manatee simulation software magnetic acoustic noise ...• successfully applied on more than 80...

© 2013-2019 EOMYS ENGINEERING / 121 rue de Chanzy CS10128 59030 Lille Cedex FRANCE / www.eomys.com / [email protected]

MANATEE® SIMULATION SOFTWARE

Magnetic Acoustic Noise Analysis Tool for Electrical Engineering


MANATEE simulation software can be used for the electromagnetic design optimization of electrical machines including the analysis of magnetic vibrations and acoustic noise due to Maxwell forces (“e-NVH”).

MANATEE unique features include:

• - fast electromagnetic Noise Vibration Harshness (e-NVH) calculation in early electromagnetic design loops- optimized e-NVH calculation in detailed design phase (coupling with structural FEA) over full operating range- advanced post-processing for e-NVH root cause analysis- design optimization environments of e-motor noise mitigation technique

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stator/rotor skewing pole/slot shaping current injection stator/rotor notching randomized PWM

OVERVIEW OF MANATEE FOR E-NVH


MANATEE is the central point for the integrated Noise, Vibration, Harshness design process of electric powertrains (e-NVH), from basic vibro-acoustic design at e-motor level to detailed vibro-acoustic design at system level:

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Third-party sound quality tools

Third-party electromagnetic design tools

Third-party structural design tools

Third-party acoustic design tools

Third-party gearbox NVH design tools

Standalone e-motor NVH solution (electromagnetics

+vibro-acoustics)

© Masta

© Actran

© Oros

© Jmag

© Ansys

Third-party NVH data acquisition tools

© Oros

v1.08 coupling

v1.09 coupling


MANATEE v1.07. graphical environment:

Scripting environment (Matlab)

Simple command line post-processings

(Matlab)

GUI for machine & simulation set-up

(Python)

no Matlab toolbox needed


MANATEE is currently under Matlab® (R2009b or later), but its GUI is in Python/Qt to set-up the machine and simulation parameters. MANATEE does not use any Matlab toolbox.

MANATEE built-in fast electromagnetic models are based on geometrical layouts (cf. website).

New lamination shapes can be easily implemented by EOMYS upon request.

The following radial flux electrical machine topologies are included in MANATEE v1.08:

• SCIM, DFIM

• Inner or outer rotor SPMSM, ISPMSM, IPMSM

• WRSM, SynRM, SRM


A few figures about MANATEE:

• Up 40 dB acoustic noise reduction after redesign based on EOMYS consulting activities

• Successfully applied on more than 80 industrial cases with IPMSM, SCIM, WRSM, DFIG, inner & outer rotor, fromW to MW range, from 5 rpm to 150 000 rpm, from 10mm to 10m diameter machines

• More than 100 multiphysic validation simulation projects open to MANATEE users

• More than 120 graphical post-processing commands (such as plot_machine) to ease e-NVH root cause analysis

Naval


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Magnet / current

excitations

ELECTROMAGNETIC MODULE

ELECTRICAL MODULE

STRUCTURAL MODULE

ACOUSTIC MODULE

MANATEE software seamlessly integrates the following multiphysic modules:

Dynamic vibrations

Variable speed NVH

Geometry and control parameters

3D force distribution

THERMAL MODULE

VARIABLE SPEED MODULEMULTI-SIMULATION MODULE

OPTIMIZATION MODULE

The interface between physics (e.g. mesh to mesh projections) are automatically defined.All module inputs can be user-defined / imported if necessary, resulting in a flexible simulation workflow. Module interface is documented for possible integration in third-party scripts.


E-NVH ELECTRICAL MODEL OPTIONS

EQUIVALENT CIRCUIT

Option 1: Simulink® PWM block

Option 2: Analytical / numerical PWM

Phase voltage waveforms

PWM MODEL

User-defined voltage waveforms

Phase currentwaveforms

User-defined currentwaveforms

• PWM model with several strategies (synchronous, asynchronous, calculated, full wave) including randomized switching strategies

• No strong circuit (yet) in v1.07

Machine and converter input

parameters

User-definedequivalent circuit


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MANATEE electromagnetic model relies on the fast calculation of the airgap radial and tangential flux density with the combination of the following modelling methods :

• Permeance / magnetomotive force analytical models (PMMF)

• Subdomain semi-analytical models (SDM)

• Finite element non-linear magnetostatic model (FEMM)

Import of airgap flux from third-party electromagnetic software is supported.

