Mode Full FEA calculation in JMAG-Express Power Mode Easy and accurate Pre-defined analysis scenarios Dashboard for result display Scenarios for PM Machines No load analysis Cogging torque, BEMF Load analysis Torque, Current, Voltage, Loss Efficiency map Inductance Iron loss including the high harmonics Magnet loss Torque segregation Copyright 2012 JSOL Corp. All Rights Reserved 9

10 JMAG-Express Power Mode Results JMAG-Express Power Mode enables the evaluation of high accuracy machine performance parameters without having to set analysis properties. Voltage waveform Cogging torque Torque-Speed curve Current phase-torque properties Magnetic flux eddy current loss Magnetic flux distribution Efficiency map Copyright 2012 JSOL Corp. All Rights Reserved 10

11 JMAG Designer JMAG Designer is the core program in JMAG software environment. Full 2D and 3D electro-mechanical FEA design and analysis Numerous analysis tools such as inductance calculation, parametric analysis, optimization, and scripting Copyright 2012 JSOL Corp. All Rights Reserved 11

13 Co-simulation Complex co-simulations require proper combination of analyses. JMAG s pre defined scenarios can automatically apply these combinations to user s models and achieve accurate results. No-load property Cogging torque geometry materials behavior range inductance Efficiency calculation NT curve Efficiency map Thermal loss computation flow Copyright 2012 JSOL Corp. All Rights Reserved 13

15 JMAG VTB (Virtual Test Bench) JMAG-VTB requires you to know NOT how but ONLY what s your objective. The procedure (how) is automated with a predefined scenario. Covers a wide variety of devices Customizable scenerios Simple operation Step1: Choose a scenario Step2: Apply the scenario to your model Step3: Evaluate the results Copyright 2012 JSOL Corp. All Rights Reserved 15

21 JMAG Express On the left side you will see four tabs Dimensions Materials Winding Drive Every parameter in these tabs can be modified based on the users requirement Requires prior knowledge of machine dimensions Copyright 2012 JSOL Corp. All Rights Reserved 21

24 JMAG Express Other optional parameters can be specified to effect the outcome of the sizing function. We will not use the optional parameters for this case. Click on the sizing button again and it will hide the sizing panel Copyright 2012 JSOL Corp. All Rights Reserved 24

25 JMAG Express The material properties of the parts can be modified on the materials tab. JMAG has a built in database of material properties from our partnership with material manufacturers. Copyright 2012 JSOL Corp. All Rights Reserved 25

26 JMAG Express The following conditions can be modified in winding tab: Coil settings (type of connection, phase resistance, and number of turns) Phase Resistance can also be calculated based on the geometry of strands Number of winding layers in each slot (1 or 2) Winding layout Automatic Automatic (Concentrated Winding) Manual For the Automatic Winding, you can set the coil pitch For the Manual Winding, you can set the Go and Return slots Copyright 2012 JSOL Corp. All Rights Reserved 26

27 JMAG Express In the drive tab, you can set the following Type of power source Amplitude Current Phase Maximum Current Rotation Speed If Adaptive Analysis should be used Copyright 2012 JSOL Corp. All Rights Reserved 27

29 JMAG Express That will open a new results tab with some basic characteristics of the 2D motor model that we just created. JMAG Express is a tool specialized to evaluate the model with high speed. More detailed analysis can be performed in JMAG Express Power mode. Copyright 2012 JSOL Corp. All Rights Reserved 29

31 JMAG-Express Power Mode To convert to power mode, select the evaluation method dropdown and choose any of the four available modes below simplified basic characteristics Copyright 2012 JSOL Corp. All Rights Reserved 31

32 JMAG-Express Power Mode For this example we will select Basic Characteristics This will modify the Drive tab with some predefined scenarios: No Load Load Inductance Efficiency Map Each of these scenarios have some settings listed for the drive properties Copyright 2012 JSOL Corp. All Rights Reserved 32

33 JMAG-Express Power Mode Select the checkbox for No Load The analysis priority can be set to speed or accuracy. Higher accuracy will take more time to run Set the rotation speed to 1800 RPM Copyright 2012 JSOL Corp. All Rights Reserved 33

