牵引电机、控制器和动力总成系统集成化解决方案register.ansys.com.cn/ansyschina/20151117aswc/...U1 E1 V A B C N U_UMR PWM Modulator DC-Link Voltage Integrating

牵引电机、控制器和动力总成系统集成化解决方案

李时伟ANSYS 高级应用工程师

[email protected]

1 ANSYS动力总成集成解决方案

2 新能源电机设计

3 控制器/变流器设计

4 动力总成系统设计

5 总结

大纲

电池包

新能源电机

总线

传感器、作动器

传动轴控制器/变流器

Controller

HEV/EV 动力总成系统

电池包• 温升• BMS

新能源电机：• 效率Map• 控制性能• NVH• 温升和散热

总线：• 寄生参数

传感器、作动器

传动轴

变流器：• EMC/EMI• 温升和散热• IGBT建模

控制器• 控制算法• 效率

性能优化

HEV/EV 动力总成系统关键技术

样机/验证

硬件设计

行为级层次详细设计

软件设计

电气设计

开环控制闭环控制

嵌入式代码/代码生成

电气模型损耗– EMC/EMI

初步分析散热 –疲劳

?

?

传统电气系统设计流程

代码自动生成

电气模型损耗– EMC/EMI系统验证系统验证

ANSYS电气系统设计理念样机/验证

硬件设计

行为级层次详细设计

软件设计

电气设计

开环控制闭环控制

初步分析散热 –疲劳

Magnetic2D/3D FEA Analysis

System AnalysisCircuits, Blocks, State Machine

PP := 6

ICA:

A

A

A

GAIN

A

A

A

GAIN

A

JPMSYNCIA

IB

IC

Torque JPMSYNCIA

IB

IC

TorqueD2D

MagneticsPExprt RLCG Parasitics

MechanicalThermal/Stress

CFDThermal

Model order Reduction

Co-simulation

Field Solution

FE Model Generation

Optimization

ANSYS动力总成集成化解决方案

Embedded Software

Embedded Design

Push Back Excitations

RMxprtMotor Design Motor-CAD

Thermal+





5 总结

大纲

初始设计有限元精确设计应力/噪声温升

基于ANSYS Workbench 多物理场耦合设计

0-D系统建模

多层次电机设计流程

• RMxprt– 模板化的电机设计

– 主流电机的快速磁路法设计

– 一键自动生成 Maxwell 2D and 3D 全设置有限元模型

–Motor-CAD– 利用热网络快速计算电机温升

– 模板化的几何建模

– 亦可通过RMxprt自动生成模型

– 稳态和瞬态温升计算

– 自动计算所有换热系数

– 易于使用

RMxprt

Motor-CAD

磁路和散热快速设计

机壳建模

• 4 类机壳模型

• 6 类散热翅片模型

• 3 类通风沟模型

端盖建模

Overall Width

Cutout Depth

Fin Thickness

Inner Diameter

Flan

ge

Diam

eter

Plat

e He

ight

Plate Thickness

Flange Thickness

Base Thickness

Base Width

Foot WidthPalm Width

Shaft HeightFoot Distance

Palm Height

Length Extension

Cap Thickness

Hold

er D

iam

eter

Bear

ing

Diam

eter

Shaft Diameter

Bearing Thickness

Out

er D

iam

eter

RMxprt 散热方式建模

0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00Time [ms]

-60.00

-40.00

-20.00

0.00

20.00

40.00

60.00

80.00

100.00

120.00

Cur

rent

(Pha

seA

) [A

]

Maxwell2DDesign1_ACVnormXY Plot 2

m1

m2

Curve InfoCurrent(PhaseA)

Setup1 : Transient

Name X Ym1 8.2000 97.6263m2 68.2000 47.1699

T=1/f

User Defined Outputs Electric Machine Toolkits

0.00 1250.00 2500.00 3750.00 5000.00 6250.0Speed [rpm]

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

Torq

ue [N

ewto

nMet

er]

current_MotorMode_EfficiencyMap2Torque vs Speed

F

Iγ

-500.00 -250.00 0.00 250.00 500.00V(d-axis) [V]

-250.00

-125.00

0.00

125.00

250.00

375.00

500.00

V(q

-axi

s) [V

]

