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Installation Manual and User Guide

1. 7 1 7 amp 2 1 1 1 n 1 E 1 Finding pattern Winding table E E Junk Era Heri a EDT Menal Miral pe Irabu Maal Hiire MI gis Selecting Export as described in the screen above will yield the following EREE File Edit Format wiew Help Open Circuit voltages Performance Table 150x80mm 6pole 3ph bldc oc res for project 150x80mm 6pole 3ph 13 16 a Freg vll vwa wo x cy amp y Xo wI WE cy T3 sw Sieg Hz C Wd CO Oo CW CO CO Ce X QD 400 85 4 49 3 2 8 8 5 5 0 aus 0 6 0 3 9 9 10 3 Open Circuit voltages Power and Loss Table 150x80mm 6pole 3ph bldc oc aux for project 150x80mm 6pole 3ph 13 RPM Torq wfan wra wrd Wwirnsta wirnRot wgear wbr wtot rpm N M Ww Cw Cw Cw Cw w Cw Cw 8000 0 128 ETAS Gr 0 0 0 0 102 0 0200 0 0 0 0 107 Design sheet for project 150x80mm 6pole 3ph 13 16 38 9 26 2006 Field type pm field Number of poles 6 Outer diameter 165 5 Stack length 80 Armature skew in slots Q Fld_lam_1 Grade M19 0 50mm Total field lam weight 1 141 kg Arm lam 1 Grade M198 0 50mm Total armature lam weight 5 833 kg Fld mag 1 Grade TDK fb9b Parallel Total volume 1 48e4 05 mm 3 Armature lam dimensions Type Outer Dia Inner pia Num slots Tooth width Yoke width Slot open Tip pef Tip Thickness Tip_Ang lt 68 Below the Tables area is the X Y Curves selection area This section allows you to select the parameters to be graphed It contains two choices an
2. RPM is the speed of the machine in revolutions per minute Hz is the frequency of the machine calculated from the entry of the above RPM value Ckt Vs is the source voltage of the DC supply remember this value will override the value set on the Drive Circuit Tab T fld is the temperature of the field winding in degrees Celsius T arm is the temperature of the armature winding in degrees Celsius Below this area is a drop down box that specifies the Finite Element FE Rotor Positions Per Slot Pitch This parameter is used to take advantage of machine symmetry so that the number of finite element calculations can be kept to a minimum and thus decrease simulation time To the right 1s a TOL CONTROL button that allows certain solution tolerances and simulation starting points to be changed The default values for these parameters should work in almost all cases therefore we do not recommend changing these values unless directed to by MagneForce technical support To the right are the APPLY and CANCEL buttons that allow you to commit ot abandon your changes 51 TRANSIENT TAB BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help Em Setting Desian Field Explorer Parameters Load Test Transient Data Link Amb Temp 22 5 Vs Time Stepping zur T Aes End nd Time 0 02 i Max Step Size Solution Text Monitor EveyN Sen 10 Rotor cycles for stead
3. A 28 7 C Performance Eon Waveforms Load 1 XData Omega t S omega t VER Vs Bl Load 1 Va gg Load 1 vb fg Load 1 vc 90 0 54 0 36 0 18 0 0 0 480 Xk 36 0 540 72 0 90 0 360 Omega_t Deg Often times you will want to see the same parameter graphed for different load points This can be accomplished by selecting a load point from the drop down list selecting the desired parameter selecting another load point and then selecting the desired parameter again We have done this below for phase current Ib for three successive load points 74 BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results File Action Window Tools Help New eB Open Design Field Explorer Parameters Load Test Transient Inverter Driven Test Tables Performance Export Losses and Parameters Design Sheet for project 150x80mm 6pole 3ph Field type pm field Number of poles Outer diameter Stack length rmature skew in slots Export LL 40 0 m XY Curves Performance Waveforms Bl Load Ib lip Load 2 b E Load 3 lb Load 3 x Data omega t Y Data 32 0 Load 2 Ib e Load 3 Ib Inverter Driven Test Torq N M 1 56 2 81 4 26 5 94 2 H9 RPM Rpm 7000 6500 6000 5500 5000 Freq Hz 350 325 300 275 250 360 Omeg
4. Iron Loss Density Ei Br Shad 97 The next option is the Material Shade check box which displays the distinct materials in the cross section with different colors BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer DER Fie Action Window Tools Help Design Results Field Explorer C Manual Excitation Existing Results Load Test Load Rotor Ang deg e o o Magnet Temp 40 00 W dg Current Dmp Bar Current Draw Export Anima Display te C3 MV Geometry Lines v Material Shade Flux Lines Bmag Shade Br Shade Current Density Operational Iron Loss Density 8r Shade e lz s l lz elo le Fie Action Window Tools Help Design C Manual Excitation Existing Results Load Test Load Rotor Ang deg e 0 0 Magnet Temp 40 00 oe Ten 3 LA AMA nr uL 7 n m W dg Current Dmp Bar Current Draw Export Animate Display z V Geometry Lines Wire Mesh Iv Flux Lines Bmag Shade Br Shade Current Density perational Iron Loss Density BrShade le l eo o 98 Under the Flux Lines option is the Bmag Shade check box that displays the magnetic flux density for this particular solution point along with a legend The flux density is diplayed in Tesla BLDC Version 3 0 C Program Files WagneForc
5. MAGNEFORCE SOFTWARE SYSTEMS INC BLDC Installation Manual and User Guide BLDC Installation Manual amp User Guide O MagneForce Software Systems Inc P O Box 4652 Timonium MD 21094 Phone 716 646 8577 Fax 716 646 1973 Copyright Copyright 2001 MagneForce Software Systems Inc MagneForce Software Systems Inc P O Box 4652 All rights reserved Timonium MD 21094 First printing November 2001 716 646 8577 STATEMENTS IN THIS DOCUMENT REGARDING THIRD PARTY STANDARDS OR SOFTWARE ARE BASED UPON INFORMATION MADE AVAILABLE BY THIRD PARTIES MAGNEFORCE AND ITS AFFILIATES ARE NOT THE SOURCE OF SUCH INFORMATION AND HAVE NOT INDEPENDENTLY VERIFIED SUCH INFORMATION THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE Trademarks MagneFotce its logo and BLDC are registered trademarks and or registered service marks of MagneForce Software Systems Inc Other parties trademarks or service marks are the property of their respective owners and should be treated as such License This Manual and the software described within is furnished under license and may only be used or copied in accordance with the terms of such license The information in this manual is furnished for informational use only is subject to change without notice and should not be construed as a commitment by MagneForce Software Systems Inc MagneForce assumes no responsibility or liability for any errors or inaccuracies that may appear in thi
6. 1 3D Field Correction 0 00 Order of Elements 1 Defaults User Defined Coefficients ius E Sud r 5 7 Defaults Apply Cancel User Defined Functions p tran Loss Model Magnet Overhang Coeff E 34 FINITE ELEMENT SOLVER amp MESH CONTROL PARAMETERS On the right side of this panel are several parameters that apply globally to the solver and to the generation of the finite element mesh The default button can be used to restore these parameters to their original values Min Distance is the minimum distance that will be allowed between two nodes This value should not normally need to be adjusted Rot Mesh Density is a factor that controls the density of the rotor mesh A value of 1 indicates a normal mesh density Decreasing this parameter will cause the mesh density to decrease while increasing it will cause the mesh density to increase Sta Mesh Density is a factor that controls the density of the stator mesh A value of 1 indicates a normal mesh density Decreasing this parameter will cause the mesh density to decrease while increasing it will cause the mesh density to increase Forced Air Gap Layers determines the number of node layers that will be forced within the airgap A value of 1 indicates that no forcing of layers will be done This setting allows the program to determine the number of air gap layers Values of 0 1 or 2 indicate this specific number of layers of nodes wil
7. 5838e 02 2 6441e 02 68228 02 71378 02 2 7299e 02 2 7239e 02 71628 02 2 7237e 02 72936 02 7133e 02 2 6831e 02 2 6462e 02 58548 02 2 4773e 02 29738 02 99798 02 1 5476e 02 1 0182e 02 66428 03 2 8476e 03 26308 03 42278 05 23288 03 85206 03 6861e 03 0199e 02 54868 02 9994e 02 29908 02 71378 02 72998 02 4A7778 02 5838e 02 6441e 02 6822e 02 72398 02 71628 02 72378 02 72938 02 2 2 71338 02 68318 02 2 64628 02 38548 02 4773e 02 29738 02 Ah 1 99796 02 5476 02 0182e 02 66428 03 8476e 03 26308 03 42278 05 eo e0 1 0 X self amp Mutual Inductance in Henries for To 3 436301e 04 10 3 438424e 04 20 3 4440296 uiian 3 4516836 04 5 40 3 4597828 045 50 3 4671798 04 60 3 473335e 04 70 3 4777698e 04 80 ren 0 10 000000 360 2 0 696e 05 1422e 05 2 2183e 05 2 2904e 05 2 3496e 05 2 3880e 05 2 4015e 05 2 38848 05 2 34008 05 2 2903e 05 2 2178e 05 2 1414e 05 2 06898 05 2 0097e8 05 1 9724e 05 1 9601e 05 1 9727e8 05 2 0102e 05 2 06968 05 2 1422e 05 2 2183e 05 2 2904e 05 2 3496e 05 2 3880e 05 2 40158 05 2 3884e 05 2 3499e8 05 2 2903e 05 2 2178e 05 2 1414e 05 2 06898 05 Q0978 05 1 9724e 05 1 9601e 05 1 97278 05 2 0102e 05 2 0696e 05 voltage Coefficient in v rpm for Run 2 x1 0 6 000000 360 2 420428 05 1 23288 03 2 8520e 03 6
8. ENS RAL a lz lE l l Lo 9 D 4 f A a B 90 The next informational button is labeled Info When clicked general finite element mesh information such as total number of nodes and elements 1s displayed The remainder of the information displayed in this window is specific to the excitation and rotor angle that the machine is currently set to The parameters displayed are the Apparent Energy Torque and the X and Y components of Force Snapshot winding information is available by clicking the Go Calc button in the lower right corner of this window BLDC will calculate and display the instantaneous Winding Flux Linkages Inductances and Rotational EMF Coefficients When finished click the Close button 3 BLDC Version 3 0 C Viragram File MAagneForcelbldc Were jects VY SOxWUmm amp pele 3ph bldc Field Explorar Info amp nap Shar Field red Esker w Calc Dupi tabla Hor propsct T T AXE L 7 4 323 OE 2904416 T7 mias mil mie a ab AC 4 bb be ec ELICIT Micro m gii 91 The final informational button is labeled Bg Clicking this button will produce a plot of the mid gap flux density in Webers vs Electrical Degrees at the current rotor angle and excitation level Click the Bg button again to return to the normal display BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Field Explorer ll B aia
9. Ear Ditelay B Gegner Lines wine Blech he Material Shade D Fielies BmegShade peirational FO don Loss Dern r l lE a E Inds Mirco E Cub y TIGER T Hirpara pu BLESS Mireia Micrel EJ Microsoft Excel Book1 Sele Type a question for help 8B x A v magnet at yes la 1 00E 04 Lb 11 1 lc KAR B mesh mul B 7 Nodes 1597 Elements 3271 Lables 8 B lamA1 sltA1 air sltA2 sltA3 lamF1 magF1 shaft Label XC nt Area Bx By Brx Bry Jz 1 lamA1 3 91E 02 1 79E 04 1 96E 07 2 15E 01 2 79E 01 0 00E 00 0 00E 00 0 00E 00 2 lamA1 7 45E 02 1 25E 02 2 03E 06 1 07E 01 6 51E 01 0 00E 00 0 00E 00 0 00E 00 SlamAl 3 93E 02 4 74E 04 2 85E 07 2 34E 01 2 55E 01 0 00E 00 0 00E 00 0 00E 00 4lamA1 3 91E 02 8 32E 04 1 60E 07 1 71E 01 2 28E 01 0 00E 00 0 00E 00 0 00E 00 5 lamA1 4 13E 02 4 26E 04 8 00E 07 2 99E 01 1 57E 01 0 00E 00 0 00E 00 0 00E 00 6 lamA1 4 37E 02 3 42E 03 1 35E 06 3 30E 01 7 58E 04 0 00E 00 0 00E 00 0 00E 00 7 lamA1 4 55E 02 4 28E 04 1 01E 06 3 74E 01 4 09E 02 0 00E 00 0 00E 00 0 00E 00 8 lamA1 4 57E 02 2 99E 03 2 66E 06 3 66E 01 7 27E 04 0 00E 00 0 00E 00 0 00E 00 9 lamA1 4 45E 02 4 26E 04 9 55E 07 3 62E 01 6 10E 02 0 00E 00 0 00E 00 0 00E 00 10 lamA1 4 46E 02 2 57E 03 1 88E 06 3 60E 01 3 26E 02 0 00E 00 0 00E 00 0 00E 00 11lamA1 3 88E 02 4 43E 03 9 09E 08 4 08E 02 3 52E 03 0 00E 00 0 00E 00 0 00E 00 12 lamA1 479E 02 3 42E 03 1 31E 06 3 87E 01 6 64E 04 0 00E 00 0 00E
10. GoNext Solver Progress Run Simulation lt gt FE rotor positions 12 per v Data Link Abon per slot pitch pole pitch The Data Link tab is used to link MagneForce s powerful BLDC simulation environment with other popular 3 party simulation software For instance rotating machines are almost always part of a larger mechanical and or electrical system If a complete simulation of this larger system is desired it can be done in Simulink Sabre or other 3 party simulation software In this way these simulators can utilize the powerful finite element and parameter calculation ability of BLDC as part of their simulation environment to allow detailed simulations of entire systems to be carried out BLDC can employ one of two different linking methods static or dynamic Using the static link the complete magnetic parameters for all rotor positions and armature current values of interest are calculated ahead of the circuit simulation Then during circuit simulation the 3 party simulator will use a lookup table to gather the appropriate magnetic parameters for that instant in time This differs from the dynamic link in which the 3 party circuit simulator will call BLDC at the certain points during the circuit simulation passing the appropriate values to BLDC BLDC will then perform the magnetic solution and pass back the magnetic parameters for that instant 54 STATIC LINK BLDC Version 3 0 C Program Files WagneForce b
11. MagneForce supplies many different functions for the most commonly exported parameters These can be accessed by clicking the FUNC MATLAB ot FUNC SPICE buttons located at the top of the window The HELP button will give detailed explanations of each of the parameters in a given function as well as a sample of its correct usage The second way to include results into the output data file is for the user to write his her own C code encased again by the sign Upon running the simulation the C code will be executed and the results written to the output file This option will only be necessary if the desired parameter is not already included in one of the predefined MagneFotrce functions Upon successful completion of the script editor click the OK button and then click the EXECUTE button to run the actual simulation A sample of the top half and bottom half of the output data file for the above data link example appears as the next two figures below Notice how the lines not encased in the sign have been explicitly written to the data file while code between the signs has been executed and the results written to the file Also note the corresponding section for each of the 4 distinct armature current runs P mymodel Notepad Seles File Edit Format View Help voltage Coefficient in v rpm for Run 1 x1 0 6 000000 360 ed 2 42278 05 1 2328e 03 2 8520e 03 6861e 03 1 0199e 02 54868 02 1 9994e 02 2 2990e 02 2 47778 02
12. Rotor Ang deg e o o Magnet Temp 40 00 W dg Current Dmp Bar Current 6 Draw Export Anima te Display IV Geometry Lines Wire Mesh Material Shade Flux Lines Bmag Shade Current Density Operational Iron Loss Density Br Shade elz l l l ello The scale of the flux density can be changed by double clicking the legend and changing the settings as desired BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Manual Excitation Existing Results Load Test Load 1 i iv Auto Scale Rotor Ang deg e o o From fo M t Temp l agnet Temp 40 00 To W dg Current Dmp Bar Current Steps 10 100e 6 Draw Export Animal Display te ea e amp j a El Aj Ej E MV Geometry Lines Wire Mesh Material Shade Flux Lines Bmag Shade IV Br Shade Current Density perational Iron Loss Density BrShade 100 The next parameter that can be displayed 1s the Current Density which when selected will show the current density in Amps square meter BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help C Manual Excitation Existing Results Load Test Load Rotor Ang deg e 0 0 Magnet Temp 40 00 W dg C
13. sl ml sl rational a Ez E This panel is unique among all panels in that it does not contain any tabs All results can be displayed from this one screen The panel is divided into two sections the settings section and the display section The settings section is to the left and is where you specify the conditions and parameters to be displayed The display section is the larger of the two sections and is where the cross sectional results are displayed 81 MANUAL EXCITATION At the top of the settings section is a check box to either select Manual Excitation or Existing Results The Manual Excitation selection allows you to enter the machine s excitation manually If the machine in question has permanent magnets you will be allowed to check or uncheck the Magnet Active check box With this box checked the effects of the machine s permanent magnets will be included and conversely the permanent magnets effects will be ignored if left unchecked Below this is a Rotor Angle field Enter the rotor angle in degrees for the solution point you are interested in Below this is a Magnet Temp field which if the machine is equipped with permanent magnets is the temperature of these magnets in Celsius Below these settings are two tables that describe the current in the armature windings and the damper bars if applicable Fill these in as appropriate Once these parameters have been completed click the Draw button BLDC Version
