Design of low electromagnetic Noise, Vibration, Harshness (NVH) electrical machines using FEMAG and MANATEE software

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1 FEMAG Anwendertreffen 2017, 2/3 November 2017 Design of low electromagnetic Noise, Vibration, Harshness (NVH) electrical machines using FEMAG and MANATEE software Pierre BONNEEL Emile DEVILLERS Jean LE BESNERAIS EOMYS ENGINEERING 1

2 EOMYS ENGINEERING, specialist of e-nvh issues Engineering consultancy company specialized in acoustic noise and vibrations of electrical machines Lille (1 hour from Paris), North of France, 5 R&D Engineers Modeling, simulation & experimental measurements Experience on more than 50 electrical machines electromagneticallyexcited Noise, Vibration, Harshness from 100 W to 30 MW Developer and distributor of MANATEE software, the first simulation software dedicated to fast electromagnetic & vibroacoustic design optimization of electric machines 2

3 Noise and vibrations of electrical machines Aerodynamic (e.g. fans) Mechanical (e.g. bearings) Electromagnetic (e.g. Maxwell forces on stator) = e-nvh Electrical machine Gearbox Outer frame Magnetic rotating fields Link with the frame Vibrations Noise Electromagneticallyexcited noise Magnetic rotating force wave Machine structure deflection 3

4 E-NVH Computation Process using MANATEE software MANATEE workflow : MANATEE GUI (PyQT) MANATEE can be used: in basic electromagnetic design phase using fast analytical / semi-analytical models (variable speed noise calculated in a few seconds) in detailed design phase using optimized coupling with third party electromagnetic or structural FEA (e.g. Optistruct, Ansys) based on Spectrogram Synthesis and Electromagnetic Vibration Synthesis techniques MANATEE currently available in Matlab (no toolbox) but migration to Python will be completed in Feb

5 Coupling FEMAG and MANATEE Coupling between FEMAG and MANATEE using airgap flux import: FEMAG flux import MANATEE e-nvh computation at variable speed FEMAG: non-linear electromagnetic simulation accounting for control strategy at variable speed MANATEE: fast NVH calculation and dedicated post-processings (e.g. harmonic analysis, spectrograms, operational deflection shapes, noise maps) 5

6 Study case: Interior PM Synchronous Machine (Toyota Prius 2004) IPMSM with : 48 stator slots (distributed single layer winding), 8 poles (V-shaped buried magnets) Femag model Operating cycle: maximum of the torque Control strategy: Maximum Torque Per versus speed curve (100 RPM/7000 RPM) 1 Ampere (MTPA) N.m Max torque : ~320 N.m Mitch Olszewski, "Evaluation of 2004 Toyota Prius Hybrid Electric Drive System, Z. Yang, M. Krishnamurthy and I. P. Brown, "Electromagnetic and vibrational characteristic of IPM over full torque-speed range," IEMDC

7 FEMAG to MANATEE coupling: development steps 1 : Define the machine in MANATEE GUI 2 : Find the corresponding Model in Femag 3: Generate the Femag model in Python with femagtools 7

8 FEMAG to MANATEE coupling: simulation workflow 4: Run the simulation in Python with femagtools 5: Automated conversion of results for import in MANATEE 6: Run MANATEE structural and acoustic models 8

9 FEMAG simulation model Simulation for 229 spatial nodes in the moving band (~38 nodes/stator pitch), 229 rotor positions and 100 speed iterations Moving band Setting MTPA control strategy for targeted RMS input phase current and output magnetic torque values or taking the Id/Iq curve from the reference. Computation time : ~25 minutes per speed (~41h 40 minutes for 100 speeds) Computer used: 3.3GHz - RAM 32Go - Windows bits 9

10 FEMAG simulation results over space Airgap waveforms of radial flux density at 3 different operating points (fixed time): N [RPM] Id [A] Iq [A] T [N.m] p No new wavenumbers despite saturation 3p 5p 7p 9p 12p = Zs - p 15p = Zs + p 10

11 FEMAG simulation results over time Time waveforms of radial flux density at 3 different operating points (fixed angle): N [RPM] Id [A] Iq [A] T [N.m] p No new time orders despite saturation 3p 5p 7p 9p 11

12 MANATEE e-nvh simulation process ELECTROMAGNETIC MODEL 3D airgap flux distribution r=0 HARMONIC FORCE PROJECTION r=2 r=3 Importing FEMAG results Tangential and radial harmonic magnetic forces (magnitude, wavenumber, frequency, phase) Unit harmonic loads for wavenumbers r=0, ±2, ±4 Complex FRFs (radial & tangential) for each wavenumber r ELECTROMAGNETIC VIBRATION SYNTHESIS Vibration and noise spectrograms STRUCTURAL MODEL STRUCTURAL FREQUENCY RESPONSE FUNCTIONS Computation time: 3 sec per speed r=0 r=2 Manatee 2,5D analytic model 12