Maxwell2DDesign1_Current_Gamma_Sweep1XY Plot 1

1Speed_rpm [rpm] 1000.000000

InputPower [kW] 27.026186OutputPower [kW] 22.435100Torque [NewtonMeter] 214.239426Speed [rpm] 1000.000000PowerFactor 0.584396SupplyCurrent [A] 141.417974PhaseVoltage [V] 109.005576CoreLoss [W] 113.115481SolidLoss [fW] 0.000000StrandedLossR [kW] 2.400000MechanicalLoss [W] 99.999532TotalLoss [kW] 2.613115Efficiency 89.567660PowerBalance 8.897381V(d-axis) [V] -137.705223V(q-axis) [V] 37.234678I(d-axis) [A] -68.404310I(q-axis) [A] 187.938422L(d-axis) [mH] 1.600205L(q-axis) [mH] 1.982361FluxLinkage(d-axis) [Wb] 0.068288FluxLinkage(q-axis) [Wb] 0.331973

Quick Guide

0.00 12.50 25.00 37.50 50.00 62.50 75.00 87.50Gamma_TSC [deg]

-12.50

7.50

27.50

47.50

67.50

87.50

100.00

Y1

[N

ew

ton

Me

ter]

Design_BH_right_Current_Gamma_Sweep1Torque vs Gamma

电机设计工具包

ANSYS电磁-温升双向耦合流程

Maxwell 模型映射损耗

温升仿真结果

几何模型

CFD 模型

全自动的电磁振动噪声分析

电磁场

结构谐响应

声场

电磁力位移

ANSYS电机电磁振动噪声分析流程





5 总结

大纲

Reduced Order Model Creation

Functional Mockup Interface (FMI)

Embedded Software Integration

Co-simulationwith 3D Physics

ANSYS 3D Physics

MechEM ThermalFluid

Multi-Domain Model Libraries

Language-BasedModeling

VHDL-AMSC/C++SPICESML

Modelica

ANSYS SCADE

SimulinkC Code

3rd Party SystemModeling tools

(AMESim, Simulink,Dymola, GT Suite etc.)

Analog

Digital

Multi-Domain

App-Specific

Power Systems

Manufacturers

ANSYS 机电系统建模

Basic Analysis, Sophisticated Tests

Waveform & Data Post-Processing

Reporting, Scripting & Automation

PythonVisual Basic

Frequency-Domain

Time-Domain

Parameter Sweeps

Optimization

Statistical

Senstivitity

Worst-Case

Simulation Synchronizer

Robust, High-Performing Solvers

ANSYS 机电系统仿真

变流器结构复杂

器件型号多

0.00 0.50 1.00 1.50 2.00 2.50Time [ms]

0.00

1000.00

2000.00

3000.00

3673.95

Y1

Ansoft LLC Sheet4_TR_Y_static_dtimePowerLossesCurve Info

Diode601.PELTR

NIGBT_AdvDyn1.POWER_TTR

器件开关损耗波形

0.00 0.50 1.00 1.50 2.00 2.50Time [ms]

27.00

27.05

27.10

27.14

Y1

Ansoft LLC Sheet4_TR_Y_static_dtimeTemperature RiseCurve Info

Diode601.TEMPJNCTTR

NIGBT_AdvDyn1.TEMPJ_TTR

器件温升曲线

母排

门极驱动

变流器驱动电路建模和分析

Infineon : eupec FZ600R12KE3

Simplorer 半导体器件特征化建模功能可自动并拟合抽取开通/关断特性曲线

0.00 1.00 2.00 3.00 4.00 5.00Vce.V [V]

0.00

200.00

400.00

600.00

800.00

1000.00

1200.00

Ic.I

[A]

x02_OutputOutput Char. @Tj=125c

Curve InfoIc.I

TR

输出特性Vce-Ic

产品手册

Simplorer

建模工具

器件模型

IGBT特征化建模开通/关断参数抽取

Infineon : eupec FZ600R12KE3

等效热网络模型（IGBT&Diode）

IGBT Diode

25℃

特性抽出ツール

0 650.0125.0 250.0 375.0 500.00

70.00

10.00

20.00

30.00

40.00

50.00

60.00

E=f(Ic)

Eon

Eoff

I [A]

E[mJ]

1k * igbt_...1k * igbt_...

Eon = f...Eoff = f...

20.0 140.040.0 60.0 80.0 100.0 120.015.00

40.00

17.50

20.00

22.50

25.00

27.50

30.00

32.50

35.00

37.50

E=f(Tc)

Eon

Eoff

E[mJ]

Tc [C]

Simplorer

特征曲线

建模工具

IGBT特征化建模热特性参数抽取

FEA

PhaseA1

PhaseA2

PhaseB1

PhaseB2

PhaseC1

PhaseC2

Rotor1

Rotor2

ω+

ICA:

1400 rpm

LL:=237.56uRA:=696.076m

B6U

D1 D3 D5

D2 D4 D6

2L3_GTOS

g_r1

g_r2

g_s1

g_s2

g_t1

g_t2

~

3PHAS

~

~

A * sin (2 * pi * f * t + PHI + phi_u)