14. the latest version of this Agreement go to www magneforcess com ot such other site designated by MagneForce Your continued use of this Software will indicate your agreement to the change Satisfaction Guaranteed If you are not 100 satisfied with this Software MagneForce s entire liability and your exclusive remedy shall be return of the Software within sixty 60 days of purchase to MagneForce Returns P O Box 4652 Timonium MD 21094 for such refund or 2 return the Software within sixty 60 days of purchase to MagneForce Returns at the above address for replacement of defective disks If the disks are defective and you would like replacement disks while this version is still commercially available after sixty 60 days from date of purchase you may obtain a replacement by sending your defective disks and a check for thirty five dollars 35 00 plus applicable tax to MagneForce DISCLAIMER OF WARRANTIES EXCEPT AS PROVIDED ABOVE THIS SOFTWARE AND ANY RELATED SERVICES OR CONTENT ACCESSIBLE THROUGH THE SOFTWARE ARE PROVIDED AS IS AND TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW MAGNEFORCE DISCLAIMS ALL OTHER REPRESENTATIONS AND WARRANTIES EXPRESS OR IMPLIED REGARDING THIS SOFIWARE DISKS RELATED MATERIALS AND ANY SUCH SERVICES OR CONTENT INCLUDING THEIR FITNESS FOR A PARTICULAR PURPOSE THEIR QUALITY THEIR SECURITY THEIR MERCHANTABILITY OR THEIR NONINFRINGEMENT MAGNEFORCE DOES NOT WARRANT THAT THE SOFTWARE OR ANY R
15. 1 0 DOT SD os D U1 248 33 theta 20 DOT 2 Los 0 L1 745 33 theta 1 0 DOT Mouse drag and move a row Right click ta append delete a row 57 1 Cos D 0174533 theta 140 0 1 Cos 0 01 74833 theta 1 30 0 o Cos 0 01 4833 theta 1 40 0 e Las 0 U1 4933 theta 1 30 0 Output File Name In this section you will specify the parameters and structure of the output file that will form the link between BLDC and the 3 party simulation package MagneForce provides a number of built in functions that you can choose to form your output file You also have the option of building your own functions and writing any C code to be executed as the program runs In this box fill in the complete path and name for the location of the output data file You may click the button labeled to browse to the desired folder Double clicking the window pane below the output file name will produce the following script window I script Editor Sel Func Matlab Func Spice i E Cancel 4 Voltage Coefficient in V rpm for Run 1 WriteMagCurveSimulink l Ea 61 sl e0 GoNextline e0 e0x x1 0 4 Self amp Mutual Inductance in Henries for Run 1 WriteMagCurveSpice l Laa 37 GoNextLine WriteMagCurveSimulink 1 Lab 37 x2 Lab GoNextLine Voltage Coefficient in V rpm for Run 2 SWriteMagCurveSimulink 2 Ea 61 xl e0 GoNextline e0 ef 1 0 4 Self amp Mutual In
16. 10 16 16 This tab describes the armature winding including wire size numbers of turns and connection type The tab has sections on the left that describe the armature winding attributes On the right is a graphical representation of the cross section of the rotor e No of Phases is the number of phases of the armature windings e Connection can be either Y or Delta choose from the drop down list e Branches is a parameter that describes how the coils are connected to each other to form the winding If they are connected in series then branches are 1 if they are connected in parallel then branches are 2 or higher Simply put branches is the number of parallel paths through a particular phase winding e Bi Filer Wdgs can be set to either YES or NO indicating whether or not the drive circuit uses a b filer design in which there are no low side switches e Insulation Thk is the thickness of the insulating material that surrounds the interior of the slot in millimeters 18 Wire Tension is the tension with which the coil is wound this tension can affect the resistance of the coil A value of 1 indicates no deformation of the wire during winding Winding Type can be either set to standard or fractional select from the drop down list A standard winding is one in which full winding symmetry exists in each pair of poles A fractional winding is one in which full winding symmetry does not exist in each pair of poles but does e
17. 25 Parameter DC Voltages C OC wdg Inductances C Dogging Torque calc range in slots m Total Pts 4 W dg Temp 60 00 30 00 60 00 30 00 60 00 30 00 60 00 30 00 Solver Progress Run Simulation Parameters Execute Load Test FE rotor positions 15 0 per Transient Abort p 5 E Tol Control s per slot pitch pole pitch The run panel has four tabs to the left a message area to the upper right and a check box field to the lower right The tabs each correspond to a test of the machine under certain load conditions they are titled e Parameters e Load Test e Transient e Data Link 46 PARAMETERS TAB BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help Save Setting Field Explorer Amb Temp 25 Parameter DC Voltages C OC Wdg Inductances C Cogging Torque calc range in slots Total Pts v 400 0 60 00 FE rotor positions 5 15 0 per per slot pitch 3 pole pitch Solver Progress Run Simulation Parameters Execute Load Test Transient Tol Control Apply Cancel in The parameters tab can be set to calculate one of three very important operational machine parameters described below In many cases these Open circuit parameters can go along way to helping a designer quantify his her design even before investigating the load parameters The tab has a space for Am
18. Br Shade l2 l l l7 lz olo Under the Flux Lines option is the Bmag Shade check box that displays the magnetic flux density for this particular solution point along with a legend The flux density is diplayed in Tesla 84 BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Em m Q Run Results Field Explorer Manual Excitation Existing Results Magnet Active lv Rotor Ang deg m 10 0 Magnet Temp 200 Wdg Current Dmp Bar Current Display Draw Export Animate M Geometry Lines Wire Mesh Material Shade v Bmag Shade Br Shade F Current Density Operational r rc The scale of the flux density can be changed by double clicking the legend and changing the settings as desired BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help a Doosso i Design Run Results Field Explorer Manual Excitation Existing Results Magnet ctiwe M i V Auto Scale Rotor Ang degm DO From 8E 12 Magnet Temp 200 To Wdg Current Dmp Bar Current 3 E Steps 10 Draw Export Animate Display M Geometry Lines Wire Mesh Material Shade Flux Lines v Bmag Shade Br Shade Curent Density Operational Br Shade is the next displayable pa
19. Ielelelp 104 When the Material Shade checkbox is active the material button represented by an M is also activated Clicking this button will allow you to change the color that each material type is displayed with Each winding slot is treated as a separate material and as such can be assigned a distinct color or you may wish to set all slots to the same color D BLDC Version 3 0 Ci iogeem File Wage orceblde Mp ro pec Es MI IR Um prole 3p bide Field Erplarar me d F E k Co I ES Ei 105 The next informational button is labeled Info When clicked general finite element mesh information such as total number of nodes and elements 1s displayed The remainder of the information displayed in this window is specific to the excitation and rotor angle that the machine is currently set to The parameters displayed are the Apparent Energy Torque and the X and Y components of Force Snapshot winding information is available by clicking the Go Calc button in the lower right corner of this window BLDC will calculate and display the instantaneous Winding Flux Linkages Inductances and Rotational EMF Coefficients When finished click the Close button Y BLDC Version 3 0 C Wrogrom Files Vdagneforcelbide projects 150x00mm amp pele 3ph bldc Field Explorer Saal E D Mamia Enia e Eating Aati Info Snap Sher Field Rot Angidege un Medes Gi Elements fie p Maya Tomp A000 App Ene 8473 W gCumni Bar C
20. JI PS MJ MIL MI PRU PS rg OO Um I A 188976 05 308636 01 501858 04 69952e 05 30956e 04 119836 00 O 696e 04 083426400 Bl18 0Ge 04 3283428 05 1554 08 04 Of F3 e 00 33f 538 05 232 7698 01 0682 08 04 B3854e8 u05 314468 04 051166 01 85206 05 2 7 f6le 01 8064 66 04 266 758 05 phi n 0 O0000e 00 4204 72 00 664 758 01 314 7e 00 21127e4 0 c TE sees m seh m ss I di EYa T fee d ca iran l Em 6119 7e8 00 55344 e U1 084026400 g4 9836 00 2324e 00 s54646 00 556 765e O1 58507er00 55315e uUl 04 201e 01 9981 se 01 39462e 02 39 866 00 31955e 00 10097 6 00 B43356er Oo336e 00 oad gt fa CA vn cn f J A Uu UJ Uu PO PO PO PU RP RP E RPP D OO JI CS P uu nag E 29166e 04 42674e 04 97 431e 04 74259e 04 0184 8e 04 15186e 04 46276e 04 8164 5e 04 12498e 03 27819e 03 44312e 03 52184e 03 81640e 03 02883 e 03 26113 e 03 51509e 03 79225e 03 09381e 03 42063e 03 305e 03 15090e 03 55358e 03 97985e 03 42788e 03 895446e 03 76 Load 2 Ib CA 1 90374e 01 NMN P8 PSOE PSOE P820 PS PSOE PE PSOE PSOE POETS PO PU FU PSU IJ IA IE P pPPpEwuPTP 91804 e 01 93238e8401 94678e 01 96128e8 01 97 5908 01 990688 01 00566e 01 020868401 03634e 01 05212e8401 06825e 01 084 79e 01 10178e401 1192984 01 13738e8401 15612e8 01 175608e4 01 195908401 21711e 401 239338401 262668
21. NONE TARGET CONTROL or LIMII CONTROL None no feedback is utilized Target Control is a targeted or desired value that you wish to achieve Limit Control is an upper limit value that you do not wish to exceed Target describes the targeted parameter either the armature phase current Armature A or the DC Bus current I am11 Measurement describes the measurement of the above parameter either RMS Average or Instantaneous Value the actual targeted value of the above parametet AA System Switch Control Rotor Angle Based Pw Square Voltage 5 ystem 5 quare Voltage PWH Drive Conduction B and 1 20 switch phase PWM Freq Style Fixed AF angle Pwm index vb vc Pw Freg 5000 oe sere Modulation Index 03 yan cael t ve Feedback Control None CM 8 0 at armature wdg phase A Rotational Emt switch Signal Rotor pos angle amp 31 System PWM Freeform employs a control strategy to try and keep the phase voltage to the motor to be a sine wave Base Waveform is either set to SINE or FOURIER If Fourier is chosen then the table below should be filled in with the magnitude and phase of the Fourier series you would like to use to create the Base waveform PWM Style Frequency is either set to FIXED or Fc Fb and is the style of the frequency of the carrier wave PWM Freq or Carrier Base if above parameter is set to FIXED then this is the frequency of the carrier wave if above is set to Fc Fb then this spec
22. The centroid of the currently selected element is displayed both in x y and r theta coordinates Below this is a listing of the elements flux density including the Br values if the element lies within a permanent magnet Under the Operational heading are several parameters that will be displayed if applicable to the selected element For example if an element lies within a steel lamination it will have a corresponding Iron Loss Density value D BLDC Version J 0 C Winogeen i Wapa F orco Made Wero jecks VI imm amp pele ph bide Field Esplsrar e m3 FM onapshol i joo Bn o Ed a penance bipm Lines Dirrty on Wikg Cuneet Dens EEI Ajeet YN KN KONN VERE haat SAT PNA VAL N fi Ley Wi NAAAARSS KIA cA K ee K DASS ata ap P D rail AN RY a h I 1E 1m llela 15 4 y A lt B 89 When the Material Shade checkbox is active the material button represented by an M is also activated Clicking this button will allow you to change the color that each material type is displayed with Each winding slot is treated as a separate material and as such can be assigned a distinct color or you may wish to set all slots to the same color gc Version 3 0 C Vcg ir Fert Mgr Force Ma Ld pono pec Es VT amm amp pole Iph bldc Finld Erplarar TETT DEL EBUBU S gt AVVO VN PT NAT KES QNSE SA 7 PESE AAA TITA DS KT AAT EE pea SEIS SIAN Si d BS A E
23. Waveforms pm field Torq RPM Freq YIL Design Sheet for project 150x80mm 6pole 1 Inverter Driven Test Performance Table 150x80mm 6pole 3ph b B P ou gg Effic 5000 4610 4220 P put e Effic 3830 3440 3050 2660 2270 1880 1490 1100 6000 RPM Rpm In the example above we have displayed Speed RPM vs Output Power P out and Efficiency Effic An export data file of this graph is available by selecting Seles Format wiew Help H OO000e8 05 200008r03 OD0O0er s 300008r03 U nOO0er s 1 146008 03 l1 910008r03 2 6 7 700e8 03 3 421008r03 4 13100e 03 9 16000e 0l1 9 45000e 01 9 76000e 01 9 54000e 01 9 55000e 01 73 selecting Waveforms will allow you to graph these machine parameters versus time In the graph below we have displayed the three phase voltages BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results File Action Window Tools Help x c m R d j Oper Setting Design Parameters Load Test Transient Inverter Driven Test Design Sheet for project 150x80mm 6pole 3ph Inverter Driven Test Tables Field type pm field Freq j V thd P in x Pett Export Pe eee ES Number of poles 6 0 0 d Losses and Parameters Outer diameter ji i E 42 3 Stack length A 43 2 rmature skew in slots F 38 5 XY Curves E
24. a type 613 permanent magnet rotor e The list button to the left of the Type field allows you to select the rotor geometry from a pop up window e Outer Dia is the rotor outside diameter including magnets measured in millimeters e Inner Dia is the diameter of the machine shaft measured in millimeters e Num Poles allows you to select the number of poles of the machine from the drop down list e Magnet Arc Style is set to 1 if the magnet arc is measured from the rotor center or 2 if the arc is measured from the tip of the magnet if so enter arc value e Magnet Thk is the thickness of the permanent magnet material measured in millimeters e Magnet Width is the width of each magnet piece in millimeters 12 EJ Ts Version 3 0 C Wrogram Files WdagneForce bidelprojects 1502 0mm amp pele 3ph bldc a Fed Lapkis Field L Type ii HE Cuter Dia 74 a PY Field Repository Foot Thk 15 Teflad ns Sie Top R ft Slot Bottom P 5 Ski Wedge Thk 1 57 Stack feo O Seu fo Weight 1 141 Weight 5 099 Ea J Modia Ar geo 1 700 Paco icd E Cat EJ ELEC Hania Miral The armature parameters will vary depending upon the exact geometry chosen The following is for a type 703 armature e The list button to the left of the Type field allows you to select the armature geometty from a pop up window e Outer Dia is the armature outside diameter measured in millimeters e Inner Dia is the armature inside diameter measured in m
25. button is similar to the nodal information button except that it displays information about the currently selected finite element The centroid of the currently selected element is displayed both in x y and t theta coordinates Below this is a listing of the elements flux density including the Br values if the element lies within a permanent magnet Under the Operational heading are several parameters that will be displayed if applicable to the selected element For example if an element lies within a steel lamination it will have a corresponding Iron Loss Density value BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Field Explorer C Manual Excitation Existing Results Load Test Load Rotor Ang deg e 0 0 Magnet Temp 40 00 Field Elemental D ata gt Centroid Ac 65 59 Rc TE A 283 M Flux Density PM snapshot Bx 04208 Bre io By 0 01660 Bry o o wa BI 0 4211 Bu 10 0 I A Wdg Current Dmp Bar Current PIU I do T IIIN Iron Loss Density E 7 26 W kg AM VE VAY a Curent Density 00 am IN SOEXBRA DSK K EXE Fen pce es RecoledPM Bd o0 Tesla ACI SN SSR n M d AA Dr uel Display MV Geometry Lines mm deg Tesla jw Wire Mesh eek Flux Lines Bmag Shade BrShade Current Density Operational Iron Loss Density E E e Pal XIV a 55 EAS le BL In