E-NVH ELECTROMAGNETIC MODEL OPTIONS


Option 1: 2,5D ANALYTICAL PERMEANCE / MMF MODEL User-defined airgap flux distribution

Phase current waveforms

Option 2: 2,5D SEMI-ANALYTICAL SUBDOMAIN MODEL

Option 3: 2,5D FINITE ELEMENT MODEL (FEMM)

Analytical mmf in linear case using winding function model

Analytical permeance incl. geometrical assymetries (e.g. uneven airgap, eccentricities)

FEA permeance incl. saturation, magnetic wedges, notches…

Airgap time and space flux

distribution

FEA mmf including non linearities


Permeance/ MMF Subdomain FEMM

Calculation time Very fast Fast Slow

Tangential field calculation No Yes Yes

Torque ripple calculation No* Yes Yes

PWM currents Yes Yes Yes

Robustness to geometry Limited Limited Good

Skewing (multi-slice w/o coupling) Yes Yes Yes

Saturation Limited (saturated permeance waves for IM)

No (except on IPMSM rotor**)

Yes

Static and dynamic eccentricities Yes No Yes

Uneven airgap Yes No No

Pole displacement, demagnetization Yes Yes Yes

Stator short-circuit Yes No* No*

IM broken bar Yes Yes No*

Topologies IPMSM**SPMSM

SCIMDFIM

WRSM**

IPMSM**SPMSM

SCIMDFIM

WRSM**

IPMSMSPMSM

SCIM (no-load)DFIM

WRSM

*can be modelled but not included yet in MANATEE v1.07**fast hybridation with FEMM

Subdomain model on SPMSM:

Permeance/mmf model on SCIM:


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Model hybridation is possible in MANATEE such as

• Calculation of mmf using non-linear FEMM (e.g. rotor mmf for interior magnet machines)

• Calculation of permeance using non-linear FEMM (e.g. saturation effects, notch effects, magnetic wedges)

Recommended fast electromagnetic models in symmetrical healthy case:

Permeance/mmf

SCIM SPMSM, IPMSM, WRSM, SRM

Subdomain


• Any winding type can be modelled (integral, fractional, user-defined, multiphase)

• A winding pattern defined in Domolites (formerly Koil) freeware can also be imported


• High accuracy and fast subdomain model for synchronous machine:

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• Automatic coupling with FEMM finite element software (symmetries, boundary conditions) in order to model more complex problems (e.g. shaped magnets, saturation effects)

Finite elementmagnetostatics (FEMM)

5 min

MANATEE subdomain models0.1 s

spacetimetime

space


> 1 hr of calculation 1 s of calculation

• Comparison between Altair Flux® (FEA) and MANATEE ® (SDM) airgap flux distribution in time and space on a loaded SPMSM include non-linearity:


E-NVH MAGNETIC FORCE CALCULATION OPTIONS

Stator and rotor nodal or lumped Maxwell harmonic forces and moments

Airgap time and space flux distribution

MAGNETIC FORCE CALCULATION, PROJECTION AND 2D FFT

Option 3: Virtual Work Principle nodal magnetic forces

Torque ripple

r=0 r=2 r=3

• Torque ripple and cogging torque are naturally obtained as a particular case of magnetic forces

• Trade-offs between torque ripple and noise minimization can therefore be obtained with MANATEE

Option 1: Lumped magnetic load vectors

Option 2**: Surface magnetic force densities

**force calculation not coupled to structural model in v1.08


S=Enveloppe fermée

Dynamic deflections

Option 1: 2,5D ANALYTICAL CYLINDER MODEL

Static radial deflections

Natural frequencies of the circumferentialmodes of an equivalent ring

User defined natural frequencies(e.g. experimental data)

Natural frequenciesautomatically calculated by

FEM on a 3D model

Force application on imported FEA model or concept stator built from scratch

Average dynamic radial deflections

3D vibration velocity field

Option 2: 3D FINITE ELEMENT STRUCTURAL MODEL Optistruct / Ansys / Nastran / Abaqus*

E-NVH STRUCTURAL MODEL OPTIONS

BASIC DESIGN

DETAILED DESIGN

Stator and rotor nodal or lumped Maxwell harmonic

forces and moments

*available in MANATEE v1.09


Tangential and radial harmonic magnetic forces (magnitude, wavenumber, frequency, phase)