36 JMAG-Express Power Mode Unlike quick mode, a full FEA calculation is performed in power mode. The results that are displayed in dashboard can directly be exported into JMAG by clicking on them. Click on the cogging torque plot will open the model and plot in JMAG- Designer Once the analysis is opened in JMAG you can observe that all the necessary study conditions are applied to the model based on the case we selected. Copyright 2012 JSOL Corp. All Rights Reserved 36

37 JMAG-Express Power Mode This us just one case study of what can be done using JMAG- Express Power Mode Other scenarios available for Scenarios available for SRM: IPM: I-Psi Characteristics Load Study Static Characteristics Inductance Drive Characteristics Efficiency map Dynamic Characteristics Harmonic Iron Loss Magnet Loss Torque Segregation Scenarios available for Induction Motor: Drive Characteristics Line Start Machine Parameters Torque Characteristics Copyright 2012 JSOL Corp. All Rights Reserved 37

38 Analysis Database Records all simulation tasks performed in JMAG-Express Power Mode and VTB. Searchable by design parameters as well as output value, device type, scenario and date/time. Dashboard can be directly opened from the search and linked to JMAG model. Copyright 2012 JSOL Corp. All Rights Reserved 38

41 Template Creation Open JMAG Express, on the Dimensions tab clink on the modify link on the rotor, and select Edit Current Template. Click [OK]. Now a template editor window will open. Here you have limited capabilities to add/edit constraints, change material type, etc.. To edit the geometry, open the Edit menu and select Edit in JMAG-Designer. That will open a new instance of JMAG-Geometry Editor with the current rotor sketch. Copyright 2012 JSOL Corp. All Rights Reserved 41

42 Template Creation In geometry editor window, open Tools menu and select Preferences. In the Document Properties tab, change the grid settings as shown below. Copyright 2012 JSOL Corp. All Rights Reserved 42

44 Template Creation The model requires strict constraint settings if you want to parameterize it using JMAG Express. Throughout this model, we will learn how constraints are set and how they can be useful. Note: While setting a reference constraint like distance, parallelity, perpendicularity, etc.. Always select the reference entity first followed by the entity on which the constraint is being set. Copyright 2012 JSOL Corp. All Rights Reserved 44

45 Template Creation Set the magnet thickness to depend on the slit width. Right click on the constraint set across the magnet region and select Edit Turn on Depends on Constraint and select the constraint specified across slit width as highlighted in the figure and click [OK]. Copyright 2012 JSOL Corp. All Rights Reserved 45

46 Template Creation Change the slit width to 1.5 mm by editing the constraint Click on the line button and create 8 lines as shown in the figure below. These will serve as the second layer of slit and magnet. Copyright 2012 JSOL Corp. All Rights Reserved 46

47 Template Creation Select the circle button and create a circle with center at origin and a radius of 27 mm Now select the Sketch trim button and trim out the excess parts on lines by clicking on them. (Do not trim the edges with the circle yet) Now your geometry should look as shown below. (highlighted lines) Copyright 2012 JSOL Corp. All Rights Reserved 47

48 Template Creation Add the constraint Perpendicularity to the diagonal lines representing the slit with respect to the 45 o symmetry line. Geometry should look like below. (Highlighted part shows the constraints added) Copyright 2012 JSOL Corp. All Rights Reserved 48

49 Template Creation Add the constraint Parallelity to the lines representing magnet ends with respect to the 45 o symmetry line. Geometry should look like below. (Highlighted part shows the constraints added) Copyright 2012 JSOL Corp. All Rights Reserved 49

50 Template Creation Select the Break at intersection button and select all the lines and circle that you have created + the 45 o symmetry line. (make sure not to select any previously existing geometry. All the points where an intersection is found is highlighted with a yellow square Click [OK]. Select the excess lines and circle, hit delete key to delete them. The final geometry should look as below. Copyright 2012 JSOL Corp. All Rights Reserved 50

51 Template Creation Set the coincident constraint on each line segment that represents the magnet and the air region just beside the magnet (highlighted in green) This will allow the intersecting point to move along with the changing dimensions of the magnet. Copyright 2012 JSOL Corp. All Rights Reserved 51

52 Template Creation Add a distance constraint between the existing and the new slit and set it to 2 mm. Find that constraint in the treeview and rename it as SLIT2:Distance between Slits Copyright 2012 JSOL Corp. All Rights Reserved 52