26. calculated parameter and is the q axis resistance parameter of the end ring e End Ring Full Connection should be checked if all bars are connected to the end ring e Damper Winding Active should be checked if you would like the simulation to proceed with the effects o Under the drawing of the machine cross section is an APPLY and CANCEL button These buttons are used to apply or cancel changes in the geometry figures from above Next to these are four buttons for FIT ALL ZOOM IN ZOOM OUT and MOVE They can be used together with the scroll bars to enlarge and inspect your geometry When satisfied click the FIT ALL button to return the cross section to normal size After you ate satisfied with your design use the SAVE button on the panel toolbar to commit your changes to disk 17 ARMATURE WINDING TAB BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit jw phase amp phaseB phaseC Armature Winding Num of phase Bo xl Bi Filar wdas Connection v g Insulation Thk 5 Branches 2o Wire Tension n Ej End Turn Ellipse Max Slot Fill 0 7656 a Wite Size 1 8x mwgB1 1 250 Min Slot Area 3568 zl Wire Size 2 8x mwgB1 1 250 Copper Weight 6 007 Total Ra 0 01004 Wdg Symmetry in Num of Poles 1 Winding Type Standard Phase PhaseB PhaseC 4 4 10
27. directory And finally the hardware key must be attached Close all applications It is best to perform the installation without any other applications open Insert the MagneForce CD ROM disk into your computer s CD ROM drive From the START menu choose the RUN command Type into the RUN command dialog box D SETUP EXE where D is the name of your computer s hard disk drive Type the name of a program Folder document or Internet resource and Windows will open it Far vau Follow the onscreen instructions You will be allowed to change the software installation directory as well as the program folder if desired Depending upon your version of Windows you may be instructed to re boot your computer and to re run the installation routine Also some versions of Windows do not completely close the installation DOS window If this is the case close the window manually by clicking the X in the upper right hand cornet After installation completion copy the LICENSE TXT file to the C PROGRAM FILES MAGNEFORCE subdirectory if you accepted the default installation directory from step 4 above If you modified this directory structure the LICENSE TXT file must be copied into the MAGNEFORCE directory that is the directory containing BLDC EXE The LICENSE TXT file unlocks and allows the appropriate simulators to run If you do not have a LICENSE TXT file please contact MagneFotce Attach the security key supplied with th
28. if any is strictly prohibited It is also prohibited to give copies to a person who has not purchased the appropriate license for the Software from MagneForce to install the Software on computers used by individuals who have not purchased the appropriate licenses for the Software from MagneForce or to duplicate the Software by any other means including electronic transmission The Software in its entirety is protected by the copyright laws The Software also contains MagneForce trade secrets and you may not decompile reverse engineer disassemble or otherwise reduce the Software to human percetvable form or disable any functionality which limits the use of the Software You may not modify adapt translate rent or sublicense including offering the Software to third parties on an applications service provider or time sharing basis assion loan resell for profit or distribute the Software disk s or related materials or create derivative works based upon the Software or any part thereof You may not network the Software Termination This Agreement may be terminated by MagneForce immediately and without notice if you fail to comply with any term or condition of this Agreement Upon such termination you must immediately destroy all complete and partial copies of the Software including all backup copies From time to time MagneForce may change the terms and conditions of this Agreement MagneForce will notify you of any such change For
29. off sequence versus electrical degrees In simple rotor position feedback control this area can provide a quick visual confirmation that you have set all of the switch on off attributes correctly BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit Armature Excitation Inverter m ALA f E Quick Parameter Set Invertor dvanced Firing D Degrees Invertor Sw Dead Angle 0 1 Degrees Advantage of Symmetry Iv Phase to Phase Iv Bi Polar v SelectAll ClearAll Appl Cancel Beginning with a blank screen you may select any of the buttons above the schematic drawing area Select the button you wish by rolling your mouse cursor over the item and clicking the left mouse button Next move the mouse cursor into the schematic drawing area and place by clicking the left mouse button again The selected item will now appear on the schematic drawing area Depending upon the item selected access the item s attributes by right clicking the item on the drawing area and selecting attributes Each item has attributes that are appropriate to itself Additionally right clicking an item will allow you to rotate flip delete copy and or paste the item These options are available to the appropriate items 24 e Armature will place an armature of the type that was selecte
30. speed will vary depending upon the operating point conditions To the right is a TOL CONTROL button that allows certain solution tolerances and simulation starting points to be changed The default values for these parameters should work in almost all cases therefore we do not recommend changing these values unless directed to by MagneForce technical support To the right are the APPLY and CANCEL buttons which allow you to commit or abandon your changes 53 DATA LINK TAB BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help m Setting Design Field Explorer Parameters Load Test Transient Data Link C Dynamic FE Data Link Temperatures END B eg 1 Incremental L Matrix Armature Current Style Function of Rotor Position 1 SQ Range Sweep Inverter l Work Sheet L 2 Mechanical Output Style Sinusoidal Dutput File N ame Ref Frame ABC C mymodel m Bl la pk A DigitVariable la Ea dea DigitVariable Voltage Coefficient in V rpm WriteMagCurveSimulink l Ea 61 Add to Table Clear Table e0 e0 1 0 Self amp Mutual Inductance in Henr WriteMagCurveSpice l Laa 37 gm DLO Cos lewriteMagCurveSimulink l Lab 3 Pole number p UWriteParameter Npoles GoNext Moment of Inertialn in kg m z J WriteParameteri Jtotal GoNext Resistance of phase in ohm R WUriteParameter Ra 75
31. tab however this tab will simulate the machine under load conditions The parameters on this tab include e Amb Temp which is the ambient temperature of the machine e Driven By is a drop down box that can be set to one 4 choices Inverter Circuit AC Sine V AC Square V or AC Sine A These choices describe the type of excitation source used to drive the machine under consideration e Inverter Circuit refers to the inverter drive circuit designed in the DRIVE CIRCUIT tab of the DESIGN panel e AC Sine V specifies the machine to be run from an ideal AC sinusoidal voltage source whose frequency and magnitude are specified in the DRIVE CIRCUIT tab of the DESIGN panel e AC Square V specifies the machine to be run from an ideal AC square wave voltage source whose frequency and magnitude are specified in the DRIVE CIRCUIT tab of the DESIGN panel e AC Sine A specifies the machine to be run from an ideal AC sinusoidal current source whose frequency and magnitude are specified in the DRIVE CIRCUIT tab of the DESIGN panel e Use Tabular Input contains a series of parameters that when checked will appear in the load point table below The purpose of 49 this 1s to allow the user to override the settings of these individual parameters on the Drive Circuit tab and use the values in the load point table for each individual load For example with Vs checked it is very easy to set up a load run with several points that differ only in supply vo
32. tabular values as well as the Fourier Coefficients for all graphs are available through the Export button Notepad File Edit Format View Help 5mega t d 1 Deg QO000e8400 90000e 00 90000e 00 00000e 00 00000e 00 90000e 00 90000e8 00 90000e 00 90000e 00 90000e 00 QO00008401 100008401 200008401 300008401 4000084 01 500008401 500008 01 70000e 01 80000e 01L 90000e 01 00000e 01L 10000e 01 20000E 01 30000e 01L 400008401 Q 1 2 3 4 5 6 Fi 8 9 E CI 1 X 1 T X xd X T 2 2 2 2 2 im ie ile Edit auriser caoefficents far Notepad A rn Format Cn cn cn 4 A amp uJ uJ nhJ hJ NJ hJ RRP FP E EP FP 09 v 4 us n3 PS 004 29e 04 21832e 04 44691e 04 69775e 04 06507e 04 28007e 04 68608e 04 01395e 03 16786e 03 33243e 03 50971e 03 70190e 03 91117e 03 13973e 03 38977e 03 66315e 03 96157e 03 28634e 03 63831e 03 01797 e 03 425078 03 858958 03 3183268 03 80120e 03 30517e 03 view Help Load 1 Ib A BPRERBB BEBE RBEBBBBBBBEBEBBEEBEE 10909e 01 11486e 01 12066e 01 12654e 01 13253e 01 13866e401 14495e401 15144e 01 15816e 01 16516e 01 17247e 01 18014 e 01 18821e401 19674e 01 205798 01 215438 01 225728 01 236758 01 24861e 01 26137e8 01 27515e 01 29003e8 01 30614e8 01 32356e8401 34241e 01 Coad ra i un OO JP n cn P w ra pS 0 5 TI 2 E w on con cn cn mw
33. the tables with data points and when finished save the new material This new material will now be available to all MagneForce Simulators In the upper right corner of the settings panel is the units selector drop down box This selector box allows you to view the B H curves and tables in the units of your choice The available selections are Tesla amp A m or Gauss amp Oersted or KGauss amp KOersted Select the units you are most comfortable with 39 STEEL LAMINATION MATERIAL DEFINITION similar to the permanent magnet material BLDC provides for the characterization of different steel materials On the settings panel in the upper left corner click STEEL LAMINATION then to the right click OPEN A dialog box will appear requesting you to select a steel material from a list of all materials saved within the MagneForce suite of simulators BLDC Yersion 1 0 C Program Files MagneForce BLDC Projects 150x80mm 6pole 3ph bldc Setting Windot Tools Help Design Results Field Explorer Ic PM Material Steel Lamination New Open Close Save C BH Curve ron Loss Lass idel K Gauss K Dersted Y FE Solver amp Mesh Control F z No Material Selected Min Distance 1e 5 Rot Mesh Density 1 0 Sta Mesh Density 1 0 Look in C MagMat e ect EB Forced airgap layers 1 j CQ bhw 3D Field Correction 0 00 v M19 0 50mm bhw Order o
34. torque and power together with more esoteric results such as flux tron loss and current density BLDC is divided into five distinct panels e Settings Panel This panel allows you to examine and adjust the material properties of all magnetic materials loaded into the MagneForce suite of simulators Here you will find magnetic cutves for both steel and permanent magnet materials You can also add new materials to the MagneForce suite of simulators This panel also contains global software parameters that control such things as mesh density e Design Panel In this panel you will define the physical dimensions of the machine as well as choose the armature and field materials plus define the windings Whenever you create or open a new or existing project you will first be placed at the design panel e Run Panel Once you have selected and described a machine the run panel is used to select the type of simulation plus initiate the simulation process Choices of simulation include parameter load fault study asymmetrical or special Once a type is selected you may then select the number of load points associated parameters and begin the simulation e Results Panel Upon simulation completion the performance results panel is used to view the various parameterized output Output ranges from the open circuit machine parameters up to and including the complete set of machine and load voltage and current waveforms as well as torque and p
35. weight 5 833 Load 1 x Data Fld mag 1 Grade TDK fb9b Total volume 1 48e 05 gt omega_t Armature lam dimensions e o he O hk OM mN oo Slot_Wedge_Thk cont unl The name of the specific Parameter Test that was executed on the Run Panel will appear at the top of the data selection area Below this is the Tables area that contains two choices and an export button e Performance when this is selected the performance parameters will be displayed in the tabular data output area to the right e Loss Separation when this is selected the loss parameters will be displayed in the tabular data output area to the right e Export button is used to export the performance loss data and or project design data sheet The output can be in either Microsoft Notepad or Excel format 67 3 BLDC Version 3 0 C Virogram FilesVdagneF orcelbide projects 1 x BUmm amp pele 3ph bldc Results jr xr Rim Paisenatert Load Tent Transient E pan Cucut Voltages Design Sheet for project 150x nn pole Jph E Open Circuit Volteges Performance Table 150x 0xn bpole Iph bldc oc res for pro Tables m i pm field 4 Freq Wii Yun v 3 CF Periomanca He qu 05 It fi 400 H5 4 49 3 Lorba and Parami 185 5 V7 W9 Va V 13 V sit V thd Oo qaj C gt S dh i 5 0 I1 Of S 8 3 RA umma V Pedomenee EWL D Maremma ira laa 1 Total armatus IFld mag 1 otal volume i Paiumance Table gd
36. your input on the lamination geometry tab from beginning to end To describe the winding fill in the columns CURRENT IN CURRENT OUT TPC and WIRE for all coils e CURRENT IN is the slot number for this coil in which current would travel into the computer screen e CURRENT OUT is the slot number for this coil in which current would travel out from the computer screen 19 e TPC is the number of turns per coil This is the physical number of wires that belong to this coil however be careful not to confuse this with the number of strands For instance a coil that is wound with 5 strands in hand but only 2 turns per coil would have a TPC setting of 2 and not 10 e WIRE can be set to SIZE 1 SIZE 2 or SIZE 1 amp 2 Simply place the cursor in the WIRE column on each line and click to toggle to the correct setting The actual size of the wire 1s specified above in the WIRE SIZE tables Along the right hand side of the table are three tabs labeled PHASE A PHASE B and PHASE C In the case of a standard winding the program will complete the winding tables for PHASES B and C based upon your input from PHASE A In the case of a fractional winding you must click each tab and complete the winding table for each phase individually Just above the armature drawing are three check boxes for the three phases of the machine Checking each box will cause the corresponding phases winding to be drawn In this way one can often spot mistakes i
37. 0 l153658r 310868400 404626 00 338338400 6243584r00 68122e 00 Fooe0e 00 615596 00 B43898 00 558226 00 a50ser a 021er 00 Bo l60e 00 a5001e4r 00 elo d5er f 0 16 00 Load 1 Ifc CA D 1 5 p e OO000e 00 464 60e 00 Pfe Bel 3964 0e 01 46892 e 01 3 23886 01 22020e 01 4944 28 01 121546 00 401098 00 B ssser A3085e8r 00 U3s25684r 00 3305l1er 383268400 290 789e 00 69512e 00 904 726 00 5653er 0 l5 655er 0 a3f230e8r a2001e4r00 EIE Once the parameters have been exported to Excel they can be graphed saved ot used in any manner in which you desire In the transient solution Fourier coefficients are not available for calculation since the waveforms by their very nature are not sinusoidal or periodic 80 Chapter The Field Explorer Panel The field explorer panel is used to display the machine geometry finite element mesh magnetic field density current density and tron loss density When first selected the Field Explorer Panel will be displayed BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help i Setting Design Field Explorer C Manual Excitation Existing Results X Load 1 Rotor Ang deg e 0 0 Magnet Temp 40 00 Wdg Current Dmp Bar Current Draw Export Animate Display r al a sl l E in ES BIG
38. 0 350 Outer diameter 165 5 0 499 6000 300 Stack length 80 Armature skew in slots 0 Iline XY Curves Fld lam 1 Grade Performance Export Waveforms Load 1 X Data S omega t Total field lam weight rm lam 1 Grade Total armature lam weight Fld mag 1 Total volume Grade Armature lam dimensions M19 0 50mm 1 141 M19 0 50mm 5 833 TDK fb93b 1 488405 Y Data Type Outer_Dia Inner_Dia Num_Slots Tooth Width Yoke Width e UII C FO F P EIN CO Slot Vedge Thk anf en Each of these windows contain horizontal and vertical scroll bars as appropriate to allow you to view the entire data set Additionally the size of each of these windows can be adjusted by placing your cursor on the area between two windows and clicking and dragging to the desired size 66 PARAMETERS TAB BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results File Action Window Tools Help Field Explorer Parameters Load Test Transient Open Circuit Voltages Design Sheet for project 150x80mm 6pole 3ph Tables j pm_field 4 Freq Vll Vwa Perf Export Hz V V Performance por 400 9E 4 493 Open Circuit Voltages Performance Table 150x80m C Losses and Parameters rmature skew in slots XY Curves Fld lam 1 Grade M19 0 50mm Performance E Pot Total field lam weight 1 141 Waveforms rm lam 1 Grade M19 0 50mm Total armature lam
