manatee software presentation - eomys · pdf filemanatee is currently under matlab ......

© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]

MANATEE® SIMULATION SOFTWARE

Magnetic Acoustic Noise Analysis Tool for Electrical Engineering

Presentation of MANATEE software (v1.06) developed and distributed by EOMYS (www.eomys.com)


I. PRESENTATION

MANATEE is a simulation software for the optimal electromagnetic design of electrical machines including the analysis of magnetic vibrations and acoustic noise due to Maxwell forces.

MANATEE unique features include:

• - quick NVH calculation during early electromagnetic design loops- optimized NVH calculation in detailed design phase (coupling with structural FEA) over full operating points of the machine- advanced post processing giving physical insight to efficiently implement noise mitigation actions

MANATEE is currently under Matlab® (R2009b or later), but its Graphical User Interface is in Python/Qt to set-up the machine and simulation parameters.

MANATEE does not use any Matlab toolbox.

2


The following topologies are included in MANATEE v1.06:

• Inner rotor squirrel cage induction machine (including doubly-fed operation)

• Inner or outer rotor surface, inset or buried permanent magnet synchronous machine

• Wound rotor synchronous machines

• Geometry is not defined by CAD import but with overlays (cf website)


A few figures about MANATEE:

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

• Successfully applied on more than 50 industrical cases with IPMSM, SCIM, WRSM, DFIG, inner & outer rotor, from W to MW range, from 5 rpm to 150 000 rpm, from 10mm to 10m diameter machines

• more than 120 validation simulation projects

• more than 120 graphical post-processings

• ~50000 code lines (without counting comments)

Naval


6

Magnet /

current

excitations

ELECTROMAGNETIC MODULE

ELECTRICAL MODULE

STRUCTURAL MODULE

ACOUSTIC MODULE

MANATEE software contains the following modules:

Dynamic

vibrationsVariable

speed noise

level

Geometry

and control

parameters

VARIABLE SPEED MODULEMULTI-SIMULATION MODULE

OPTIMIZATION MODULE

3D force

distribution

THERMAL MODULE


II. ELECTRICAL MODEL

EQUIVALENT CIRCUIT

Option 1: Simulink® PWM block

Option 2: Numerically generated 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)

• No strong circuit coupling for the moment

Machine and converter input parameters

User definedequivalent circuit


8

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

• Permeance / magnetomotive force (MMF) analytical models

• Subdomain semi-analytical models

• Finite element non-linear magnetostatic model (FEMM)

The permeance / MMF decomposition based on winding functions allows to include PWM harmonics, skewing and geometrical asymmetries (eccentricities, non uniform airgap) and faults (broken bars, short-circuits) within a few seconds of calculation.

The subdomain models also allows to include PWM harmonics and skewing within a few seconds of calculation, but does not not account for uneven airgap and eccentricity.

III. ELECTROMAGNETIC MODEL


Permeance/ MMF Subdomain FEMM

Calculation time ++ + -

Tangential field calculation No Yes Yes

Robustness to geometry + + ++

Skewing (multislice) Yes Yes Yes

Saturation Yes (saturatedpermeance waves)

No Yes

Eccentricities & uneven airgap Yes No No

Faults (e.g. short circuits, brokenbar, demagnetization)

Yes No* No*

Topologies IPMSM**SPMSMSCIMDFIMWRSM

IPMSM**SPMSMSCIMDFIMWRSM

IPMSMSPMSM

SCIM (no-load)DFIMWRSM

Preferred model for fast vibroacoustic analysis in healthy

variable speed operation

*can be modelled but not included yet in MANATEE v1.06**fast hybridation with FEA

Subdomain model on SPMSM:

Permeance/mmf model on SCIM:


10

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 models in symmetrical healthy case:

Permeance/mmf

SCIM SPMSM, IPMSM, BPMSM, WRSM

Subdomain


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

• A winding pattern defined in Koil freeware can also be imported


• High accuracy and fast subdomain model for synchronous machine:

12

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

Finite element linearmagnetostatics (FEMM)

5 min

MANATEE subdomain models0.1 s

spacetimetime

space


> 1 hour of calculation 1 sec of calculation

• Comparison between Flux and Manatee on a loaded SPMSM non-linear magnetostatic simulation (confidential geometry) using Hybrid SubDomain Method


