manatee software presentation - eomys · pdf filemanatee is currently under matlab ......
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© 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)
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
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.
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© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
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)
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
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
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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
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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
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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
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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:
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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 models in symmetrical healthy case:
Permeance/mmf
SCIM SPMSM, IPMSM, BPMSM, WRSM
Subdomain
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• Any winding type can be modelled (integral, fractional, user-defined, multiphase)
• A winding pattern defined in Koil freeware can also be imported
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• 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 element linearmagnetostatics (FEMM)
5 min
MANATEE subdomain models0.1 s
spacetimetime
space
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> 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
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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
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• 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
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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
Dynamic radial deflections
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
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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
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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
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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)
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CLAMPED – FREE
Boundary conditions
FREE – FREE
Boundary conditions
Resulting modal basis (simplified representation of cylindrical modes – « tooth rocking modes » are included):
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Dynamic radial deflections
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
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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
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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
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© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
VII. 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
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
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
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
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
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
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
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
Case of a salient pole synchronous hydroelectric generator with damper bars
Fast vibroacoustic model neglecting 3D effects can be used in basic design phase to avoidstrong resonances, no need of detailed multiphysic numerical models
Sound level during a run-up
Sound level during a run-up ~10 sec on a laptop
TESTS MANATEE
2 resonances
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
Case of a traction distributed winding PMSM with interior magnets at partial load:
Fast vibroacoustic model neglecting 3D effects can be used in basic design phase to avoidstrong resonances, no need of detailed multiphysic numerical models
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
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VIII. POST PROCESSINGS & PLOT TOOLS
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• MANATEE includes more than 100 plots accessible directly in the command line• Example of Matlab
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
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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)
-2000
0
2000 -100
0
100
0
0.5
1
1.5
Spatial order [r]Frequency [Hz]
Mag
nitude [T]
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Visual fitting tool for B(H) curve model at high excitation field
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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
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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(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
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Static (top) and dynamic (bottom) radial vibration spectra
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Spectrogram of radial / tangential force harmonics for each spatial wavenumber
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Spectrogram of radial / tangential force harmonics of a given order, including rotation direction
Operational deflection shapes at a given frequency
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Plot of tangential and radial forces per tooth in time and frequency domain
r=0 r=2 r=3
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Space vector diagram to analyze the origin of a radial or tangential force harmonic in terms of flux density waves
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
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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Possibility to visualize the modal basis under Gmsh (freeware)
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Modal contribution to acoustic and vibration spectra up to 20000 Hz
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Contribution of each structural mode to the acoustic noise at variable speed
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Spectrogram and order analysis with automatic identification of main magnetic force harmonics orders and frequencies
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« Spatiogram » noise analysis: decomposition of acoustic noise spectrogram per force wavenumber
=
r=0
r=2
+ +…
r=4
+
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Order analysis per circumferential vibration wavenumber (including rotation direction)
r=0 r=1
r=+2r=-2
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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
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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
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Unbalanced magnetic pull calculation (example of the slotting effect on eccentric UMP including skew of the stator)
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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
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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
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Mutisimulation Viewer for post processing sensitivity & optimization results
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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
© 2013- EOMYS ENGINEERING / 121, rue de Chanzy 59260 Lille-Hellemmes FRANCE / [email protected]
• 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
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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
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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
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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
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Example of the vibroacoustic effect of an interturn short circuit
New noise & vibration line
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Example of the vibroacoustic effect of magnetic wedges using permance /mmf model and coupling with FEMM
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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.
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• Special algorithm based on winding functions & subdomain models to decrease CPU time:
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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
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Automated phasor diagram and various control strategies (torque speed curve, MTPA, etc)