PHI = 0°

PHI = -120°

PHI = -240°

LDUM:=100mCDC:=10mLDC:=10mRDC:=10VZENER:=650

AMPLITUDE := 800 VFREQUENCY := 60 Hz

-297.50

300.00

-200.00

0

200.00

0 100.00m50.00m

LA.I [A]

LB.I [A]

LC.I [A]

FREQ := 800 HzAMPL := 800PHASE := 0 deg

AMPL := 500PHASE := -315 deg

FREQ := 50 Hz

PHASE := -195 deg

PHASE := -75 deg

SA

SB

SC

G_R1 := SA.VAL

G_R2 := -SA.VAL

G_S1 := SB.VAL

G_S2 := -SB.VAL

G_T1 := SC.VAL

G_T2 := -SC.VAL

+ V

Name Value

SIMPARAM1.RunTime [s] 111.29k

SIMPARAM1.TotalIterations 40.51k

SIMPARAM1.TotalSteps 10.00k

FEA1.FEA_STEPS

-500.00

1.50k

0

1.00k

0 100.00m50.00m

100.00 * LD.I [A]

VDC.V [V]

-715.00

425.00

-500.00

0

0 100.00m50.00m

电流转矩

速度

Fed by ac-dc-ac inverter

Frequency controlled speed

ANSYS 场路耦合仿真案例

PMSM with SPWM Control

ANSYS 场路耦合仿真案例

旋转变压器系统设计

ANSYS 传导干扰仿真案例

ANSYS 变流器 EMI/EMC 仿真分析

0.00 3.50

1.08 1.10 1.12 1.14 1.16 1.18Time [us]

0.00

0.50

1.00

1.50

2.00

2.50

Y1 [V

]

Ansoft LLC Nexxim1Rcvr Pattern

Curve Info

V(Rcvr)Transient

时域波形频

域波

形

场图





5 总结

大纲

0

00 0

PMSM_DQn1

n2

n3

m1

SIMPARAM1

L1

L2

L3

N1

N2

N3

I1 I3

I_Motor

-~P

N

V

U

W

V1 V2 V3 V4 V5 V6

U1E1

V

A B C

N

U_UMR

PWMModulator

DC-LinkVoltage

IntegratingCurrentSampling

MechanicalAngle Input

u1u2

Udc

u3

V1V2V3V4V5V6

I_1

I_3

I1f

I3f

phi_m

phi_el

w_el

FPGA

PWM_3PH1

+V

VM1

+

FSM_ROTB1

A B C

N

U_MOT

L1

L2

L3

N1

N2

N3

S_Motor

CTRL=S1

OFF

SET: S1:=0

Time >= Tsw ON

SET: S1:=1

MASS_ROTB1

A

AM4

C1

C2

R1

R2

R3 L1

TF_ROTB1

w_ref

phi_el

i1f

i3f

w_el

u1u2u3

n_ref

TDELAY=5msAMPL=n_ref-n0TRISE=300msOFF=n0

Load_Torque

TDELAY=t_loadAMPL=trq_load

TRISE=20msOFF=0

EV动力总成设计电源

控制器/变流器驱动电机(PMSM)

机械传统和载荷

电缆

嵌入式代码

采用VHDL-AMS器件库对整车建模

FMI应用于嵌入式代码仿真

1. 建立 CFD 模型

2. 建立阶跃响应分析 Cannot use Icepak Can only use FLUENT

4. Simplorer内部仿真

3. 抽取 SVD ROM Use Simplorer

电池冷却ANSYS CFD

巡航控制

CAR Structure

Wheels

Drive Cycle

End acceleration

Set CruiseSpeed

Accelerate

End brakingBrakeCruiseControl On

0

WeightF

minus plus

plus minus

WeightF WeightR

Motion

Motion

WeightF

Battery

Battery

P N

EngineMacro8

tire_basic4tire_basic3tire_basic2 tire_basic1

brake2 brake1

D

aerodrag1

1600kg

GAINYt

Alternator& Electrical Ciruit

P1 P2

P3

Plus1 Minus1

ElectricalCircuitSimplorer7

SET: CCon:=0Time > 9 Time > 10Time > 8

SET: CCset:=1SET: CCon:=1 SET: BrakePrs:=0Time > 22

SET: BrakePrs:=0.15Time > 20

SET: CCset:=0Time>=12Time > 11

SET: CCacc:=80SET: CCon:=0SET: BrakePrs:=0SET: CCresume:=0

Cruise Control

O0_CruiseSpeedO1_ThrottleCmdO2_CruiseState

GA

IN

GAIN1

Time > 25SET: CCresume:=1

Time > 25.1SET: CCresume:=0SET: CCacc:=0

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00Time [s]