Option 1: 2,5D ANALYTICAL PERMEANCE / MMF MODEL User defined 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…

Harmonic magnetic forces

Airgap time and space flux distribution

PROJECTION TOOL

Radial and tangential forces FFT2

r=2

r=3

…

FEA mmf including non linearities

Torque ripple


• 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

[email protected]


S=Enveloppe fermée

Dynamic radial deflections

Option 1: 2,5D ANALYTICAL CYLINDER MODEL

Static radial deflections incl. tooth-induced moments

Natural frequencies of the circumferentialmodes of an equivalent ring

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

Natural frequenciesautomatically calculated by FEM (GetDP) on a 3D model

FRF calculation of main spatial orders of magnetic forces


Vibration synthesis of radial deflections

Option2: 3D FINITE ELEMENT STRUCTURAL MODEL GetDP (free) or Optistruct (commercial)

Harmonic magnetic forces

IV. STRUCTURAL MODEL

BASIC DESIGN

DETAILED DESIGN


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 harmonic loads for wavenumbers

r=0, ±2, ±4 …

STRUCTURAL FREQUENCY RESPONSE FUNCTIONS

r=0 r=2

ELECTROMAGNETIC VIBRATION SYNTHESIS

Complex FRFs (radial & tangential) for each wavenumber r

Vibration and noise spectrogramsOperational Deflection Shapes

Modal contributionRadiating surface velocities

Electromagnetic Vibration Synthesis (EVS) efficient algorithm

• 2D or 3D external FEA software (Flux, Jmag, Maxwell, Magnet etc…)

• Manatee 2,5D analytic model• Manatee 2,5D semi analytic model• Manatee 2,5D numerical model (FEMM)

• 3D external FEA software (Optistruct, Ansys)

• Manatee 2,5D analytic model• Manatee numerical model (GetDP)

Torque/speed curve (variable speed control law)

SPECTROGRAM SYNTHESIS


Coupling with structural FEA Optistruct:

• Possibility to automatically couple an existing FE model of Optistructwith any other electromagnetic software, or to rebuild a laminationmodel 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


Coupling with open-source structural FEA GetDP:

• Automated mesh generation using Gmsh• Automated identification of coupled circumferential / longitudinal modes

with different boundary conditions• Modal shape selector to visualize the modes and validate the automated

modal identification

(2,0)

(3,0)

(4,0)

(0,0)

(2,1)

(3,1)

(4,1)


CLAMPED – FREE

Boundary conditions

FREE – FREE

Boundary conditions

Resulting modal basis (simplified representation of cylindrical modes – « tooth rocking modes » are included):


21


SEMI-ANALYTICAL ACOUSTIC MODEL

Radiation efficiency of an equivalent cylinder

V. ACOUSTIC MODEL

Sound power levelSound pressure level

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


Spectrogram Synthesis algorithm

Single speed calculation

Extrapolation at higher speeds

Extrapolation at lower speeds

• 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


VI. ADVANTAGES

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

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

• Several industrial validations of the vibroacoustic model

• Advanced harmonic post-processings to understand the root cause of acoustic noise and find design improvements

• Possibility of decoupling electromagnetics & structural mechanics (EVS algorithm) to perform efficient NVH optimization (e.g. pole shaping, current injection)

• Coupling with your own Matlab/Python scripts

• Extensive online documentation with tutorials and validation cases

23


VII. VALIDATIONS AND DOCUMENTATION

24

• 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


EXAMPLES OF MANATEE SOFTWARE VIBRO-ACOUSTIC 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


VIII. POST PROCESSINGS & PLOT TOOLS

30

• MANATEE includes more than 100 plots accessible directly in the command line• Example of Matlab


31

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

-2000

0

2000 -100

0

100

0

0.5

1

1.5

Spatial order [r]Frequency [Hz]

Mag

nitude [T]


Visual fitting tool for B(H) curve model at high excitation field


33

Magnetic harmonic forces analysis with automated identification of lines expression

-8-7-6-5-4-3

-2-101 2 3 45 6 7 8

1000

2000

3000

0

5000

10000

15000

f=4fs=382 Hz

r=6

f=2fs=191 Hz

r=3

spatial order [r]

f=22fs=2099 Hz

r=6 f=20fs=1908 Hz

r=3

f=5fs=453 Hz

r=-3

Airgap radial force FFT2

f=3fs=262 Hz

r=-6

f=16fs=1526 Hz

r=-3 f=14f

s=1336 Hz

r=-6

Frequency [Hz]