39. 00 0 00E 00 13lamA1 485E 02 8 56E 04 2 23E 06 3 91E 01 1 62E 02 0 00E 00 0 00E 00 0 00E 00 14 lamA1 4 75E 02 8 56E 04 2 13E 06 3 91E 01 2 41E 02 0 00E 00 0 00E 00 0 00E 00 15 lamA1 4 66E 02 1 28E 03 2 36E 06 3 89E 01 2 20E 02 0 00E 00 0 00E 00 0 00E 00 WR _ 16 lamA1 ARTE 2 57F f3 2 37F DR 375F n1 1 49F 02 n nne4nn onoesnn n nnE nnT i M4 WN Sheet Sheet1 lt i Ready BORO TRO TROT RO N mS ad f ad 1 A Co h2 ejoo 4 A Co rt2 1o 108 The Animate button allows you to see the field parameters in action as the machine would run BLDC will step through a series of rotor positions and calculate the field parameter flux density for example at each position You will then have the option of displaying these solutions one after another thereby forming an animation of a rotating machine Clicking the Animate button will change the screen as below BLDC Version 3 0 C Program Files WMagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Ee Setting Design Run Results Field Explorer C Manual Excitation Existing Results Load Test Load 1 Rotor Ang deg e 0 0101 Magnet Temp 40 00 Wdg Current Dmp Bar Current Electrical Degree Step Angle 0 Repeat ngle d Animation Speed Input the following parameters e Step Anole is the increment between each rotot position solution point p Ang p p e Repeat A
40. 00 360 ed 2 4295e 05 21 28275 03 2 8520e 03 68618 03 1 0199e 02 54868 02 2 2990e 02 2 4777e 02 58388 02 2 6441e 02 68226 02 2 72998 02 2 7239e 02 71638 02 2 7237e 02 72938 02 2 6831e 02 2 6462e 02 5854e 02 2 4773e 02 29738 02 1 5476 02 1 0182e 02 66428 03 2 8477e 03 26318 03 2 4295e 05 1 232728 03 85206 03 6861e 03 1 0199e 02 5486e 02 59 ED mymodel Notepad File Edit Format View Help voltage Coefficient in v rpm for Run 3 x1 0 6 000000 360 ed 2 42958 05 1 9994e 02 2 7137e 02 2 7133e 02 1 99798 02 2 4295e 05 9994e 02 71378 02 71338 02 99798 02 42958 05 2 2 2 b 2 2 2 T I eo eOo 1 0 1 23276 03 2990e 02 7299e 02 6831e 02 54768 02 23276 03 2990e 02 7299e 02 6831e 02 5476e 02 2 2 2 2 1 2 2 2 2 s 8520e 03 4777e 02 72398 02 6462 02 8520e 03 4A777e 02 7239e 02 6462e 02 0182e 02 0182e 02 self amp Mutual Inductance in Henries for Run 3 0 3 436303e 04 10 3 438428e 04 20 3 444032e 04 30 3 451685e 04 40 3 459783e 04 50 3 467180e 04 60 3 473336e 04 70 3 477771e 04 80 x2 0 10 000000 360 Lab 2 0696e 05 2 4015e 05 2 0689e 05 2 069628 05 2 4015e 05 2 0689e 05 2 0696e 05 2 2e 2 2 2 2 14228 05 3884e 05 0097e 05 1422 05 3884e 05 0
41. 097e 05 22 m 2 2 l 2183e 05 3498e 05 5724e 05 2183e 05 34988 05 9724e 05 Voltage Coefficient in v rpm for Run 4 x1l 0 6 000000 360 ed 2 4249e 05 1 1 99948 02 2 2 71378 02 2 2 7133e 02 2 1 99798 02 1 2 4249e 05 99948 02 7137e 02 71338 02 99798 02 4249e 05 eo eO 1 0 23278 03 2990e 02 72998 02 6831e 02 54768 02 23278 03 29908 02 7299e 02 6831e 02 54768 02 2 2 2 2 l 8520e8 03 4A777e 02 7239e 02 6462e 02 0182e 02 8520e 03 47778 02 72398 02 6462 02 0182e 02 self amp Mutual Inductance in Henries for Run 4 2 2 2 2 l 6861e 03 5838 02 7163 02 58548 02 6642 03 6861e 03 5838e 02 7163e 02 5854e 02 6642e 03 2904e 05 2903e 05 9601e 05 2904e 05 2903e 05 9601e 05 6861e 03 58388 02 7163e 02 5854e 02 66428 03 68618 03 3838e 02 7163e 02 5854e 02 66428 03 01998 02 6441e 02 72378 02 4A7738 02 84778 03 0199e 02 6441 02 72378 02 47738 02 84778 03 2 lt 2 2 2 l 0199e 02 6441e 02 72376 02 47 738 02 84776 03 0199e 02 6441e 02 72378 02 47738 02 84776 03 3497 05 2178e 05 97278 05 34976 05 2178e 05 97276 05 2 ed 2 2 2 2 5486e 02 6822e 02 7293e 02j 2973e 02 2631e 03 548
42. 1 4 71E 02 0 00E 00 0 00E 00 0 00E 00 4 lamA1 3 91E 02 8 52E 04 1 60E 07 3 80E 01 8 57E 02 0 00E 00 0 00E 00 0 00E 00 5 lamA1 4 13E 02 4 28E 04 6 00E 07 5 61E 01 2 67E 03 0 00E 00 0 00E 00 0 00E 00 5 lamA1 4 37E 02 3 42E 03 1 35E 06 6 48E 01 6 06E 05 0 00E 00 0 00E 00 0 00E 00 7 lamA1 4 55E 02 4 28E 04 1 01E 06 6 31E 01 7 38E 04 0 00E 00 0 00E 00 0 00E 00 8 lamAT1 4 57E 02 2 99E 03 2 56E 06 6 56E 01 9 56E 04 0 00E 00 0 00E 00 0 00E 00 9 lamA1 4 45E 02 4 28E 04 8 55E 07 6 30E 01 1 96E 03 0 00E 00 0 00E 00 0 00 E 00 10 lamA1 445E 02 2 57E 03 1 88E 06 5 38E 01 1 03E 02 0 00E 00 0 00E 00 0 00E 00 11 lamA1 3 88E 02 4 43E 03 9 09E 08 4 45E 01 3 78E 01 0 00E 00 0 00E 00 0 00E 00 12 lamA1 479E 02 3 42E 03 1 31E 06 6 54E 01 1 37E 03 0 00E 00 0 00E 00 0 00E 00 13lamA1 4666 02 8 56E 04 2 23E 06 6 34E 01 4 20E 05 0 00E 00 0 00E 00 0 00E 00 14 lamA1 4 75E 02 8 56E 04 2 13E 06 6 34E 01 1 48E 04 0 00E 00 0 00E 00 0 00E 00 glans septal 1 285 08 2385508 8 3351 1 86 03 DD son DOO son DOE og Sheet2 5 Sheet1 i 93 The Animate button allows you to see the field parameters in action as the machine would run BLDC will step through a series of rotor positions and calculate the field parameter flux density for example at each position You will then have the option of displaying these solutions one after another thereby forming an animation of a rotating machine Clicking the Animate button will change the screen as below BLDC Versio
43. 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Manual Excitation Existing Results Magnet Active M Rotor Ang deg m 0 0 Magnet Temp 20 0 Wdg Current Dmp Bar Current pen T p 77 as Neem Draw Export Animate Display Iv Geometry Lines Wire Mesh v Material Shade Iv Flux Lines Bmag Shade Br Shade Current Density perational lz l elole p z s fiz it 82 In the box below the draw button you will have several options The first is Geometry Lines which is automatically selected This check box causes the machine s cross sectional geometry to be displayed to the right BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer SE File Action Window Tools Help Manual Excitation Existing Results MagnetActive M Rotor Ang deg m joo Magnet Temp ono Wdg Current Dmp Bar Current 1 B E 2 E Draw Export Animate Display Iv Geometry Lines Wire Mesh Flux Lines Bmag Shade Br Shade Current Density perational T Iron le l l l l le lele The next option is the Wire Mesh check box which displays the finite element mesh used in the solution BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Exp
44. 4 13 16 43 VA Cw 1446 405 5 P F PU 0 865 0 953 P_loss Cw POSA 72 92 P in Cw 257 386 6 P out Cw 1146 313 7 Ld CH 365e 6 365e 6 wbhr Cw 0 0 Q Q wtot Cw 106 72 9 Lg CH 3728 6 3728 6 Cw 0 0 0 0 9 26 2006 kg kg Parallel mm 3 72 Effic cktvs CPU Cv Q UurS ZP2O0 0 0 811 96 00 PM LmdaA pk web 0 0287 0 0287 Performance Table 150x80mm 6pole sph bldc ld res for project 150x80mm 6pole 3ph Pw CP Q i Tarm 13 16 4 Indx A u C oS 0 Test Power and Loss Table 150x80mm 6pole sph bldc ld aux for project 150x80mm 6pole 3ph 13 1 Tpm C 40 40 Below the Tables area is the X Y Curves selection area This section allows you to select the parameters to be graphed It contains two choices and an export button along with a list of parameters that may be graphically displayed BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results File Action Window Tools Help m Setting Design Field Explorer Parameters Load Test Transient Inverter Driven Test Tables Field type Performance Export N M Rpm Hz V Nunber of poles 5 1 56 7000 350 86 9 Losses and Parameters Outer diameter 165 5 2 981 325 88 1 Stack length 80 4 26 300 90 0 Armature skew in slots D 5 94 275 Lar Y Curves 7 89 250 93 7 ll 3 Performance Export C
45. 401 287208 01 31305e 01 340338r01 KES TRANSIENT TAB The Transient Tab is used to study machine parameters during a mechanical or electrical transient The layout of this Tab is similar but not exact to the previous tabs on this panel EY BLDC Version 3 0 C Program FilesWagneForceWldcWprojectsM 50x80mm 6pole 3ph bldc Results De Acn Window Took Heb a Setting Run Paramelers Load Test Transient Transient Test Design Sheet tor project 15U0x8 ma 6pole 3ph Transient Test FPerlorasnos Table 15Ux3Uma 6pole 3ph bldc tr res tor proj Tablet Field type pa field Torg RPM Freq V11 Iline lav V thd Pin P out P loss f Pel Egat N M Rpa Hz V x M ae ner eot haber of poles 6 412 6000 300 5891 2719 Losses and Parameters Outer disnmeter 165 5 7 01 5000 250 22 6 3 48 3 31 8 4200 4091 Steck length 80 Armature skev in slots n Xr Curves Fld l amp sm 1 Grade M13 U 5Unxn C Ped Ent Total field lam weight 1 461 Wrvefcems Arn_laa_l Grade M13 U 5Uxnxn Total armature lam weight 5 833 Load 1 x Fld_aag_1 Grade TD K Lb9b Total voluxe 1 48e 05 lire Omega 1 Vs IV s Ia Io Itc Eta Etb Ecc The Transient tab differs from the Parameters and Load Test Tabs in that it contains only Waveform data Since this tab 1s used to calculate the machine s response to a transient and 1s not normally used to view the steady state response the Performance and Loss Sep
46. 6e 02 6822e 02 7293e 02 2973e 02 2631e 03 3880e 05 1414e 05 01028 05 3880e 05 141428 05 0102e 05 5486e 02 68226 02 72938 02 29738 02 2631e 03 5486e 02 6822e 02 72938 02 29738 02 2631e 03 0 3 4363068 042 10 3 4384308 04 20 3 4440348 04 2 30 3 4516878 04 2 40 3 4597858 04 50 3 4671828 042 60 3 4733398 04 70 3 4777738 04 2 80 x2 0 10 0 Lab 0689e 05 0696e 05 4014e 05 0689e 05 06968 05 00000 360 2 06968 05 2 4014e 05 2 2 2 J moment of Inertialn in J 0 001339 Resistance of phase in R 0 0119745 lt The above file is now ready to be accessed by the 3 party simulator 2 1422e 05 2 2 2 2 2 3884e 05 0097e 05 1422e 05 3884e 05 0097e 05 2 2 l 2 2 1 2183 05 3498e 05 9724e 05 2183e 05 3498e 05 9724e8 05 2 2 2 2 1l 2904e 05 2903e 05 9601e 05 2904e 05 2903e 05 9601e 05 2 2 2 2 1 3496e 05 2178e 05 9727e 05 3496e 05 2178e 05 9727e 05 60 2 2 2 2 2 2 3880e 05 1414e 05 o102e 05 3880e 05 141428 05 01028e 05 DYNAMIC LINK BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help m a m Setting Design Field Explorer Parameters Load Test Transient Data Link C Static Model Export Disc B
47. 861e 03 1 0199e 02 54868 02 1 9994e8 02 2 2990e 02 2 4777e 02 5838e 02 2 6441e 02 6822e 02 71378 02 2 7299e 02 2 7239e 02 71628 02 2 7237e 02 72938 02 7133e 02 2 6831e 02 2 6462e 02 5854e 02 2 4773e 02 29738 02 99798 02 1 54768 02 1 0182e 02 66428 03 2 84778 03 2630e 03 42048 05 23288 03 85208 03 68618 03 0199e 02 5486e 02 9994e 02 2990e 02 47778 02 5838e 02 6441e 02 68228 02 71378 02 72998 02 72398 02 71628 02 72378 02 72938 02 71338 02 6831e 02 64628 02 58548 02 47738 02 29738 02 1 9979 02 54766 02 0182 02 6642 03 84776 03 2630e 03 4204e 05 eo 0 1 0 self amp Mutual Inductance in Henries for to 3 436301e 04 5 10 3 43842568 04 20 3 1440298 TUGO 3 451684e 04 40 3 459782e 04 50 3 467179e 04 60 3 473335e 04 70 3 477769e 04 80 ym 0 10 000000 360 2 0 696e 05 1422e 05 2 2183e 05 2 2904e 05 2 3496e 05 2 3880e 05 2 401528 05 2 3884e 05 2 34088 05 2 2903e 05 2 2178e 05 2 1414e 05 2 0689e 05 2 0097e 05 1 9724e 05 1 9601e 05 1 9727e 05 2 0102e 05 2 069068 05 2 1422e8 05 2 2183e8 05 2 2904e 05 2 3496e 05 2 3880e 05 2 4015e 05 2 3884e 05 2 3498e 05 2 2903e 05 2 2178e 05 2 1414e 05 2 0689e 05 0097e8 05 1 9724e 05 1 9601e 05 1 9727e8 05 2 0102e 05 2 0696e 05 voltage Coefficient in v rpm for Run 3 xl 0 6 0000
48. Amps square metet 86 BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help etting Manual Excitation Existing Results Magnet Active lv Rotor Ang deg m 10 0 Magnet Temp 20 n Wdg Current Dmp Bar Current Draw Export Animate Display S a a n E H V Geometry Lines M Wire Mesh Material Shade Flux Lines Bmag Shade Br Shade V Current Density Operational H ju The scale of this parameter can also be adjusted by double clicking the legend and adjusting the parameters as appropriate BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help E etting Field Explorer Manual Excitation C Existing Results Magnet Active M v Auto Scale Rotor Ang deg m 10 0 From 61000 Magnet Temp 20 0 To BI Wdg Current Dmp Bar Current 3 P Steps 10 Draw Export Animate Display S al a n H info s V Geometry Lines Wire Mesh Material Shade Flux Lines Bmag Shade Br Shade Iv Current Density Operational Lj E 87 To the right of these check boxes are several sizing and information buttons To zoom in on the image use the Plus button or to zoom out click the Minus button to normalize the image size click the Normalize button or to sh
49. E button to the right hand side of this box begins the entire simulation process Each test checked will be run and the results stored for later analysis as described in the next panel 64 Chapter The Results Panel Upon simulation completion the results panel is used to view the various parameterized output Output includes the complete set of machine and load voltages and currents as well as torque and power When first selected the results panel will be displayed BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results File Action Window Tools Help m Setting Design Parameters Load Test Transient Inverter Driven Test for project 150x80mm 6r Tables Torq RPM Freq Vll Iline Iaw 3 P in Pout a V P F Effic 7 Performance Export N M Rpm Hz V A W W W PU PU 1 56 7000 350 86 9 gs 9 1 1252 1146 1446 0 865 0 916 0 499 6000 300 68 2 386 6 313 7 405 5 0 953 0 811 Inverter Driven Test Performance Table 150x80mm 6pole 3ph bldc ld res nib N jes bees Losses and Parameters XY Curves Performance Export Waveforms Load 1 X Data gt omegat ll Load la 15 0 Sar HH mino 4 12 0 9 00 6 00 3 00 0 0 3 00 6 00 9 00 12 0 15 0 0 0 360 Omega t Deg This panel contains several tabs In fact each type of load simulation has its own tab just a
50. ELATED SERVICES OR CONTENT IS FREE FROM BUGS VIRUSES ERRORS OR OTHER PROGRAM LIMITATIONS NOR DOES MAGNEFORCE WARRANT ACCESS TO THE INTERNET OR TO ANY OTHER SERVICE OR CONTENT THROUGH THE SOFTWARE SOME STATES DO NOT ALLOW THE EXCLUSION OF IMPLIED WARRANTIES SO THE ABOVE EXCLUSIONS MAY NOT APPLY TO YOU IN THAT EVENT ANY IMPLIED WARRANTIES ARE LIMITED IN DURATION TO SIXTY 60 DAYS FROM THE DATE OF PURCHASE OF THE SOFTWARE HOWEVER SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASIS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY HAVE OTHER RIGHTS AS WELL WHICH VARY FROM SIATE TO STATE LIMITATION OF LIABILITY AND DAMAGES THE ENTIRE LIABILITY OF MAGNEFORCE AND IIS REPRESENTATIVES AS DEFINED BELOW FOR ANY REASON SHALL BE LIMITED TO THE AMOUNT PAID BY THE CUSTOMER FOR THE SOFIWARE UNLESS OTHERWISE SEPARATELY AGREED TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW MAGNEFORCE AND IIS SUBSIDIARIES AFFILIATES LICENSORS PARTICIPATING FINANCIAL INSTITUTIONS THIRD PARTY CONTENT OR SERVICE PROVIDERS DISTRIBUTORS DEALERS OR SUPPLIERS REPRESENTATIVES ARE NOT LIABLE FOR ANY INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO DAMAGES FOR LOSS OF BUSINESS LOSS OF PROFITS OR INVESTMENT OR THE LIKE WHETHER BASED ON BREACH OF CONTRACT BREACH OF WARRANTY TORT INCLUDING NEGLIGENCE PRODUCT LIABILITY O
51. R OTHERWISE EVEN IF MAGNEFORCE OR ITS REPRESENTATIVES HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES AND EVEN IF A REMEDY SET FORTH HEREIN IS FOUND TO HAVE FAILED OF ITS ESSENTIAL PURPOSE SOME STATES DO NOT ALLOW THE LIMITATION AND OR EXCLUSION OF LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU THE LIMITATIONS OF DAMAGES SET FORTH ABOVE ARE FUNDAMENTAL ELEMENTS OF THE BASIS OF THE BARGAIN BETWEEN MAGNEFORCE AND YOU MAGNEFORCE WOULD NOT BE ABLE TO HAVE PROVIDED THIS SOFTWARE OR SERVICES WITHOUT SUCH LIMITATIONS U S Government The Software is a commercial item as that term is defined at 48 C F R 2 101 OCT 1995 consisting of commercial computer software and commercial computer software documentation as such terms are used in 48 C F R 12 212 SEPT 1995 and the Department of Defense Federal Acquisition Regulations Sections 252 227 7014 a 1 5 Consistent with 48 C F R 12 212 and 48 C F R 227 7202 1 through 227 7202 4 JUNE 1995 all U S Government End Users acquire the MagneForce software or Licensed Product with only those rights set forth herein MagneForce Software Systems Inc P O Box 4652 Timonium MD 21094 Export Restrictions You acknowledge and agree that the MagneForce Software is subject to restrictions and controls imposed by the Export Administration Act and the Export Administration Regulations the Acts You ag