-5.02

0.00

20.00

40.00

60.00

80.00

100.00

120.00

Y2

-4.00

0.00

12.50

25.00

37.50

50.00

62.50

75.00

84.00

Y3

0_Regular1Vehicule_Speed

18.4063

100.056699.3645

3.0000

0.00000.0000 0.00000.0000

Curve Info Y AxisCruiseControl1.O0_CruiseSpeed

TR Y2

VehicleMass.V*3.6TR Y2

CruiseControl1.I0_OnTR Y3

CruiseControl1.I3_SetTR Y3

CruiseControl1.I6_AccelTR Y3

CruiseControl1.I7_BrakeTR Y3

CruiseControl1.O2_CruiseStateTR Y3

• 巡航控制仿真电路

• 全面的嵌入式代码解决方案，涵盖设计、仿真、验证和代码生成

电动转向系统设计

无线充电系统仿真

0

0

0

R1

(1/87-0.004) ohm

R2

(1/348-0.001) ohm

Cs

1.93uF

Cp

5.24uF

Rload

10ohm

W+

WM1

W+

WM2

D4

D3

D2

D1

IGBT4

IGBT3

IGBT2

IGBT1

C1

1000uF

TRANS4

DT4

TRANS3

SINE1.VAL > TRIANG1.VAL

TRANS2

DT1

TRANS1

SINE1.VAL < TRIANG1.VAL

STATE_11_4

SET: TSV4:=0SET: TSV3:=0SET: TSV2:=0SET: TSV1:=0DEL: DT4##Dead_Time

STATE_11_3

SET: TSV4:=0SET: TSV3:=1SET: TSV2:=1SET: TSV1:=0

STATE_11_2

SET: TSV4:=0SET: TSV3:=0SET: TSV2:=0SET: TSV1:=0DEL: DT1##Dead_Time

STATE_11_1

SET: TSV4:=1SET: TSV3:=0SET: TSV2:=0SET: TSV1:=1

TRIANG1

AMPL=1FREQ=Carrier_Freq

SINE1

AMPL=Modulation_IndexFREQ=Frequency

ICA: FML_INIT1

Modulation_Index:=0Carrier_Freq:=10kFrequency:=10k

DC_Source:=200Dead_Time:=2u

~

3PHAS

~

~

A * sin (2 * pi * f * t + PHI + phi_u)

PHI = 0°

PHI = -120°

PHI = -240°

THREE_PHASE1D5

D6

D7

D8

D9

D10 Battery- +

LBATT_A1

D11

D12

D13

D14

C2

1e-006farad

0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00Time [ms]

-40.00

-20.00

0.00

20.00

40.00

Y1 [A

]

Curve Info rmsWM1.I

TR 9.4139

WM2.ITR 10.5939

0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00Time [ms]

-300.00

-100.00

100.00

300.00

Y1 [V

]

Curve Info rmsWM1.V

TR 154.9045

WM2.VTR 120.2425

1.90 1.92 1.94 1.96 1.98 2.00Time [ms]

-40.00

-20.00

0.00

20.00

40.00

Y1 [A

]

-200.00

-100.00

0.00

100.00

200.00

Y2 [V

]

MX1: 1.9753MX2: 1.9783

-6.0797-1.2036-0.0090

131.1979

-0.51411.340627.9814

156.0455

0.0030

Curve Info Y Axis rmsWM1.I

TR Y1 9.3501

WM2.ITR Y1 10.5176

WM1.VTR Y2 153.6594

WM2.VTR Y2 119.4615

Current_1st_1:src

Current_1st_2:src

Current_2nd_1:src

Current_2nd_2:src

Current_1st_1:snk

Current_1st_2:snk

Current_2nd_1:snk

Current_2nd_2:snk

0

Rload

10ohm

Battery- +

LBATT_A1

D11

D12

D13

D14

C2

1e-006farad

AC200V Rectify Inverter

Wireless Power Transformer Battery

Controller

大纲





5 总结

全面的集成化设计解决方案

ElectronicsStructuresFluids EmbeddedSoftware

全面的多物理场仿真

谢谢

Documents

牵引电机、控制器和动力总成 系统集成化解决方案register.ansys.com.cn/ansyschina/20151117aswc/...U1 E1 V A B C N U_UMR PWM Modulator DC-Link Voltage Integrating

牵引电机、控制器和动力总成系统集成化解决方案register.ansys.com.cn/ansyschina/20151117aswc/...U1 E1 V A B C N U_UMR PWM Modulator DC-Link Voltage Integrating