σ r [N/m

m2]

(PMSM)(SCIM)

Wavenumber

Wavenumber


34

Magnetic harmonic forces analysis


35

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

>> find_harmonic_PMSM_open_circuit(2, 10, 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


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


Possibility to visualize the modal basis under Gmsh (freeware)


43

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


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


0 2000 4000 600050

100

150

200

250 2-th

3-th

4-th

Frequency [Hz]

Supply frequency [Hz]

SPL [dBA]

0

10

20

30

40

50

60

Listen to your electrical machine (direct sound synthesis)

Verification of the MANATEE synthesized sound using AudacityMANATEE spectrogram

resonance

resonance


is_mmfs

is_ideal_mmfs

is_mmfr

is_ideal_mmfr

is_slotS

is_slotR

LwrA

LwrA_max

ismmfs

dealmmfs

ismmfr

dealmmfr

isslotS

isslotR

LwrA

LwrA

max

corr factor

0

0.2

0.4

0.6

0.8

1

Automated harmonic source analysis

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


Mutisimulation Viewer for post processing sensitivity & optimization results


ACOUSTIC FEA MODEL

Unit radiating surface displacements

ACOUSTIC FREQUENCY RESPONSE FUNCTIONS

Acoustic Transfer Vector (ATV)

m=0 m=1

SOUND SYNTHESIS

Complex FRFs for each structural mode

(MATV)

SonagramsSound Power LevelDirectivity patternsModal contributions

Modal contributionsfrom vibration synthesis

VIBRATION SYNTHESIS

APPENDICES


• The permeance / mmf and winding function model allows to make a fast analysis of the effects of skewing, rotor and stator asymmetries (e.g. tolerances, segmentation, gaps, weldings), rotor dynamic and static eccentricities, saturation, interturn short circuit, and broken bar for squirrel cage machines

-0.1 0 0.1

-0.2

-0.1

0

0.1

0.2

stator shape

symmetrical

deformed

-0.1 0 0.1

-0.2

-0.1

0

0.1

0.2

rotor shape

symmetrical

deformed+eccentric

Example of the vibroacoustic effect of stator segmentation or rotor tolerance

circular airgap non circular airgap


0 1 2 3 4 5 6 7-1

-0.5

0

0.5

1

angle [rad]

airgap

rad

ial flux density [T]

with saturation

without saturation

Example of the effect of additional permeance harmonics due to saturation in induction machines


Sound Power Level at variable speedCase of a squirrel cage induction machine Zr=96 Zs=84 p=4

Frequency f=fs(Zr/p+2)Order r=Zr-Zs+2p=-4

Frequency f=fs(Zr/p+4)Order r=Zr-Zs+4p=+4

WITHOUT SATURATION

WITH SATURATION

VARIABLE SPEED NOISE CALCULATED IN 1 sec


0 200 400 600 800 10000

20

40

60

80

100

120

Frequency [Hz]

Acceleration leve

l [dB Re 1e-6 m

/s2]

Radial acceleration spectum

0 200 400 600 800 10000

20

40

60

80

100

120

Frequency [Hz]

Acceleration leve

l [dB Re 1e-6 m

/s2]

Radial acceleration spectum

Healthy condition Broken bar

Example of the vibroacoustic effect of a broken bar in a squirrel cage induction machine


Example of the vibroacoustic effect of an interturn short circuit

New noise & vibration line


Example of the vibroacoustic effect of magnetic wedges using permance /mmf model and coupling with FEMM


Example of the effect of skew of rotor slots (or stator slot) on the maximum acoustic noise level

0 0.5 1 1.5 250

60

70

80

90

100

110

rotor skew pitch in stator slot pitch

sound power leve

l (dBA)

This sensitivity study is done on the maximum noise level at variable speed as a function of the rotor skew angle. Its calculation takes less than 2 min.


• Special algorithm based on winding functions & subdomain models to decrease CPU time:

62

Full time and space airgap radial and tangential flux distribution due to armature field (suitable with PWM current harmonics): • standard subdomain algorithm: 40s• optimized algorithm: 0.8s


Automated phasor diagram and various control strategies (torque speed curve, MTPA, etc)

manatee software presentation - eomys · pdf filemanatee is currently under matlab ......

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