52. RON LOSS button BLOC Version 1 0 C Program Files MagneForce BLDCWrojects 1 50x80mm 6pole 3ph bldc Setting Sele File Action Window Tools Help FE Solver amp Mesh Control Min Distance He Hat Mesh Density 1 0 Loss Curves 0 5800 e o E 1 010 Forced airgap layers 1 480 3D Field Correction 0 00 2 170 Order of Elements 1 3 020 i i i im 1 Defaults 5 090 User Defined Coefficients 6 640 Fld wdg ET g 9 300 Permeance TE 12 48 Arm dg ET i Permeance D efaults ep __Cancel_ User Defined Functions m De ago B Tesla F A series of loss curves in Watts Kg Hz is displayed in both graphical and tabular format Each of the curves is at a certain frequency The table to the left indicates the frequency at which these losses have been determined Each curve is represented by the pair of columns titled B and W with the same Frequency entry n Use the scroll bars to see the table in its entirety The values in the table can be adjusted and the results reflected in the curve to the right Simply click on an entry and change it The table will be immediately sorted and the graph updated Additional data points can be added by using the scroll bars to position the cursor at the end of ot to the right of the table Simply enter your new values and the graphs and table will again be immediately updated Additionally the viewable size of the table and the graph area c
53. Weight 5 EX Gy dq Modius Al gap 1 700 Deck on an image to chee it T Start 7 Irisz Micrel Cul EJ ELEC Hinia Hira m Be n TIGER 2 Heer plhsern m E TERT The general machine parameters near the bottom of the screen are e Stack is the length of machine measured in millimeters e Skew is the machine skew end to end measured in slots e Weight is a calculated value of the rotor and stator lamination s weight in kilograms The program will calculate the machine air gap based upon your input dimensions If the resultant air gap is negative it will be displayed in red Please note that when making large wholesale changes to the machine dimensions the graphical display may be left blank or seem distorted This is due to the fact that some geometry parameters have changed while others have not yet been updated Continue with your geometry change inputs and the display will return to normal once all parameters have been correctly updated 14 Under the drawing of the machine cross section is an APPLY and CANCEL button These buttons are used to apply or cancel changes in the geometry figures from above Next to these are four buttons for FIT ALL ZOOM IN ZOOM OUT and MOVE They can be used together with the scroll bars to enlarge and inspect your geometry When satisfied click the FTT ALL button to return the cross section to normal size The button MODIFY DRAW button is used to launch ARBIDRAW which is MagneForce s stan
54. _Defauts Save in C MagMat e Ee User Defined Coefficients E co bhw FdWdgET pes 15 j E m19 0 50mm bhw diio Ir tm Wdg mis 0 50mm usr bhyy plates 7 5E 7 T E M36 0 64mm bhw amp Defaults m spy Cancer 10 f User Defined Functions File name REFIERE n Save as type Steel Material Type bhw Cancel EUM 0 5 0 0 0 00 50000 00 100000 00 150000 00 200000 00 250000 00 H Am Save Current Material File start K Inbox Outlook Express mw BLDC Manuali Micro hi Bldc A new material can be defined by closing any open material using the CLOSE button and then clicking the NEW button The system will request a name and then open the material with blank tables You may then populate the table with data points and when finished save the new material This new material will now be available to all MagneForce Simulators In the upper right corner of the settings panel is found the units selector drop down box This selector box allows you to view the B H curves and tables in the units of your choice The available selections are Tesla amp A m amp Watts Kg or Tesla amp KA m amp Watts Kg or Tesla amp A m amp Watts Lb or Gauss amp Oersted amp Watts Kg or KGauss amp KOersted amp Watts Kg or Gauss amp Oersted amp Watts Lb or KGauss amp KOersted amp Watts Lb Select the units with which you are most comfortable 42 With STEEL LAMINATION still selected click the I
55. a files of BLDC Below these parameters is a box to select the actual 3 party simulator you are linking to either Simulink or Sabre 61 Once the above parameters are set correctly CLICK the EXECUTE button BLDC will now prepare itself to be called by Simulink A set of data files will be prepared and written and you will see the following screen BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help Field Explorer Parameters Load Test Transient Data Link Could not find rotor geometry variable damp bar number Static Model Export Dynamic FE Data Link Vs Ga m oie m Ak salen i Could not find stator geometry variable aux slot number Field and Armature M N o Could not find stator geometry variable damp bar number Temperatures e Finished for material LO C Uti gn Finished for material L1 Constant x 5 Finished for material L2 Arm Temp 25 2 Finished for material L3 Field Temp 25 S Finished for material L4 Finished for material L5 Inverter Rotor nodes 526 elements 328 Finished for material LO Finished for material L1 Output Finished for material L2 JV Apparent Energy Finished for material L3 Finished for material L4 IV Winding Flux Linkage Finished for material L5 and Inductance Finished for material L6 Finished for material L7 v w dg Rotational Emf Stator nodes 809 elem
56. a_t Deg Performance Table 150x80mm 6pole 3ph b Vll V thd P in 1 1252 zd 2022 ne 2798 5 3570 4324 When viewing multiple data sets simultaneously any particular data set can be emphasized by clicking upon it in the Y Data column In the picture below notice the enhanced nature of the curve for the current in phase B of the load for load point 2 Load 2 Ib BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results File Action Window Tools Help Cs S m Open Setting Design Field Explorer Parameters Load Test Transient Inverter Driven Test Tables Performance Esport Losses and Parameters r xY Curves 4 Design Sheet for project 150x80mm 6pole 3ph Field type pm field Number of poles Outer diameter Stack length Armature skew in slots 6 165 5 80 d t Inverter Driven Test Torq N M 1 56 2 81 4 26 5 94 7 89 RPM Rpm 7000 6500 6000 5500 5000 Freq Hz 350 325 300 275 250 Performance Table 150x8 mm 6pole 3ph b V11 V thd P in 1252 2022 2798 3570 4324 Performance _EXP0tt Waveforms Load 2 X Data S omega t Y Data S Load 1 la Load 1 Ib Load 2 la Bl Load la Bg Load 1 lb gg Load 2 a JJ Load 2 Ib 30 0 H 360 Omega_t Deg 75 t As you might expect the
57. ach of the specified current values With this selection you will be required to enter the following Ia pk A peak value of phase A current Ia Ea deg angle between the A phase current and resultant MMF DQ 1 refers to the popular dq reference frame in which much control work is done Multiple values can be entered separated by a comma so that BLDC will calculate the magnetic parameters at each of the specified current values Id A magnitude of q axis current Iq A magnitude of d axis current DQ 2 refers also to the dq refrence frame Again multiple values can be entered separated by a comma so that BLDC will calculate the magnetic parameters at each of the specified current values However with this selection you will describe the armature current by specifying the magnitude and phase of Is the resultant vector formed by Id amp Iq Is A magnitude of Is Is Er deg angle of Is After setting the above parameters be sure to click the button titled CLEAR TABLE and then click ADD TO TABLE This will clear and then populate the armature current table below with the appropriate values from the above inputs BLDC will populate the table with each combination of the above parameters For example the figures below show 2 values entered for the magnitude of Ia and 2 values entered for the Ea angle This will produce 4 lines in the table since each magnitude needs to be paired with each angle This table can be thought of
58. ages from the various BLDC components For example when the meshing of the machine geometry is complete you will see a message indicating the number of nodes as well as elements created This window contains a scroll bar to the right that allows you to scroll back through the status messages to review the programs actions Below this window is a progress status bar that will indicate the progress of the finite element solver or the spice solver as appropriate 63 RUN SIMULATION CHECK BOX BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help Field Explorer Parameters Load Test Transient Data Link Inverter Circuit Use Tabular Input AF Angle M Vs Ix m Inverter a Mechanical Output Amb Temp 22 Vs Driven by mU OMEN j Demag Prediction Ckt Inverter local square voltage Load Pts 4 Specify RPM Wdg Temp Given 120 0 110 0 100 0 30 0 Solver Progress Run Simulation MV Parameters Execute TRIER Transient Abort FE rotor positions per slot pitch 5 pole pitch Tol Control Apply Cancel E Under this message box is the RUN SIMULATION check box that allows you to select the simulation tests that you wish to run Multiple simulation tests with the exception of the Data Link test can be checked simultaneously for example you may select Parameters and Load Test and both tests will be performed The EXECUT
59. ais Link fe Vs Field and Armature Temperatures 7 Arm Temp p5 e Field Temp 55 Inverter f ear Mechanical Output Output Apparent Energy Iv Winding Flux Linkage and Inductance v Wdg Rotational Emf iv Torque System Simulator SimuLink C Saber Solver Progress Run Simulation Z r Execute r v Data Link The parameters on this tab define the variables that will be passed between BLDC and whatever other simulator is employed e Field and Armature Temperatures is either set to Constant or Dynamic If set to constant you must specify the actual temperatures If set to dynamic this parameter is passed in from the other simulator for use by and within BLDC e Apparent Energy is a calculated parameter within BLDC and output to the other simulator Select the check box to cause this parameter to be included in the output data files of BLDC e Winding Flux Linkage and Inductance is a calculated parameter within BLDC and output to the other simulator Select the check box to cause this parameter to be included in the output data files of BLDC e Winding Rotational EMF is a calculated parameter within BLDC and output to the other simulator Select the check box to cause this parameter to be included in the output data files of BLDC e Torque is a calculated parameter within BLDC and output to the other simulator Select the check box to cause this parameter to be included in the output dat
60. an be changed Simply position your cursor on the area between the table and the graph area and click and drag to the desired size As with the B H curve the units of the loss curves can be changed In the upper right corner of the settings panel select from the drop down list the units you are most comfortable with The available selections are Tesla amp A m amp Watts Kg or Tesla amp KA m amp Watts Kg or Tesla amp A m amp Watts Lb or Gauss amp Oersted amp Watts Kg or KGauss amp KOersted amp Watts Kg or Gauss amp Oersted amp Watts Lb or KGauss amp KOersted amp Watts Lb 43 With STEEL LAMINATION and IRON LOSS still selected click the LOSS MODEL button BLDC Version 1 0 C Program Files MagneForce BLDCWProjects 1 50x80mm pole 3ph bldc Setting File Action Window Tools Help Field Explorer Steel Lamination Close Save BH Curve Iron Loss fLoss Model Tesla A m Watts Kg m m19 0 50mm usr bhw Loss Curves FE Solver amp Mesh Control Min Distance 1e 5 Rot Mesh Density o 05800 3 3 i Sta Mesh Density 1 0 1 010 Forced airgap layers li v 1 480 3D Field Correction 0 00 2 170 Order of Elements 1 X 3 020 i a 4 200 i am A 1 Defaults 5 090 nh 6 640 2 a me my i T zT s Fld W dg ET 3 300 i 0 50 i l i i Permeance 1E 6 1248 B Tesla Arm Wdg ET 7 5E 7 Parameters K amp Y Curves Loss Model Curves Permeance i 2 Defau
61. ap 0 500 Magnet Active IV Rotor Ang deg m Magnet Temp 0 Wdg Current Dmp Bar Current ray Export Animate Display v Ma etry Lines EN X Bile we Current Density ational e a m rot nes Density Br Shade le I LE lebelelo mi ml Angle Deg e 92 The Export button allows a number of parameters to be exported in Microsoft Excel format The parameters that can be exported are the machine s cross sectional image and the complete finite element file Zi BLOC Versinn 3 0 C Program Files MWagneorceMsldc prn jects V 50xd mm fpele Jph bldc Field Explarer Hana Eralan Existing aiui Magee Arie iv Raana ldem D Mapei Ten x00 Wig Curent Dee Bar Comer Expert Field lerages aj aj lt LI D E E Irisa Proa t Dk i TGERZ Hemriplhere BLDC Miaa cim m i E Microsoft Excel Book1 EIE dE File Edit View Insert Format Tools Data Window Help Adobe PDF Type a question for help 2 amp x Ll ug i 2 3 54 31 14 5307 412 0 8 ESE D B Z 2 28 A 4 i a E Ya Reply with Changes End Review 1726 Elements 3271 Lables 8 sltA1 air sltA2 sltA3 lamF1 magF1 shaft Label XC Yc Area Bx By Brx Bry Jz 1 lamA1 3 81E 02 1 79E 04 1 86E 07 3 76E 01 2 24E 03 0 00E 00 0 00E 00 0 00E 00 2 lamAt 7 45E 02 1 25E 02 2 03E 06 5 26E 02 3 22E 01 0 00E 00 0 00E 00 0 00E 00 3 lamA1 3 93E 02 4 74E 04 2 65E 07 4 45E 0
62. aration data sets are not calculated The waveform data that 1s available includes machine currents EMF s and electromagnetic torque as well as any current ot voltage sources placed in the drive circuit on the design panel Additionally the x axis of this result panel can be selected to display either Omega t in degrees ot Time in seconds The figures below all apply to a machine which undergoes a change in speed from 6000 rpm to 5000 rpm Notice the response from one steady state condition to another Please note that the beginning of these plots display a numerical transient because the exact starting condition can never be known ptior to running the simulation 77 EY BLDC Version 3 0 C Program Files WMagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results Parameters Load Text Transient Transient Tesi Design Sheet tor project 15Ux98 mm 6pole 3ph Tbe Field type fe Palamara Erat C Losses and Parameters pa field Number of poles Cuter disneter Steck length Armature skev in slots eee o Pedossance Eno Wawefemas Bg Lodi EmTorg 900 f oad 0 04 708 61 5 16 420 324 220 1 32 0300 h Transient Test Torq N 4 12 7 81 RPM Rpm 6000 5000 Performance Table 150x80ma 6pole 3ph bldc tr res for proj Freq Vll Iline lav V thd P in Hz v UD W 300 89 1 24 8 45 n 2719 250 92 6 49 3 49 2 31 0 4209 The above figur
63. arre Hoke H M m CERIS m nei Fann Foce foo E Minchingr Field Explorer Wg Cale Duputtabls A Simm pole Joh b for progect T peirational FO don Loss Der r EJ ELEC Hinia Micra m gs Lac Mirga t Ergal Been 106 The final informational button is labeled Bg Clicking this button will produce a plot of the mid gap flux density in Webers vs Electrical Degrees at the current rotor angle and excitation level Click the Bg button again to return to the normal display BLDC Version 3 0 C Program Files WMagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Field Explorer ll B aiaap 0 500 Rotor Ang deg e 1 0101 Magnet Temp 10 0 Wdg Current Dmp Bar Current av Export nimate Display x tru Lines EN UK eg lear hE br onade Bie BE Curent Density ational e D g 0 0 Angle Deg e ror nes Densitu Br Shade RU ml elz l LE lebelelo 107 The Export button allows a number of parameters to be exported in Microsoft Excel format The parameters that can be exported are the machine s cross sectional image and the complete finite element file ey Tl Version 3 0 C MI rogum Filet Vaga orcelbide projects VI Simm amp pele 3pli bldc Field Eaplarar Rott Ang idege un Med Tom aL WdgCumeni Dee Bar Cunert Export Field images l amp E man
64. as the load point table from the parameter or load test tab When the static link is executed BLDC will sequentially calculate the output data file using each of these 4 table entries as an input In this way the output 56 file will consist of 4 distinct sections of output corresponding to each one of these inputs BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help Design Field Explorer Parameters Load Test Transient Data Link Static Model Export C Dynamic FE Data Link Temperatures Armature 25 Field 25 Incremental L Matrix Armature Current Style Function of Rotor Position C Range Sweep M Work Sheet Style Sinusoidal w Ref Frame la pk A 1 5 tuia a Add to Table Clear T able ib MES 1 Cos 0 01 1 Cos 0 01 1 Cos 0 01 5 Cos 0 015 Cos 0 01 5 Cos 0 01 5 Cos 0 01 zm FE rotor positions per slot pitch Vs Inverter Output File Name C mymodel m Voltage Coefficient in V rpm for WriteMagCurveSimulink l Ea 61 e0 e0 1 0 Self Mutual Inductance in Henr WriteMagCurveSpice l Laa 37 WriteMagCurveSimulink l Lab 3 amp Voltage Coefficient in V rpm for WriteMaqgCurveSimulink 2Z Ea 61 e0 e0 1 0 Self Mutual Inductance in Henr WriteMagCurveSpice 2 Laa 37 WriteMaqgCurveSimulink 2 Lab 3 Vo