53 Template Creation Add another distance constraint between the magnets and set it to depend on the Slit Width constraint. Rename the constraint as DMAG: Distance between Magnets Add distance constraints on the other half of the magnet and slit and set them dependent on their counterparts across the symmetry line. With the constraints added your geometry should look as below Copyright 2012 JSOL Corp. All Rights Reserved 53

54 Template Creation Repeat the same procedure and add constraints to the width of the slit set to 1.5mm and named SW2: Slit2 Width, thickness of the magnet set to depend on SW2 and named as TMAG2: Mag2 Thickness The geometry after applying all 8 constraints should look as shown below. TMAG2: Mag2 Thickness DMAG: Distance between Magnets SW2: Slit2 Width SLIT2: Distance between Slits Copyright 2012 JSOL Corp. All Rights Reserved 54

55 Template Creation Set a Concentric constraint on the arc representing the end of new slit and the outer arc of the rotor. Add a distance constraint between the two arcs and set it to depend on constraint DSLIT: Slit Depth Repeat the above steps on the arc across the opposite end. Copyright 2012 JSOL Corp. All Rights Reserved 55

56 Template Creation One last constraint will be the width of the magnet set to the two small lines parallel to the symmetry line. Set the distance to be 8.5mm and name it as WMAG2 Mag2 Width. Set a dependent distance constraint on the other side of symmetry line. The final geometry with total 10 constraints should look as shown below. Copyright 2012 JSOL Corp. All Rights Reserved 56

57 Template Creation Click on the Create region button, select all the lines that create the magnet and click [OK] to create a region. Similarly select all the lines for rotor core and create the regions in two separate parts. Copyright 2012 JSOL Corp. All Rights Reserved 57

58 Template Creation Right click on the 2D Sketch in treeview and select End Sketch The final Geometry Editor window should look similar to the image below Copyright 2012 JSOL Corp. All Rights Reserved 58

59 Template Creation In the express template editor window, click on Edit and select Get from JMAG-Designer Now the geometry will be imported into Template editor window as shown in the image below. Copyright 2012 JSOL Corp. All Rights Reserved 59

60 Template Creation You can switch to the Preview tab to look at the constraints that give you control over the new geometry. Next step is to assign material properties to the new regions created. In the Model tab, scroll down to Materials. Select any of the untitled material and change title to Rotor Core Change material type to Magnetic Material. Copyright 2012 JSOL Corp. All Rights Reserved 60

62 Template Creation Click on the Back to Main Window button, name the template as Double_Layered IPM and click [OK]. Switch to Materials tab in the Express window and set the following for Rotor Core: Material category : JSOL Steel_Sheets Product : 50A1000 The template creation for doubled layered IPM machine is completed. Copyright 2012 JSOL Corp. All Rights Reserved 62

64 JMAG Designer JMAG Designer is the core program in JMAG software environment. Full 2D and 3D electro-mechanical FEA design and analysis Numerous analysis tools such as inductance calculation, parametric analysis, optimization, and scripting Copyright 2012 JSOL Corp. All Rights Reserved 64

66 Drive settings In the Express window, switch to Drive tab and set the following: Drive Circuit mode: Current Current Amplitude: 10 Check Do not use Adaptive Analysis Copyright 2012 JSOL Corp. All Rights Reserved 66

69 Study Conditions All the conditions and circuit for the study are already set. This is done by JMAG Express and imported along with the geometry into Designer. We will look at few of these condition settings in detail. Copyright 2012 JSOL Corp. All Rights Reserved 69

70 Groups and Sets Grouping works best for similar components (i.e. all the Coils) In the Assembly tab, you can group components by: Material Name Number of characters (4 or 6) Sets are simply sub groups where the components are grouped by conditions that apply to them For custom templates, JMAG automatically creates the groups by part names and conditions are assigned using sets created by user. Copyright 2012 JSOL Corp. All Rights Reserved 70

71 Rotational Periodic Boundary The size of the analysis model can be reduced when the model has rotational periodicity. This model has a rotational periodicity of 90 o and the periodicity nature is set to be Antiperiodic Copyright 2012 JSOL Corp. All Rights Reserved 71

72 Periodic Versus Antiperiodic The periodic boundary condition means that flux is the same for each period The anti-periodic boundary condition means that flux is reversing each period The axial reverse boundary condition applies to models whose cross section vertically reverses each period (claw pole motor) Copyright 2012 JSOL Corp. All Rights Reserved 72