13 MANATEE magnetic forces model Projection of the airgap Maxwell stress tensor on stator tooth tips:,,, 2,,, /² / Maxwell stress tensor is available in.plt0 of FEMAG Lumped forces per tooth using Maxwell stress integration over stator tooth not available yet, but one can show that they are equivalent to Maxwell stress airgap projection Harmonic decomposition of time and spatial pressure distribution (FFT2D): /, /,!" # $%, &,' : frequency and wavenumber : magnitude of the harmonic &,' ( : phase of the harmonic&,' r=0 r=1 r=2 13

14 MANATEE structural model: modal basis Analytical models can be used for the calculation of natural frequencies and deflections of an equivalent 2.5D cylinder Some rules are used to take into account teeth stiffness and mass as well as winding and frame The effect of boundary conditions (clamped / free / simply supported) is also included & ), * ), 2+ If necessary MANATEE can also be coupled to structural FEA (e.g. GetDP, Optistruct) 14

15 MANATEE structural model: Frequency Response Function Computing the static displacement,,) due to each magnetic excitation, considering the stator structure as an equivalent ring: /,, /,,,. )0. ) )0. )1, 32 5 ' 1² Computing the dynamic displacement accounting for modal basis: -.- &,, 1 & & ) /,, 6 27 & &) The Frequency Response Function -.- & is obtained by putting unit rotating wave as input (, =1) If the analytical model assumptions are not fulfilled FRF can be automatically calculated by calling a structural FEA model (e.g. free software GetDP, or commercial software Optistruct) 15

16 MANATEE structural model: Electromagnetic Vibration Synthesis Overall radial yoke displacement & velocity levels are given by linear superposition:, &-.- &, 8 &92+&, & Unit magnitude FRF allow to understand better the physics (e.g. presence of multiple resonances, relative effect of tangential & radial forces), to decouple structural characterization from operational electromagnetic force calculation and to more computationally efficient

17 MANATEE acoustic model Acoustic noise is deduced from vibrations by calculation of a cylindrical modal radiation factor:

18 FEMAG to MANATEE NVH results of Prius 2004 magnetic forces Graphical representation of FFT2D spectrum:,,!" # $%, f=2f s, r=8 f=6f s and 12f s, r= Time orders are proportional to 2f s (2pf R ) and wavenumbers are proportional to GCD(Zs,2p)=2p=8 Radial pulsating (wavenumber r=0) force harmonics (red boxes) are likely to produce air-borne acoustic noise 18

19 FEMAG to MANATEE NVH results of Prius 2004 structural modes A comparison is made between MANATEE results (analytical) and FEA results (Ansys) found in literature 2 in free-free boundary conditions MANATEE Significant differences are found for high circumferential indices but the winding modeling strategy is not detailed in the article 2 using Ansys Risk of resonance: r = m = 0 f :& ) = 5173 Hz or r = m = 8 f :& ) = 7854 Hz 2 Z. Yang, M. Krishnamurthy and I. P. Brown, "Electromagnetic and vibrational characteristic of IPM over full torque-speed range," IEMDC

20 FEMAG to MANATEE NVH results of Prius 2004 magnetic forces Automated derivation of theoretical spectrum of magnetic forces and potential resonances: Analytical derivation of magnetic force characteristics and structural modal analysis predict a resonance of mode (0,0) stator lamination at 6463 rpm with magnetic forces at 12f s involving 11p and 13p rotor mmf harmonics:

21 FEMAG to MANATEE NVH results of Prius 2004 Overal sound power level including modal participation factors, and noise spectrogram: 6f s 12f s There is no unphysical harmonics due to meshing issues On Prius 2004, sound power level is fully dominated by breathing mode of stator lamination mainly under 6f s excitation and there is no strong resonance occuring below 6000 rpm

22 FEMAG to MANATEE NVH results of Prius 2004 Acoustic noise spectrogram per force wavenumber

23 FEMAG to MANATEE NVH results of Prius 2004 Order tracking & Operational Deflection Shape analysis Stator deflection at 700 Hz

24 FEMAG to MANATEE NVH results of Prius 2004 MANATEE post-processings allow to identify the root cause of force harmonics (rotor / stator mmf and permeance harmonics) Noise mitigation techniques can then be implemented both on structural, electromagnetic & control design - stiffening / damping - slot combination - rotor of stator skewing - pole shaping / shifting - slot opening optimization - rotor or stator notches - magnetic wedges - winding short pitch optimization - harmonic injection -