3D airgap flux distribution

HARMONIC FORCE PROJECTION

r=2 r=3

ELECTROMAGNETIC MODEL

r=0

STRUCTURAL MODEL

Unit rotating loads identified with MANATEE

r=0, ±2, ±3 …

STRUCTURAL FREQUENCY RESPONSE FUNCTIONS

r=0 r=2

ELECTROMAGNETIC VIBRATION SYNTHESIS

Complex FRFs (radial & tangential) for each force

wavenumber r

Electromagnetic Vibration Synthesis (EVS): faster than a direct coupling, more physical insights

• 2D or 3D external FEA software (e.g. Flux, Jmag, Maxwell, Magnet)

• MANATEE 2,5D electromagnetic models (SDM, PMMF, FEMM)

• 3D external FEA software (e.g. Optistruct, Ansys, Actran)

• MANATEE 2,5D structural models

Vibration and noise spectrum with modal participation

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Spectrogram Synthesis Algorithm (SSA): fast calculation of variable-speed NVH behaviour

Single speed calculation

Extrapolation at higher speeds

Extrapolation at lower speeds

• Calculation of electromagnetic excitations at only 1 to 6 single speeds depending on load state

• Extrapolation of operational magnetic loads to variable speed based on the knowledge of the evolution of magnetic forces with operating point and Id/Iq strategy (saturation of reference operating point is assumed to be constant over speed)

• Speeds-up NVH calculation and reduces parasitic forces as there is no need to interpolate magnetic force harmonics magnitude between speed

Vibration and noise waterfallsOperational Deflection ShapesModal contribution

ELECTROMAGNETIC VIBRATION SYNTHESIS

SPECTROGRAM SYNTHESIS


Coupling with third party structural FEA :

• Possibility to automatically call from MANATEE an existing FEA model of Optistruct / Ansys / Nastran, or to rebuild a lamination model (« concept stator ») from scratch:• circular lamination with any slot geometry (possibility to simplify the slot geometry to

have a lighter structural model)• application of physics: orthotropic properties, winding mass• application of boundary conditions (e.g. clamped/clamped, free/clamped, fixed nodes)• meshing based on the number of nodes in the different regions

• Automated magnetic force application (load collectors)

• Vibration synthesis post-processing using operational magnetic loads from MANATEE electromagnetic model or third party electromagnetic software


CLAMPED – FREE

Boundary conditions

FREE – FREE

Boundary conditions

Automated identification of cylindrical modes based on enveloppe nodes


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Dynamic radial deflections

Option 1: SEMI-ANALYTICAL ACOUSTIC MODEL

Radiation efficiency of an equivalent cylinder

E-NVH ACOUSTIC MODEL OPTIONS

Sound power levelSound pressure level

2D (analytical) or 3D (FEM) spatial-averagedvibration velocity

Sound synthesis .wav

Option 2: NUMERICAL FEA ACOUSTIC MODEL

Coupling with


KEY FEATURES OF MANATEE SOFTWARE

• Fast variable speed vibroacoustic calculation (from 1 sec to 1 mn) based on efficient calculation methods even with 3D effects and converter harmonics

• Possibility of decoupling electromagnetics & structural mechanics (EVS algorithm) to speed up NVH Vs electromagnetic performances optimization studies

• High frequency acoustic calculations (up to 20 kHz) within seconds, contrary to numerical approaches

• Large number of NVH root cause analysis post processing tools

• Easy implementation of all e-machine noise and vibration control actions (e.g. current injection, skewing, pole shaping, notching)

• Extensive online documentation with tutorials and validation cases

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VALIDATIONS AND DOCUMENTATION

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• A full website is dedicated to MANATEE validations, post-processings, and tutorials:

www.manatee-software.com

• All modules are validated using special validation projects which can be run and modified by the user:

>>run_MANATEE(‘EM_SPMSM_NL_001');

• Validation cases are daily tested on the current version of MANATEE

• The input and output simulation data are stored in structures and substructures which are documented in an Excel file

• Three main tutorials for the electromagnetic and vibroacoustic simulation of squirrel cage induction machines, interior and surface PMSM


MANATEE SOFTWARE VALIDATIONS

Case of a traction concentrated winding PMSM with interior magnets at partial load (blind test):

Sound level during a run-up (experiments with gearbox+water-cooling+converter harmonics)