65. atic layout of the machine s drive circuit The tab is divided into two major sections the schematic drawing area to the right and a column to the left used for parameter settings and switch visualization The operation of the drawing section is similar to many popular schematic drawing and capture packages Using the drawing aids and component buttons along the top of the schematic area you can quickly amp easily construct Brushless DC drive circuits ranging from simple rotor position feedback to complex PWM control The drive circuit topology will then be used in the simulation of the machine The upper portion of the left hand column contains several parameter settings e Inverter Advanced Firing is the amount in degrees that you wish to advance fire the inverter switches e Inverter Switch Dead Angle is the amount in degrees that you wish to reserve between one inverter switch turning off and the next switch tutnine on The middle portion of this column contains several symmetry settings These settings ate used to conserve simulation time The program will use these 23 settings in determining exactly how much of the machine and how much of the complete AC cycle it needs to simulate e Phase to Phase can be checked if the machine exhibits drive phase to phase symmetty e Bi Polar can be checked if the drive circuit exhibits Bi Polar symmetry The lower portion of this column is a graphical representation of the switch on
66. b Temp which is the ambient temperature of the machine in degrees Celsius OC Voltage check box which should be checked if you are interested in obtaining the machine s Open Circuit Voltages Waveform OC Wdg Inductances check box which should be checked if you are interested in obtaining the machine s Open Circuit Winding Inductances versus rotor position BLDC can calculate either the apparent or incremental inductances If you wish to calculate the incremental inductances simply check the box otherwise the apparent inductances will be calculated In either case the complete set of self and mutual inductances will be calculated Cogging Torque check box which should be checked if you are interested in obtaining the machine s cogging torque waveform versus rotor position In the box enter the slot range over which you would like the cogging torque calculated 47 e Total Pts drop down box which sets the number of data points that the simulation will run for e Wdg Temp field is not active on this tab Underneath this area is where the individual parameters are set for each load point For the open circuit voltage and winding inductance test you will supply the following e RPM is the speed of the machine in revolutions per minute e Hz is the frequency of the machine in Hertz This is a calculated value based upon the number of poles and the rpm e T_fld is the temperature of the field winding in Celsius e T arm is the temperature
67. bic rpm e Rotor HF Loss Coef estimated high frequency eddy current loss in rotor in Watts per cubic rpm e Thermal Model drop down box to select external user defined thermal model not yet implemented e Rotor M I is the calculated rotational moment of inertia of the rotor e Additional M I is any additional moment of inertia that you would like to add such as a fan or the load e Total M I is the sum of the above rotational and additional moments of inertia e Gearing Efficiency is the efficiency of any gearing attached to the motor in per unit e Viscous Torque Loss is any mechanical torque loss in the above gearing 21 In the lower right corner is an APPLY and CANCEL button These buttons are used to apply or cancel changes in the mechanical parameters from above After you are satisfied with your design use the SAVE button on the panel toolbar to commit your changes to disk 22 DRIVE CIRCUIT TAB BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit Armature Excitation Inverter AN a ALA f amp Quick Parameter Set Invertor Advanced Firing D Degrees Invertor SW Dead Angle 0 1 Degrees Advantage of Symmetry Iv Phase to Phase Iv Bi Polar 3ph Y Arm Winding Select All Clear All Within this tab you will describe the schem
68. ced airgap layers 1 3D Field Correction 10 00 Order of Elements 1 Defaults User Defined Coefficients Fld w dg ET Permeance E 6 Arm w dg ET Permeance 7 57 Defaults User Defined Functions m m 36 PERMANENT MAGNET MATERIAL DEFINITION On the magnet tab of the design panel you were required to select a permanent magnet material for the rotor This section explains how to view and modity an existing material s properties or define a new material Towards the upper left corner of the settings panel is a box that allows you to select either PM MATERIAL or STEEL LAMINATION Select PM MATERIAL and then click OPEN to the right This will bring up a list of all permanent magnet materials saved within the MagneForce suite of simulators BLDC Version 1 0 C Program Files MagneForce BLDC Projects 150x80mm 6pole 3ph bldc Setting s PM Material Steel Lamination New Open Close Save C BH Curve C Iron Loss Made I r No Material Selected FE Solver amp Mesh Control Min Distance 1e 5 Rot Mesh Density 1 0 Sta Mesh Density 1 0 Look in B MagMat ex E3 Forced airgap layers 1 E Mg1 08 pmt 3D Field Correction 0 00 E TDK FB5E pmt Order of Elements 1 v E TDK fb9b pmt f E TDK fb9h pmt _Defauits d vac 677ap pmt User Defined Coefficients fS vac 688ap pmt ser Defined Coeffi
69. cients Fld Wdg ET Permeance TE 6 Arm W dg ET File name Permeance fz 5E 7 Default Files of type PM Material Type pmt X Cancel User Defined Functions Iron Loss Mode pz ba OPen an Existing Material File start K Inbox Outlook Express taj BLDC Manuali Micro Ili Bide 37 Select a material from the list and click OPEN BLOC Version 1 0 C Program Files amp MagneForceXBLDCAP rajectskl50x80mm pole 3ph bldc Setting Sele File Action Window Tools Help Ef m etting Design Field Explorer f FPM Material Close Save i BH Curve K Giauss K Dersted FE Solver amp Mesh Control vac b7 7 ap pmt 15 0 3 Min Distance 1 amp 5 20 00 Hat Mesh Density 10 l Sta Mesh Density H Forced airgap layers ao 3D Field Correction o oo Order of Elements Hoo l Defaults User Defined Coefficients Fld da ET Permeance i E G Am Widg ET Permeance 17 5E 7 a i zh n e x hm ww cH A EEEN RE Defaults 1000 100 ESO s pone 0 9700 0 78 i T 1 0 9520 0 68 j 1 i User Defined Functions 0 9330 0 59 i j i i 1 i 0 9120 0 50 i Av 24 50 18 60 12 40 B B E nore naso gt H K Gersted This screen displays in tabular and graphical form several B H curves for the selected permanent magnet material Each curve is at a different temperature The name of the selected material appears above the up
70. ction Window Tools Help pen Circuit Voltages Design Shee Open Circuit Voltages Performance Table 150x80mm 6pole 3ph bldc oc res for project 15t Tables i V 11 V 13 V salt V thd Perf Export A X X A A erformance por i 6 i 0 6 C Losses and Parameters XY Curves Bl Load 1 Va Performance _Export 70 0 Waveforms 56 0 Load 1 X Data 42 0 gt omega_t Y Data Load 1 Va 140 28 0 0 0 14 0 28 0 42 0 56 0 70 0 0 0 360 Omega t Deg The drop down box containing Load 1 can be set to any of the load points specified on the Parameters tab of the Run panel In this way you can graph the same machine parameter for different load points and or different parameters for the same or different load points This section also contains an Export button which can be used to export the graphical data The output can be in either Microsoft Notepad or Excel 70 LOAD TEST TAB The layout of the Load Test Tab is similar to the Parameters Tab BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x60mm 6pole 3ph bldc Results File Action Window Tools Help Save Setting Design Field Explorer Parameters Load Test Transient Inverter Driven Test Design Sheet for project 150x80mm 6pole 3ph Inverter Driven Test Performance Table 150x80mm 6pole Tables Field type pn field RPM Freq Vll i Iaw Perfo
71. d alone drawing package that will allow you to make major geometry changes to a slot module Please see the ArbiDraw user manual for further explanation After you ate satisfied with your design use the SAVE button on the panel toolbar to commit your changes to disk 15 MATERIALS TAB BLDC Version 3 0 C Program FilesWagneForce bldc projects 1 50x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit Magnets Laminations Fld mag 1 Fld lam 1 SEEEUETMM X Grade TDK fb3b X Arm lam 1 M19 0 50mm v Magnitization Orientation C Radial Parallel Relative Angle 0 Other EM Materials Conductivity RN name Fld shaft Volume mm 3 148 0e3 Permeability i em Conductivity fo Damper Winding Active Damp Bar Ohm per Meter Damp Bar A End Ring Ohm per Meter End Ring Ad End Ring Rq Eee ica aAA This tab has sections on the left that describe the attributes of the permanent magnet material steel laminations and other electromagnetic materials as applicable to the design On the right is a drawing of the cross section of the rotor and below is an area that describes the damper bar windings The permanent magnet parameters are e Grade is the type of magnet material that the field is made from select from the drop down list If your particular material is not listed you may add it using the settings panel desc
72. d an export button along with a list of parameters that may be graphically displayed BLDC Version 3 0 C Program Files WMagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results File Action Window Tools Help Parameters Load Test Transient Open Circuit Voltages D Open Circuit Voltages Tables i Freq YEL Performance Esport Hz V 400 85 4 Losses and Parameters 350 74 7 Performance Table 150x80mm 6pole 3ph bldc oc res for project 15 XY Curves Performance Esport C Waveforms Selecting Parameters and Torq for the X axis data and Wtot for the Y axis data will produce the following BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x60mm 6pole 3ph bldc Results File Action Window Tools Help Open Circuit Voltages Open Circuit Voltages Tables i Freq 11 Performance Esport V Performance Table 150x80mm 6pole 3ph bldc oc res for project 15 Losses and Parameters XY Curves Export Performance Waveforms z x Data Tora Y Data Witot 0 110 0 0950 0 0900 Tora N M 69 Selecting Waveforms will allow you to graph these machine parameters versus time For instance phase A open circuit voltage can be displayed as BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results File A
73. d on the armature winding tab previously For example if a 3 phase Y connected winding was selected on the armature tab you will see a schematic of this exact armature with access to the following leads A B C and N There are no attributes available for the armature item e Excitation will place one of three voltage sources onto the schematic drawing area When initially selecting excitation you will be presented with 3 additional choices V source AC Bridge and DC Excitation Choosing V source will place a simple ideal voltage source while choosing AC Bridge will place a standard AC bridge rectifier voltage soutce and choosing DC Excitation will place a standard voltage soutce in series with a resistor onto the drawing area The attributes of the actual voltage source in each of these excitation models can be accessed by right clicking the source itself Attribute options are AC or DC voltage magnitude and frequency if AC is selected Additionally you can rotate or scale the objects size from this pop up window as well The other items such as resistors and diodes contained in the AC Bridge and DC Excitation models also have attributes that may be displayed by right clicking the actual device e Inverter will place onto the drawing area a standard drive circuit inverter based upon the exact armature selected on the armature tab previously This inverter will be composed of the appropriate number of switches and diodes connected in a manner
74. ductance in Henries for Run 2 UriteMagCurveSpice 2 Laa 37 GoNextline UriteMagCurveSimulink 2 Lab 37 zx2 Lab GoNextline 4 Voltage Coefficient in V rpm for Run 3 UriteMagCurveSimulink 3 Ea 61 xl e0 5 GoNextline e0 e0x1 0 4 Self amp Mutual Inductance in Henries for Run 3 WriteMagCurveSpice 3 Laa 37 GoNextline UriteMagCurveSimulink 3 Lab 37 x2 Lab GoNextLine 4 Voltage Coefficient in V rpm for Run 4 UriteMagCurveSimulink 4 Ea 61 xl e0 5 GoNextLine el e0x1 0 4 Self amp Mutual Inductance in Henries for Run 4 UriteMagCurveSpice 4 Laa 37 GoNextline WriteMagCurveSimulink 4 Lab 37 zx2 Lab GoNextline ZPole number p WriteParameter Npoles GoNextline 4Moment of Inertialn in kg nm 2 J SWriteParameter Jtotal GoNextline ZResistance of phase in ohm R2 UriteParameter Ra 75 GoNextline Use C statements within pairs This is the script editor that is used to define the output file Two simple rules ot conditions apply to the script editor 1 Any line not encased by signs will be written to the output data file exactly as it appears in this table 2 Any line ot group of code that is encased by a sign is interpreted as C code and will be executed and its result will be written to the output data file 58 P There are two methods to include results in the output data file First
75. e ga d 7 1 7 amp 2 1 1 1 n 1 E 1 pe BLOC Missus Micro 7 Inverter Driven Test vil v S 9 e lav A 7 60 3 43 Freq Thine Hz 250 200 ee 1 55 0 433 6000 Poin iw 1252 106 6 P_out E 313 7 lnmm iW 105 7 2 92 Parturxace Table 150x80mm bpaole bldc ld res for projec 405 5 0 Selecting Export as described in the screen above will yield the following screen Notice that the performance data loss separation data and design data sheet are all output D Notepad File Edit Format View Help Inverter Driven Test v11 v2 86 9 68 2 Torq RPM N M Rpm 1 56 7000 0 499 6000 Freq Hz 350 300 Inverter Driven wfan Cw 3 43 2 16 RPM rpm 7000 6000 wra Cw 2 97 0 379 Torg N M T 56 0 499 Design sheet for Field type Number of poles Outer diameter Stack length Armature skew in slots Fld lam 1 Grade Total field lam weight Arm lam 1 Grade Total armature lam weight Grade Fld mag 1 Total volume Armature lam dimensions Type Outer pia Inner Dia Num slots Tooth width Yoke width Slot open Tip pef lt project 150x80mm 6pole 3ph v thd CX PHP 19 7 Iline CA 5 60 343 3 43 wr d Cw 0 0 Q Q Cw 99 1 70 3 Cw pm field 6 165 5 80 Q M19 0 50mm 1 141 M19 0 50mm 5 833 TDK fb9b 1 486 05 wirnsta wirnRot wgear 0 159 0 057
76. e animation You may also use the Red Arrows and the Pause button to step through each of the rotor positions manually When finished viewing the animation click the Exit button to return to the normal field explorer display 95 EXISTING RESULTS At the top of the settings section click Existing Results Two drop down lists appear One allowing you to select from the various tests that were selected and performed on the run panel These test range from parameters to load test to transient The other drop down list allows you to specify the load point of interest Next you must select the rotor angle expressed in degrees and enter it in the box labeled Rotor Ang deg Upon completing these fields the program will populate the appropriate values for the following parameters Magnet Temperature Magnet Temp Armature Current Arm Current and Damper Bar Current Dmp Bar Current Once these parameters have been completed click the Draw button BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help C Manual Excitation Existing Results Load Test Load 1 Rotor Ang deg e 0 0 Magnet Temp 40 00 Wdg Current Dmp Bar Current Draw Export Animal M Display te amp amp J n 83 MV Geometry Lines Wire Mesh v Material Shade BmagShade BrShade Current Density Operational Iron Loss De
77. e bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help ZB S jum Design Run Results Field Explorer C Manual Excitation Existing Results Load Test load 1 Rotor amp ng deg e 10 0 Magnet Temp 40 00 Wdg Current Dmp Bar Current Draw Export Animate Display iW Geometry Lines Wire Mesh Material Shade iw Bmag Shade Br Shade Current Density Operational ron Loss Density The scale of the flux density can be changed by double clicking the legend and changing the settings as desired File Action Window Tools Help LJ nel a EB 13 Results Field Explorer C Manual Excitation Existing Results LoadTest Load i V Auto Scale Rotor ng dege 00 Magnet Temp 40 00 From E 8 Te Steps 10 W dg Current Dmp Bar Current Draw Export Animate Display iW Geometry Lines Wire Mesh Material Shade Flug Lines iW Bmag Shade Br Shade Current Density Operational Iron Loss Density 99 Br Shade is the next displayable parameter and when selected displays the flux density in the permanent magnets BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Field Explorer C Manual Excitation Existing Results Load Test Load