25 Conclusions MANATEE can be used in early electromagnetic design phase to seamlessly evaluate electromagneticallyexcited noise and vibrations of electrical machines, avoiding long simulations times and tedious set-up of multiphysic numerical models MANATEE fast electromagnetic models v are based on linear subdomain models so vibroacoustic effects of saturation cannot be modelled yet FEMAG allows to carry fast non-linear electromagnetic finite element simulations without introducing spurious numerical force harmonics («blocked step» technique) FEMAG.PLT0 file can now imported in MANATEE to carry vibroacoustic calculations in a few seconds per speed and benefit from advanced NVH post processings

26 Future work Comparison between linear, non linear, and coupled circuit NVH behaviour If saturation vibroacoustic effects can be neglected, MANATEE spectrogram synthesis technique could be used to calculate variable speed NVH calculation from 1 (open circuit) to 6 (partial load) elementary.plt0 FEMAG output files, reducing overall calculation time down to 30 mn in open circuit and 2.5 hours in partial load at variable speed In current simulation workflow, the machine topology has to be defined twice (in FEMAG and in MANATEE GUI) so future coupling will include the automated analysis of.fsl file to identify the stator geometry and build the corresponding structural model Acknowledgements Special thanks to R. Tanner & J. Krotsch for technical support on Femag developments

27 Thank you for your attention Any questions? 27

28 BACK UP SLIDES 28

29 Spectrogram Synthesis algorithm Calculation of electromagnetic excitation at a single speed Extrapolation to variable speed based on the knowledge of the evolution of magnetic forces with operating point Single speed calculation Extrapolation at higher speeds Extrapolation at lower speeds EOMYS ENGINEERING / 121, rue de Chanzy Lille-Hellemmes FRANCE / contact@eomys.com

30 MANATEE experimental validations Case of an automotive traction motor (concentrated winding IPMSM) at load: TESTS MANATEE -40 db Motor B Motor A Sound level during a run-up (experiments with gearbox+watercooling+converter harmonics) Sound level during a run-up (MANATEE simulation without converter harmonics) ~10 sec on a laptop Fast electromagnetic model neglecting saturation can be used in basic design phase to avoid strong resonances, no need of detailed multiphysic numerical models EOMYS ENGINEERING / 121, rue de Chanzy Lille-Hellemmes FRANCE / contact@eomys.com

31 Case of a squirrel cage induction motor for hydraulic pump at no-load: TESTS Sound level during a run-up (experiments with PWM + gearbox +air-cooling) MANATEE Sound level during a run-up (simulation without PWM) ~2 sec on a laptop 15 db reduction reached after redesign with MANATEE (change of rotor slot number) Fast electromagnetic model neglecting saturation can be used in basic design phase to avoid strong resonances, no need of detailed multiphysic numerical models EOMYS ENGINEERING / 121, rue de Chanzy Lille-Hellemmes FRANCE / contact@eomys.com

32 Case of a railway squirrel cage traction induction machine with Sound Power Level measurements according ISO3745 in semi-anechoic chamber: TESTS Sound power level during runup (including fan noise) MANATEE Sound power level during a run-up (without air cooling) ~2 sec on a laptop Fast vibroacoustic model neglecting 3D effects can be used in basic design phase to avoid strong resonances, no need of detailed multiphysic numerical models EOMYS ENGINEERING / 121, rue de Chanzy Lille-Hellemmes FRANCE / contact@eomys.com

33 Case of a salient pole synchronous hydroelectric generator with damper bars TESTS First 136 rpm Second 120 rpm MANATEE Sound level during a run-up Sound level during a run-up ~10 sec on a laptop 3 db reduction reached after design optimization of magnetic wedges Fast vibroacoustic model neglecting 3D effects can be used in basic design phase to avoid strong resonances, no need of detailed multiphysic numerical models EOMYS ENGINEERING / 121, rue de Chanzy Lille-Hellemmes FRANCE / contact@eomys.com

34 MANATEE magnetic forces calculation The radial and tangential pulsating forces applied on the stator are: - ;, <= C, < - ;, <= > C, < The instantaneous electromagnetic torque is obtained from the tangential force: D -. Radial pulsating forces can resonate with stator breathing mode shape 0 at high speed A. Hofmann, F. Qi, T. Lange, and R. W. De Doncker, The breathing mode-shape 0: Is it the main acoustic issue in the PMSMs of today s electric vehicles?, ICEMS

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