Sound level during a run-up (MANATEE simulation without

converter harmonics)~10 sec on a laptop

TESTS MANATEE

Motor A

Motor B-40 dB

Fast electromagnetic model neglecting saturation can be used in basic design phase to avoidstrong resonances, no need of detailed multiphysic numerical models


Case of a squirrel cage induction motor of a naval dredge pump at no-load:

Sound level during a run-up (experiments with PWM + gearbox +air-cooling)

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)

TESTS

MANATEE

gearbox lines


Case of a railway squirrel cage traction induction machine with Sound Power Level measurements accordingISO3745 in semi-anechoic chamber:

Sound power level during run-up (including fan noise)

Sound power level during a run-up (without air cooling)~2 sec on a laptop

TESTS

MANATEE

Fast vibroacoustic model neglecting 3D effects can be used in basic design phase to avoidstrong resonances, no need of detailed multiphysic numerical models


Case of a salient pole synchronous hydroelectric generator with damper bars


Sound level during a run-up Sound level during a run-up

~10 sec on a laptop

TESTS MANATEE

2 resonances


Case of a traction distributed winding PMSM with interior magnets at partial load:


Sound level during a run-up (experiments in non ideal acoustic

conditions)Sound level during a run-up

(MANATEE, coupling with non linear FEMM)~6 hours on a standard PC

Sound level during a run-up (MANATEE simulation, linear subdomain)

~10 sec on a standard PC

overall

SPL avg 3 micros


Geometry / Currents (manual - automated import

upon request)

MANATEE INTEGRATION TO E-MACHINE DESIGN WORKFLOW

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Step 1 : basic electromagnetic + basic vibro-acoustic design loops

Option A. Standalone electromagnetic & vibroacoustic design optimization

Option B. Coupling with third partly fast electromagnetic design tools (optional)

Speed, FluxMotor, RPMXpert etc.

• Fast assessment of electrical machines air-borne noise to rank different topologies (ex: SyRM Vs IPMSM, slot/pole combinations) at variable speed along torque/speed curve under sine supply

• Possibility to drive MANATEE models from Python/Matlab scripts

• First electromagnetic design NVH optimization by implementing electrical noise mitigation techniques (skewing, notching)

Matlab/Python scripts

Note: these workflows are given as examples, other use may be possible


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Step 2 : detailed electromagnetic + basic vibro-acoustic design loops:

Coupling with third party FEA electromagnetic design tools

Airgap flux lookup tables

NVH maps in torque / speed plane

Skew / torque ripple / axial ripple optimization

• Refinement of electromagnetic force calculation compared to MANATEE built-in electromagnetic models (e.g. 3D FEA magnetic model with axial effects, strong circuit coupling)

• Fast study of best trade-offs between NVH, torque ripple, losses etc on the whole operating range using MANATEE flux interpolation, skew pattern optimization, noise maps, sensitivity study features


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FRF

Export to third partly sound quality software (optional)

Coupling with third party FEA structural software

Sound .wav

Step 3 : detailed electromagnetic + detailed vibro-acoustic design loops:

• Refinement of structural and acoustic calculations using complex structural CAD model including both airborne and structure borne vibrations based on Electromagnetic Vibration Synthesis

• Quantification of e-motor / gearbox interactions by exporting MANATEE magnetic forces

• Implementation of further NVH minimization focusing on structural solutions (e.g. housing, footings)

• Potential extension to other sources of noise (e.g. gear whine, aerodynamic noise) and sound quality studies

Coupling with third partly FEA electromagnetic software

forcesvibrations

Airgap flux lookup tables


BUILT-IN PLOT COMMANDS

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• MANATEE includes more than 120 plot commands directly accessible in command line• Example of Matlab

quick plot command without arguments


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Geometry, time and space visualization, real and complex spectra for all quantities (permeance, mmf, radial and tangential flux density, force, acceleration, velocity, displacements), 2d/3d animation


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Magnetic harmonic forces analysis with automated identification of lines expression

(PMSM) (SCIM)

Wavenumber


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Magnetic harmonic forces analysis


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Automated analysis of magnetic force waves in open circuit / partial load