73 Types of Boundary Symmetry Boundary: Magnetic flux flow parallel and current flows perpendicular to the symmetry boundary. Natural Boundary: Magnetic flux flow perpendicular and current flows parallel to the natural boundary. Note: The boundary conditions set field properties, but in terms of results are purely mathematical constraints Copyright 2012 JSOL Corp. All Rights Reserved 73

74 Notes on Boundaries Periodic Boundary: Multiplies the result by the periodicity. Symmetry Boundary: If sufficient air region is not created surrounding the model the flux is forced to flow parallel to external boundary Natural Boundary: Magnetic flux is forced to flow perpendicular to the boundary even if it is not perpendicular in reality Copyright 2012 JSOL Corp. All Rights Reserved 74

75 Rotational Motion Condition Defines motion in a rotating model Can be in various forms: Constant Revolution Speed Constant displacement Speed point sequence Displacement point sequence Cumulative displacement point sequence Equation of motion Link to external simulator Can add rotor eccentricity Both static and dynamic eccentricity Can set the initial rotor position Set RPM to 1800 and set initial position to 0 Copyright 2012 JSOL Corp. All Rights Reserved 75

76 Torque Nodal Force: calculates the torque based on the electromagnetic force acting on each node. This method works best for electric machine rotors Lorentz Force: calculates the Lorentz force and the torque based on that force. This method is used to calculate the torque in a non magnetic material such as a coil. Surface Force: calculates the torque based on the integral value of electromagnetic force acting on a face of edge. This condition can be used when the magnetic material is in contact with another magnetic material, or where the electromagnetic force is acting on a part of the magnetic material. Copyright 2012 JSOL Corp. All Rights Reserved 76

77 Mesh Tips Areas where flux is changing rapidly usually require a finer mesh The air gap mesh of an electric machine is critical Make sure that the mesh is uniform in the stator and rotor sections closest to the air gap Each time step should move the rotor approximately 1 element Adaptive meshing is useful in 2D but may take too long in 3D A course mesh will run quickly, but may not be accurate while a fine mesh will run more slowly and may or may not be more accurate. Mesh is highly controllable in JMAG Copyright 2012 JSOL Corp. All Rights Reserved 77

78 Mesh Properties Basic Settings: Right Click on Mesh and select Properties This opens the Basic Settings Tab Meshing types: Standard Mesh Slide Mesh Choose the Generation Method Method 2 is currently the most efficient method Scale controls the size of the air region generated outside the model. Change this to 1.05 Slide division is applicable if slide mesh is selected Specify the Radial Divisions (between rotor and stator) to 5 Specify the Circumferential Divisions (from the first periodic boundary to the second periodic boundary) to 180 If the model has multiple rotating parts, multiple slide planes can be created Copyright 2012 JSOL Corp. All Rights Reserved 78

79 Mesh Properties Element Size: A global element size can be specified for parts and air region Set element size for parts as 1 mm air region as 2mm Adaptive Adaptive meshing can be toggled On/Off from here. Copyright 2012 JSOL Corp. All Rights Reserved 79

80 Setting Mesh Features Running the analysis through Express will use Adaptive mesh. Since we will not use adaptive meshing, some mesh settings need to be specified Right click on Mesh and select Add Size Control on part. Select the Magnets as target and specify a size of 0.5 mm Copyright 2012 JSOL Corp. All Rights Reserved 80

81 Setting Mesh Features Similarly add a size control on the edge feature and select all the edges of rotor and stator next to the air gap. Also select the edges at the barrier of the magnet. Right click on the Mesh and select Rotating Periodic Mesh with Automatic. This will enable JMAG meshing algorithm to automatically detect periodic geometry and apply similar mesh to each segment. Copyright 2012 JSOL Corp. All Rights Reserved 81

82 Generating a Mesh Right click Mesh and select Generate Click OK if there is are any warnings Click on the Mesh View button Toggle the air regions on. The meshed model should look as in the figure below: Copyright 2012 JSOL Corp. All Rights Reserved 82

83 Model Properties- Steps Right click the study and select Properties Set the Steps to steps per 90 mechanical degrees Model 1 electrical cycle (180 mechanical degrees) Set the type to Regular Intervals Set the unit to seconds Set the end time as 1 second Set division There are 720 steps (180steps*4periods) per revolution Rotor is spinning at 30 revs/sec (1800revs/60) which implies 720*30 = steps per second. The end time is 1 second so that means there are divisions. Copyright 2012 JSOL Corp. All Rights Reserved 83