78. e displays the electromagnetic torque response from the above speed change while the figure below displays the phase A current during the same event EY BLDC Version 3 0 C Program FilesWMagneForceMldcWprojectsM 50x80mm 6pole 3ph bldc Results Transient Test Design Sheet for project 150x30ma 6pole 3ph Loren Field type fe Palamara Expat pa field Number of poles ter disneter Steck length Armature skev in slots Transient Test Tora N M 4 1 7 01 78 RPM 5000 Pertoraance Table 150xS9 mm bpole 3ph bldc tr res tor pro Vili Iline lav Vithd Pin Pout v A Ux W V 24 8 24 8 45 n 2719 2586 92 6 48 3 48 3 31 8 4268 4091 Freq 250 EY BLDC Version 3 0 C Program FilesWMagneForceWldeWprojectsM 50x80mm 6pole 3ph bldc Results Transient Test Tables Fa Tora RPM Freq Vll i V thd Pin fe Palamara Erpat N M Rpm Hz v iW 412 6000 300 891 450 2719 I DE aad ERES i 7 01 S000 250 92 6 31 0 42098 Transient Test Perlorasnos Table l150xS8 mm 6pole 3ph bldc tr res for proj f pad XDaa time gt Loac t a Load 1 Ith e Load 1 Ife The above figure displays the 3 phase machine currents before during and after the rotational speed change All of these parameters xy coordinate data are available for export into Notepad or Excel by utilizing the EXPORT button D BLDC Version J 0 C Wirogian Fi
79. e software The security key will either be the parallel port variety or the USB variety In the case of the USB variety your computer will perform a brief installation routine the first time that the key is inserted in each USB port Congratulations Software installation is now complete Starting BLDC BLDC zs written to follow normal Windows operating standards and conventions To start BLDC Click the START button e Goto PROGRAMS e Click on MAGNEFORCE SIMULATION SUITE e Click on BLDC e The following screen is displayed If this is the first time you have started BLDC or you have not saved any projects your only option will be to select NEW from the PANEL TOOLBAR Doing so will give you a list of default projects from which to choose Y BLDC Version 3 0 File Action Window Tools Help L New Project Sele Choose a default project 150x80mm 6pole 3ph 1ph bifilar wdg unipolar drive 2ph bi filar wdg drive Cancel Outer PM 150x80mm 6pole 3ph SEE Choose a project that most closely resembles your desired project Once a choice has been made you will be prompted to save the project under a new name At this point you may choose to save the project to any folder you wish The default project location is C PROGRAM FILES MAGNEFORCE BLDC PROJECTS 2 BLDC Version 3 0 Sana CS pececis t tj e EJ 2 Eo tik ZH 15000mm CeO be Ed zph bifilar wach defen bii T lecim Apol Aph hice MyRecent Si ach bi
80. e table can be adjusted and the results reflected in the curve to the right Simply click on an entry and change it The table will be immediately sorted and the graph updated Additional data points can be added by using the scroll bars to position the cursor at the end of the table Simply enter your new values and the graph and table will again be immediately updated The viewable size of the table and the graph area can be changed Simply position your cursor on the area between the table and the graph area and click and drag to the desired size 41 After modifying the material properties you may click the SAVE button found along the top of the settings panel Upon doing so the program will open a dialog box requesting you to save the material with a new name The system will not allow you to over write a default material If however you have opened a user defined material the system confirms that you wish to over wtite the existing material and does so BLDC Version 1 0 C Program Files MagneForce BLDC Projects 150x80mm 6pole 3ph bldc Setting aj E Field Explorer cS Steel Lamination Close BH Curve Iron Loss Tesia A m Watts Kg m19 0 50mm usr bhw FE Solver amp Mesh Control 25 Min Distance 1e 5 vr Rot Mesh Density 1 0 vr Sta Mesh Density 1 0 Forced airgap layers 1 Y 3D Field Correction 0 00 v x i i Order of Elements 1 Save As 2 JL
81. either the table and the graphs or between the two graphs and click and drag to the desired size 44 After modifying the material properties you may click the SAVE button along the top of the settings panel Upon doing so the program will open a dialog box requesting you to save the matetial with a new name The system will not allow you to over write a default material If however you have opened a user defined material the system confirms that you wish to over wtite the existing material and does so Results Field Explorer Ks PM Material e Steel Lamination Nev Ipe Close Save C BH Curve lronLoss Loss Model Tesla A m Watts Kg m19 0 50mm usr bhw Loss Curves 1200 50 Hz 0 5800 i iras MADE Rx MR LE DN d MEL Lo MM ee CC 1 010 c TA E E RE 2170 TET SPEED spe a Re Ra Es Save As 3 020 E 4 200 Save in Magt eferk E3 FE Solver amp Mesh Control Min Distance tes Rot Mesh Density ho gt Sta Mesh Density fio x Forced airgap layers 1 i 5 030 6 640 9 300 12 48 J cQ bhw E M19 0 50mm bhw isi M19 0 50mm usr bhw E M36 0 64mm bhw Parameters K amp Y Curves 3 0e 01 2 0e 02 ir 1 0e 01 0 00 0 50 1 00 150 200 250 B Tesla 440 00 110 00 550 00 220 00 330 00 Frequency Hz Save Current Material File Save j eb sses
82. ents 1473 M Torque done Open Circuit OP Inductance Computation Solver started at 10 23 57 10 18 2006 System Simulator FE rotor position range 60 00 degle SimuLink Flux and inductance mapping 3 6 Saber Load 1 iteration 1 Simulation succeeded Normal finish at 10 23 57 10 18 2006 Data Link ready please start SimuLink now Finite Elemente Run Simulation m r fis Abort Execute You may now minimize this window start Simulink and perform the desired simulation All viewing and plotting of results is done in Simulink fot these simulations 62 MESSAGE BOX BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help E E Setting Desian Field Explorer Parameters Load Test Transient Data Link Amb Temp 122 Vs Driven by noe EE Inverter Circuit Use Tabular Input AFAnge M Vs u i T Inverter Seer Mechanical Output Demag Prediction Ckt Inverter local square voltage Load Pts 4 Specify RPM Wdg Temp Given 7000 120 0 7000 110 0 7000 100 0 7000 30 0 Solver Progress Run Simulation Parameters Execute Load Test Transient Abort FE rotor positions 15 0 per per slot pitch g pole pitch Tol Control Apply Cancel in The right hand portion of this panel contains a message box in which the simulation progress is tracked As the simulation proceeds you will see mess
83. er write a default material If however you have opened a user defined material the system confirms that you wish to over wtite the existing material and does so p BLDC Version 1 0 C Program Files MagneForce BLDC Projects 150x80mm 6pole 3ph bldc Setting EH 5 mmm uu V e i Field Explorer PM Material C 5i l Close Save BH Curve C lior K Gauss K Dersted vac 677ap pmt FE Solver amp Mesh Control Min Distance 16 5 Rot Mesh Density 1 0 Sta Mesh Density 1 0 Save in Magat my EJ Forced airgap layers la xl Ie Mq1 08 pmt 3D Field Correction 0 00 Ed TDK FBSE pmt Order of Elements NES quce E Deis E Vac 677ap pmt s 2 E Vac 688ap pmt 41414 4 4 4 User Defined Coefficients Fid Wdg ET i Permeance 1E 6 Filename MER ea e 757 B Am W dg ET rM 2 Save as type PM Material Type Ppr v Cancel Defauits 09700 07660 7 j n _ Apply __Cancel_ an ree EE User Defined Functions 0 03120 0 5070 a 0 8770 0 3820 0 8370 0 2700 18 60 12 40 H K Oersted Save Current Material File start K Inbox Outlook Express mw BLDC Manuali Micro Bldc A new material can be defined by closing any open material using the CLOSE button and then clicking the NEW button The system will request a name and then open the material with blank tables You can then populate
84. f Elements fi M19 0 50mm usr bhw fault E 36 0 64mm bhw _ Defaults User Defined Coefficients Fld Wdg ET Permeance 1E 6 Am W dg ET OI Pemeance 57 Default Files of type Steel Material Type bhw Cancel elauls A npnply 2arncel User Defined Functions lron Loss Mode Magnet Overhang C e OPen an Existing Material File utlook Express taj BLDC Manuali Micro gn Bldc 40 Select a material and click OPEN BLOC Version 1 0 C Program Files amp MagneForceXBLDCXProjectskd50x80mm 6pole 3ph bldc Setting Sele File Action Window Tools Help Field Explorer 5 f Steel Lamination Close Save f BH Curve Iron Loss Tesla A m watts Kg m19 0 50mm uer bhw T FE Solver amp Mesh Control l Min Distance He Hat Mesh Density 10 l Sta Mesh Density 1o l Forced airgap layers a l 3D Field Correction o oo Order of Elements Ho l Defaults User Defined Coetticiernts Pameance E pone 5E Dew __Caneel_ User Defined Functions oO 20000 00 100000 00 150000 00 200000 00 250000 00 Li H CAAT m i D a Similar to the permanent magnet material the B H curve for the steel material is displayed in both tabular and graphical format The name of the selected material appears just above the B H tabular values while a graph of these points appears to the right The values in th
85. f the inverter switches It is important to note that all switches should be set similarly it would not make any sense to have some of the switches operating under one control scheme while others are following a different scheme To set each switch double click it and select one of the SYSTEM modes in the ALGORITHM parameter as shown below 29 Mame 11 Change Mame s17 RotcrAng Control Rotor ng Delay Er sec Algorithm ang Current LocaiSauare Voltage 5 ustem Square Valtage C usar IE sabare Lucie Sustem FwVM Freefarm 7 5 System Bang t Bang Current V at 1 Amp Resistance Rotate ef Scale Bgl 30 Once all system switches have been set appropriately you may click on the ROTOR ANG PWM button to further define the selected control scheme The 3 different PWM modes that BLDC can simulate are as follows System Square Voltage uses a strategy to try and keep the phase voltage to the motor to be a square wave Conduction Band is the conduction band in degrees of the base waveform PWM Style Frequency is either set to FIXED or Fc Fb and is the style of the frequency of the carrier wave PWM Freq or Carrier Base if above parameter is set to FIXED then this is the frequency of the carrier wave if above is set to Fe Fb then this specifies the ratio of the carrier to base frequency Modulation Index is an index that controls the PWM switching Feedback Control specifies whether feedback is employed and can be set to
86. f this meter will appear in the results portion of the program It s attributes consist only of name which is automatically generated sequentially however may be changed if desired e Voltmeter can be placed across any portion of the circuit in which you would like to know the voltage Upon simulation the results of this meter will appear in the results portion of the program It s attributes consist only of name which is automatically generated sequentially however may be changed if desired BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit Armature Excitation Inverter mj AJAA e Quick Parameter Set Invertor amp dvanced Firing fo Degrees Invertor SW Dead Angle 0 1 Degrees Advantage of Symmetry Iv Phase to Phase Iv Bi Polar At B C N 3ph Y Arm Winding Select Al Clear All Apply Cancel Once all appropriate components have been placed upon the schematic drawing area you may connect them to form the desired drive circuit To connect components roll your cursor over the device endpoint until a red circle appears At this point left click and drag to the next component Please note that as soon as you left click the first component the cursor will change to 28 a hand symbol and remain until the connection to the other compo
87. filar vido drive bide Ed 1 cto pole Goh bkit Document Eri CN AMatri EWIDO bik T Hi1 mm pale Space Tiia amp Makrix EVr2600 PED ble Ed Bn bee id CR tantric SRD de t aa ET vay For cbe Jan lee T Biker 584863 original bl iTi 24k 30cog blc d Dakar 05563 bk id Serger et 24i sOcQ eh bide Td Bakker BMG 3 excernix icc EH 37 frame 2652 bie T Balter ESME3 menembar_ cogn T Ed Poem Zpole Lph bl e d taller DG excerte_cogging U ird POR 2 pole 2ph bie T Bakker KIMA Tentet igj ft T SiTi pede ph ble T Balder EME3 excenbe cogna 0 El 120 Form boole pth bide fd akde ihesten togara m 151r apale ph bik T Baker PSIG renard bei After Clicking SAVE your newly named project will be opened and you will be placed at the DESIGN panel BLDC Version 3 0 C Program Files MagneForce bldc projects 150x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit m Field Armature z Type type613 zl Type tope 703 Outer Dia pemi Outer Dia a Inner Dia fo Inner Dia 18 Num Poles 6 Num Slots 18 Magnet Arc Style CE Tooth width K Yoke Width e o Magnet Thk ES Slot Open 25 Magnet Ww 26 6 Tip Def E Tip Thickness I 5 Foot Thk 1 5 Tip Rad 0 5 Slot Top A E Slot Bottom A 5 Slot Wedge Thk 1 57 Stack po Skew fo X Weight 1 141 Weight 5 833 A listing of recently
88. form Conduction Band active only for the Trapezoid or Square wave options and is the width of the base wave Peak Value is the maximum of the phase current that we are trying to control Tolerance is the tolerance around the above peak value that the control scheme will operate around FAI System Switch Control Rotor Angle Based Bang Bang Current System 6 ang Bang Current Drive Base Waveform Sine Switch phase AF angle AF angle Peak Value A 50 Tolerance 1 8 Rotor pos angle amp 8 U at armature Rotational Ernt wg phase A switch Signal Base Waveform 33 Chapter The Settings Panel This panel allows you to examine and adjust the material properties of all magnetic materials loaded into the MagneForce suite of simulators Here you will find magnetic curves for both steel and permanent magnet materials This panel also contains global software parameters that control such things as mesh density When first selected the settings panel will be displayed as BLOC Version 1 0 C Program Files amp MagneForceXBLDCXProjectskd50x80mm 6pole 3ph bldc Setting File Action Window Tools Help Field Explorer C PM Material c Steel Lamination Mew Open Close Save BH Curve Iron Loss Loss Model FE Solver amp Mesh Contra No Maternal Selected Min Distance 1e 5 l Rot Mesh Density ra Sta Mesh Density 1 0 Forced airgap layers
89. h this parameter it should always be greater than the duration parameter above Vj at 1 amp is the switch junction voltage drop at 1 amp See below Resistance is the switch junction resistance See below These parameters should be available from the data sheet of the device and are used to construct a switch resistance model based upon the cutrent flow through the device The window to the right of these parameters shows the current vs voltage relationship of this switch based upon your input of these two parameters Mame 11 Change Name Control Roter ng Phase Angle 270 deg Algorithm Local S quare Voltage On Band Width i zl deg V at 1 Amp a 0 wolt Resistance a 01 ahm Rotate a LIE Scale 1 Cancel Diode attributes consist only of name which is automatically generated sequentially however may be changed if desired Voltage Source attributes consist of name source type AC or DC magnitude Ground point must be set as a reference typically on the negative lead of the excitation source The ground point does not have any attributes Intersection point is used to connect multiple component leads to a common voltage point within the circuit It s attributes consist only of 27 name which is automatically generated sequentially however may be changed if desired e Ammeter can be placed anywhere within the circuit in which you would like to know the current Upon simulation the results o