>> find_harmonic_PMSM_open_circuit_fr(10, 2, 5, 12)Force wave {f=10fs, r=2} is created by the product of flux waves B1=P1.F1 and B2=P2.F2 such as:B1={0,0}.{9fs,9p} and B2={0,-4Zs}.{fs,p}B1={0,0}.{fs,p} and B2={0,-4Zs}.{11fs,11p}B1={0,0}.{7fs,7p} and B2={0,-4Zs}.{3fs,3p}B1={0,0}.{5fs,5p} and B2={0,-4Zs}.{5fs,5p}B1={0,0}.{3fs,3p} and B2={0,-4Zs}.{13fs,13p}B1={0,0}.{5fs,5p} and B2={0,-4Zs}.{15fs,15p}

Example of a 12s10p PMSM (Zs=12, p=5) in open circuit conditions: to know how the origin of the force wavenumber r=2 occurring at f=10fs one can simply type:

stator slottingpermeance waves

rotor magnetflux density waves


Static (top) and dynamic (bottom) radial vibration spectra

Possibility to plot frequencies as electrical or mechanical orders


Spectrogram of radial / tangential force harmonics for each spatial wavenumber


Spectrogram of radial / tangential force harmonics of a given order, including rotation direction

Operational deflection shapes at a given frequency


Plot of tangential and radial forces per tooth in time and frequency domain

r=0 r=2 r=3


Space vector diagram to analyze the origin of a radial or tangential force harmonic in terms of flux density waves


Space vector diagram to analyze the origin of a radial or tangential flux density in terms of permeance and magnetomotive force waves


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Modal contribution to acoustic and vibration spectra up to 20000 Hz


Contribution of each structural mode to the acoustic noise at variable speed


Spectrogram and order analysis with automatic identification of main magnetic force harmonics orders and frequencies


« Spatiogram » noise analysis: decomposition of acoustic noise spectrogram per force wavenumber

=

r=0

r=2

+ +…

r=4

+


Order analysis per circumferential vibration wavenumber (including rotation direction)

r=0 r=1

r=+2r=-2


Acoustic noise maps in torque/speed plane

First resonance depends on torque/current level -> due to armature/pole/slot interactions

Second resonance independent of torque/current level -> due to pole/slot interactions (open circuit noise)

Example of a 48s8p IPMSM with stepped-skew rotor

NVH behaviour is different in traction and braking


Automated skew optimization environment

• Automated study of torque maximization / torque ripple minimization / noise minimization tradeoffs

• Fast calculation based on flux lookup table as a function of Id/Iq

• Possibility to use this tool based on FEMM or third party FEA electromagnetic software


Automated harmonic analysis

• Automated study of e-motor NVH harmonic sources

• Rotor/stator winding space harmonics, rotor/stator slotting, PWM, saturation, eccentricities


Unbalanced magnetic pull calculation (example of the slotting effect on eccentric UMP including skew of the stator)


Listen to your electrical machine (direct sound synthesis)

• Sound synthesis can be carried at single speed or variable speed

Sound with 4800 Hz PWM Sound with 10000 Hz PWMSound under sine supply

Run-up at variable speed

• Sound can be exported to third party sound quality software (e.g. Artemis from HeadAcoustics) for further analysis


is_mmfs

is_ideal_mmfs

is_mmfr

is_ideal_mmfr

is_slotS

is_slotR

LwrA

LwrA_max

ism

mfs

de

alm

mfs

ism

mfr

de

alm

mfr

isslo

tS

isslo

tR

LwrA

LwrA

max

corr factor

0

0.2

0.4

0.6

0.8

1

Automated harmonic source analysis on electromagnetically-excited noise

High correlation between maximum noise level and rotor slotting harmonics

High correlation between maximum noise level and rotor mmf

Low correlation between maximum noise level and stator winding armature spatial harmonics

High correlation between maximum noise level and nominal noise level


5D « Muti-simulation Viewer » for post processing sensitivity & optimization results


CONCLUSIONS

• MANATEE is the only software fully dedicated to the assessment of magnetic forces, magnetic vibrations and acoustic noise with validated force projection algorithms and validated noise results

• MANATEE is the only simulation environment giving physical insights on e-NVH, combining noise troubleshooting and noise mitigation tools

• MANATEE can be integrated both in pre-sizing and detailed design workflows and provides accelerated simulation times compared to a direct coupling approach

• MANATEE semi-analytic models and numerical algorithms give no parasitic numerical noise

• MANATEE is highly flexible based on Matlab/Python scripting

• MANATEE can be used as a standalone electromagnetic design software of electrical machines

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manatee simulation software magnetic acoustic noise ...• successfully applied on more than 80...

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