84 Model Properties - Conversion You can set the model height for a 2D analysis. This value of 37.5mm is set in Express window. For this case, there would not be any other conversions Copyright 2012 JSOL Corp. All Rights Reserved 84

86 Model Properties - Solver Toggle the Advanced Properties on Under Solver the following settings can be changed: Parallel computing conditions using Shared memory multiprocessing (SMP) Massively Parallel Processing (MPP) Utilize GPU The Steady State Approximate Transient Analysis is for modeling induction machines in steady state Time Periodic Explicit Error Correction can force a transient model into steady state more quickly Copyright 2012 JSOL Corp. All Rights Reserved 86

87 Model Properties - ICCG Increasing the tolerance on the ICCG can increase the model s accuracy I do not recommend changing the acceleration coefficient Copyright 2012 JSOL Corp. All Rights Reserved 87

88 Model Properties - Nonlinear Change the number of nonlinear iterations if the materials are non-linear This will ensure an accurate calculation for saturated regions For this model the default settings will be adequate. Turn on the Use High Speed Solver checkbox. High-speed solver can be used when the flux vector in the mesh element does not change rapidly. Copyright 2012 JSOL Corp. All Rights Reserved 88

89 Model Properties - Output You can select what the output of the analysis is Removing features will shrink the solved file size and help the simulation run faster Copyright 2012 JSOL Corp. All Rights Reserved 89

90 Model Properties - Restart Restart will continue a calculation using the previous study as the starting point You can also restart an analysis by right clicking on the Study and selecting Restart Copyright 2012 JSOL Corp. All Rights Reserved 90

91 Run the Analysis Right click on the Study and select Run Active Case The project can also be run from a Scheduler or Batch processor The Scheduler Tool creates a job queue The batch processor can farm jobs to separate computers Copyright 2012 JSOL Corp. All Rights Reserved 91

92 Results Monitor While the model is running you can view various parameters progress Press the Customize Monitor button Select the parameters you would like to observe Can observe more than one Solver Dialog shows the simulation s progress Copyright 2012 JSOL Corp. All Rights Reserved 92

94 Plotting Contour Plot Under Study right click on Results and select New Contour Plot Various settings can be changed: Type of result in the contour plot and its component Type of contour Scaling Color scale for the contour plot Currently it is set to create a contour plot for Magnetic Flux Density. Click [OK]. Copyright 2012 JSOL Corp. All Rights Reserved 94

95 Plotting Contour Plot Select the display contour result button Rotor can be moved with the slider bar Rotor motion can be seen as an animation using the animation control bar Similarly, vector plots and flux line plots can be created and displayed using the vector result and flux line buttons Copyright 2012 JSOL Corp. All Rights Reserved 95

96 Graph Manager The Graph manager contains the results of all the studies in a project The results can be sorted into groups You can also select multiple results to display at the same time A transform function can perform a FFT or combine two graphs. Combine FFT Copyright 2012 JSOL Corp. All Rights Reserved 96

97 Section Graph Section Graphs can be used to plot quantities like magnetic flux across a line or an arc specified for a model. This example shows the section graph of Flux density across the air gap for step 1. Copyright 2012 JSOL Corp. All Rights Reserved 97

98 Probe Probe can be used to plot quantities at a desired point in the model. Multiple points can be specified. This example shows field strength variation across the barrier. Copyright 2012 JSOL Corp. All Rights Reserved 98

100 3D Modeling A 2D model can be converted into 3D by using the extend model to 3D option. The stack length used in 2D model will be used for the extrude length Copyright 2012 JSOL Corp. All Rights Reserved 100

101 3D Modeling JMAG has special meshing functions, like the Extruded Mesh, which can substantially reduce the number of elements without degrading the accuracy Analysis time is also reduced and the solution more stable with extrude mesh Standard Mesh 81,262 Elements Extruded Mesh 43,734 Elements Copyright 2012 JSOL Corp. All Rights Reserved 101

102 Coil End Modeling Complicated End winding geometries can be created easily using the coil template It supports following type of coils Concentric Spiral Rectangular Copyright 2012 JSOL Corp. All Rights Reserved 102