90. ically generated sequentially however it may be changed if desired and the inductance value is set in Henrys e Capacitor attributes include name and capacitance The capacitor name is automatically generated sequentially however it may be changed if desired and the capacitance value is set in Farads e Switch attributes include name control and a junction resistance model Name the switch name is automatically generated sequentially however it may be changed if desired Control Rotor Ang Phase Ang in simple rotor position feedback control the degree at which the switch will turn on Algorithm can be set to one of 4 different choices which determines simple rotor position feedback local square voltage or one of 3 different PWM control schemes which are described in more detail in the next section On Band Width amount of time the switch will remain on in degrees Time the switch operates for a predetermined time as described by the following parameters Delay the delay in seconds if any before the switch starts operating Algorithm Pulse Local used to pulse the switch according to the following parameters ot Time Local used to control the switch according to time Frequency the frequency of the pulse Duty Cycle in per unit the ratio of the on to off time of the switch 26 Duration is the time the switch remains closed in seconds Cycle is the time in seconds that the whole operation will repeat Be careful wit
91. ifies the ratio of the carrier to base frequency Modulation Index is an index that controls the PWM switching Feedback Control specifies whether feedback is employed and can be set to NONE TARGET CONTROL or LIMII CONTROL None no feedback is utilized Target Control is a targeted or desired value that you wish to achieve Limit Control is an upper limit value that you do not wish to exceed Target describes the targeted parameter either the armature phase current Armature A or the DC Bus current I am11 Measurement describes the measurement of the above parameter either RMS Average or Instantaneous Value the actual targeted value of the above parametet AA System Switch Control Rotor Angle Based Pw Square Voltage 5 ystem 5 quare Voltage PWH Drive Conduction B and 1 20 switch phase PWM Freq Style Fixed AF angle Pwm index vb vc Pw Freg 5000 oe sere Modulation Index 03 in cael t ve Feedback Control None il 600 Rotor pos angle amp 8 0 at armature wd phase A switch Signal Rotational Erf 32 System Bang Bang Current employs a control strategy to try and keep the motor phase current as close to a specified waveform sine trapezoidal or square as possible Base Waveform is either set to SINE TRAPEZOID SQUARE or FOURIER If Fourier is chosen then the table below should be filled in with the magnitude and phase of the Fourier series you would like to use to create the Base wave
92. ift the image click the 4 Arrows button then move your cursor to the drawing area and click and drag the image the desired distance The button labeled N is the nodal button which when clicked displays information about the nodes This button is most often used in conjunction with the wire mesh check box An information box will be displayed that contains parameter information about two different nodes labeled PO and P1 and you will be allowed to click on the wire mesh The most recently clicked node is P1 and the node clicked just prior 1s PO In the nodal information box the x y r Theta and Az parameters are listed Just below this 1s the differential information between PO and P1 Listed here are Delta x Delta y Delta Az as well as the Vector Length and Direction Below this 1s a Flux calculator that will give you the flux in Webers for a given depth between P1 and PO E BLDC Version 3 0 C Wiroga Elbe Maa F orco Made pro jecks VI Seton gpele 3plibldc Field Esplsrar TONY NVA MSAN E x Flux webi Hi 20 6 Depth Kec Fiux Cale gen i pts GRRE a EDEN AI NAIVE QQS SAAN NON AE VR D NANANA W NND pk 2 M TA SA Z y zd iv EEL lo Loo D i E 8 88 Under the nodal information button is a button labeled E which is the elemental information button This button is similar to the nodal information button except that it displays information about the currently selected finite element
93. illimeters e Num Slots is the number of armature slots This parameter must be an integer multiple of the number of phases e Tooth Width measured at the tooth stem in millimeters e Yoke Width is the distance from the bottom of the slot to the outside diameter of the armature in millimeters e Slot Open is the slot width at the opening measured in millimeters e Tip Def e Tip Thickness at the slot opening in millimeters e Foot Thk foot back thickness in millimeters e Tip Rad tip radius in millimeters e Slot Top R corner radius at top of slot in millimeters e Slot Bottom R corner radius at bottom of slot in millimeters 13 e Slot Wedge Thk is used if slot wedges are used and is the thickness from the inner diameter towards the outer diameter measured in millimeters MOL Werwan LU iW nog ras Piles age ance Mi hde ipara ata JI Iph bie Lievig n IW In Fw A Lambon Goecelry Maher ursatare Winding Mechanical Drive Circuit Hrid fumatunn El Type peti E Type ipar Duter Dia 74 4 Der Dia 165 5 Inner Dia 20 tones Doo 77 0 MumPales 5 Ham ski ha MEO Ste 1 zi Tooth wil 77 M Armature Repository Yoke width fg Maget Th ize Swapan s Hagi W 20 6 Te Dd 1 Tie Thickness 5 Fool Thi 15 y Tip Bad 0 amp 2 Si Top A i Type ahi caer ler Hatin A s f Slot Wedge Thk 157 J type cam 1 ilak en Shaw o weigh 1 141
94. l be forced 3D Field Correction is parameter that corrects for 3D effects If yout machine is heavily saturated you can choose to add up to 10 flux linkage amp inductance due to the end effects with this parameter Order of Elements can be set to either 1 or 2 to use first or second order finite elements Please note that cogging torque calculations always use second order elements 35 USER DEFINED COEFFICIENTS amp FUNCTIONS Under the solver and mesh control parameters are several settings that allow the user to describe end turn effects and to invoke an iron loss model and or a permanent magnet overhang model The default button can be used to restore these parameters to their original values e Fld Wdg ET Permeance is a coefficient that describes the permeance of the end turn winding of the field e Arm Wdg ET Permeance is a coefficient that describes the permeance of the end turn winding of the armature e Iron Loss Model is currently not implemented within BLDC e Magnet Overhang Coeff is currently not implemented within BLDC BLDC Version 1 0 C Program FilesuMagneForceXBLDCWProjectsVl 50x80mm 6pole 3ph bldc Setting Sele File Action Window Tools Help Setting Design Field Explorer C PM Material Steel Lamination New Open Close Save C BH Curve Iron Loss No Material Selected FE Solver amp Mesh Control Min Distance 1 5 Rot Mesh Density 38 38 v Sta Mesh Density 1 5 For
95. l result in the data from the last 2 AC cycles 52 of each load point being used to calculate the steady state performance for each load point being studied e Demag Prediction not available on the Transient Tab Below these parameters are several boxes for additional parameters e Total Steps is the number of total events or transitions from one operating point to another during a solution e Specify is set to either RPM or TORQUE and controls whether speed or torque is being given during the simulation e Wdg Temp is currently not implemented on this tab Below these parameters is the area where you further describe the operating points selected above All operating points will require the following parameters e Start Time is the time in seconds at which the operating point will take effect Note this point should be before the end time as specified above e RPM is the speed of the machine in revolutions per minute e AF Angle is the advanced firing angle used during the simulation This parameter will override the setting on the Drive Circuit tab of the DESIGN panel e T fld is the temperature of the field winding in degrees Celsius e T arm is the temperature of the armature winding in degrees Celsius Below this area is a field labeled e INITIAL RPM amp Rotor Ang Deg are the initial speed and rotor angle of the machine This parameter is simply a starting point and used only when TORQUE is the given parameter as the
96. ldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help m i Setting Design Field Explorer Parameters Load Test Transient Data Link C Dynamic FE Data Link Vs Temperatures Amatue 25 Field 25 1 Incremental L Matrix i Armature Current Style Function of Rotor Position PQ Range Sweep Inverter Work Sheet L 2 Mechanical Output Style Sinusoidal Dutput File N ame Ref Frame ABC C mymodel m Bl la pk A DigitVariable la Ea dea DigitVariable Voltage Coefficient in V rpm WriteMagCurveSimulink l Ea 61 Add to Table Clear Table e0 e0 1 0 Self amp Mutual Inductance in Henr WriteMagCurveSpice l Laa 37 gm DLO Cos lewriteMagCurveSimulink l Lab 3 Pole number p UWriteParameter Npoles GoNext Moment of Inertialn in kg m z J WriteParameteri Jtotal GoNext Resistance of phase in ohm R WUriteParameter Ra 75 GoNext Solver Progress Run Simulation Execute lt gt FE rotor positions s 12 per Abon per slot pitch E Iv Data Link pole pitch In the static data link method BLDC pre solves for the machine s magnetic parameters and produces an output data file that contains all of the desired data The 3 party simulator then reads this data file for the parameters of interest at the desired time step The structure and content of the data file produced by BLDC is under the control of the user a
97. let Wagar orcetblde projects 1 mm amp pele 3pl bldc Results Sie cm Wire us Hen Pametan Load Text Transat Tranier Tear Design Sheet for project 150a00en pole mi fi Tables Fimld type pe_fiold Wumber ol pales Trensient Test Performance Table 150x50am 6pole Jph bldc tr res for project 15025 Torq e Freq 1 Hom je V ibd ein rom amp j p Sa a ds i bis iege 155 5 7 81 so 48 3 4 3 231 8 4288 A031 ll Lon Rs MI Lon Wb I Le e 7D 0 36 0 79 P Notepad File Edit Format wiew Help ime sec Q 1 6 1 1 1 1 2 2 2 3 3 3 3 4 4 4 id 5 5 5 5 D OO00er 00 B OOnDe 0s 250858 06 145228 05 921281e6 05 78850 05 995276 0 5 24911e 045 i38458 05 f 538538 05 OO 7098 045 l1895548 05 2265508 05 31726 05 03814e 05 2904 76 05 J 8728 05 a 08128 05 50828 05 234528 05 19020 05 8568558 05 Load 1 Ifa CAD 00000e 00 Bs350er Bl5924er 00 O84 66 00 2903 66e 00 214238e4 00 44116er 361626 00 83296 00 137246 00 021036 00 9302 786 00 34240400 28005er 450653er 0 0 2 9045 56 00 1 7396e 00 654 908 01 04 9588 01 B23338 Ul aff54e Ul 10699 01 Load 1 ICh CA zl mr eig ee 3 sgi sas 3 ee m ES SET SEE 3s 3 p m sai 3 FA noQQer ji587 0er 0 141568400 3 1858r 0 0 a5055er 3566284r0
98. lorer File Action Window Tools Help Manual Excitation Existing Results MagnetActive M Rotor Ang deg m 0 0 Magnet Temp 20 0 W dg Current Dmp Bar Current B Kk TE Draw Export Animate Display NA eA ANO N ONE Iv Geometry Lines V Wire Mesh SSRIS AAA VRE ONO ET MA FEM S CORR Flux Lines Bmag Shade Br Shade Current Density Operational lz eleloo T Ww Jc ls EN The next option is the Material Shade check box which displays the distinct materials in the cross section with different colors 83 BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Field Explorer Manual Excitation Existing Results MagnetActive M Rotor Ang deg m 0 0 Magnet Temp 20 0 Wdg Current Dmp Bar Current Draw Export Animate Display V Geometry Lines v Material Shade Flux Lines Bmag Shade Br Shade Current Density perational T iron Loss Density Br Shade lz l l olo Manual Excitation Existing Results MagnetActive M Rotor Ang deg m o o Magnet Temp 20 0 W dg Current Dmp Bar Current Draw Export Animate m Display 3 V Geometry Lines Wire Mesh Iv Flux Lines Bmag Shade Br Shade Current Density perational Iron Loss Density Iu
99. ltage Below these parameters are several check boxes for additional parameters e Demag Prediction when checked the program will calculate any potential demagnetization of the permanent magnet material while under load e Load Pts field specifies the total number of load data points that you wish to simulate After specifying the number of points here you will be given the opportunity later to further specify each load point e Specify is set to either RPM or TORQUE and controls whether speed or torque is being controlled during the simulation e Wdg Temp is currently not implemented on this tab BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help Field Explorer Parameters Load Test Transient Data Link Amb Temp p2 Vs Driven by DN pares Inverter Circuit v 1 Use Tabular Input AFAngle M Vs r Mechanical Output Demag Prediction Ckt Inverter local square voltage Load Pts 4 Specify RPM Wdo Temp Given 7000 120 0 7000 110 0 7000 100 0 7000 90 0 Solver Progress Run Simulation Parameters peer Load Test FE rotor positions Jx 15 0 per Transient per slot pitch pole pitch Tol Control Apply Cancel In rares 50 Below these parameters is the area where you further describe the load points selected above Depending upon the selections from above the table may contain the following fields
100. ltage Coefficient in V rpm for WriteMagCurveSimulink 3 Ea 61 12 per pole pitch Finished for material L2 Finished for material L3 Finished for material L4 Finished for material L5 Finished for material LE Finished for material L7 Stator nodes 809 elements 1473 done FE rotor position range 60 00 degle Flux and inductance mapping 3 Load 1 iteration 1 Winding OC inductance and flux linkages done FE rotor position range 60 00 dea e Flux and inductance mapping 3 Load 1 iteration 1 Load 2 iteration 1 Load 3 iteration 1 Load 4 iteration 1 Normal finish at 12 06 54 10 18 2006 FE done now generating output file Borland C 5 5 1 for Win32 Copyright c 1993 2000 Borland C Program Files M agneForceXBLD CAT emp 150 80mm 6pole 3ph temp cpp Warning W805 C Program Files MagneForce BLDC T emp 150 80mm 6pole 3ph temp cpp 69 Parameter argc is never used in function mainfint char Turbo Incremental Link 5 00 Copyright c 1997 2000 Borland Stack DataLink output file saved Finite Elements Run Simulation Parameters Speciali LoadTest Special2 Transient Special 3 M Data Link Execute Abort Double click to bring up editor m Script Editor COGN RN l Cos D 0174533 theta 250 0 S Dos D L1 74533 theta 250 D a Las D L1 745 33 theta 230 0 1 Cos 0 0174533 theta 20 00 1 Co3 0 01 74533 theta
101. lts 2 2e 01 TM E NES i User Defined Functions Watts VKa Hz User Defined Coefficients K amp Y 1 4e 01 6 0e 02 Watts WWKgHz Parameters 2 0e 02 1 0e 01 04 0 00 050 100 150 200 250 0 00 11000 22000 33000 44000 55000 B Tesla Frequency Hz Two additional graphs and one table will appear on your screen The graphs are the LOSS MODEL CURVES which plots Loss versus Frequency and the K amp Y PARAMETERS CURVES which plots K amp Y versus Flux Density The loss model curves are best fit curves to the associated data points which is the loss expressed in Watts Kg Hz vs Hz for a given flux density The slope and Y intercept of these best fit curves are then the K and Y parameters to the left which are plotted vs the peak flux density from a sinusoidal excitation This loss model is used in the program s iron loss calculation The table to the left contains the data points for the K amp Y Parameters The values in the table can be adjusted and the results reflected in the curves to the right Simply click on an entry and change it The table will be immediately sorted and the graph updated Additional data points can be added by using the scroll bars to position the cursor at the end of the table Simply enter your new values and the graph and table will again be immediately updated The viewable size of the table and the two graphs can be changed Simply position your cursor on the area between
102. n the winding table by comparing winding symmetry among the phases Under the drawing of the machine cross section is an APPLY and CANCEL button These buttons are used to apply or cancel changes in the geometry figures from above Next to these are four buttons for FIT ALL ZOOM IN ZOOM OUT and MOVE They can be used together with the scroll bars to enlarge and inspect your geometry When satisfied click the FTT ALL button to return the cross section to normal size After you ate satisfied with your design use the SAVE button on the panel toolbar to commit your changes to disk 20 MECHANICAL TAB BLDC Version 3 0 C Program Files WMagneForce bldc projects 1 50x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit Fan amp Stray Losses Fan Power Coeff 1E 11 Stator HF Loss Coef 0 Rotor HF Loss Coef p Thermal Model None Moment of Inertial Rotor M 1 338e 3 Additional M 0 Total M I 1 339e 3 Gearing Efficiency 1 Viscous Torque Loss 0 Apply Cancel This tab allows you to enter mechanical parameters that describe the machine s mechanical properties The active parameters are e Fan Power Coeff is a parameter that describes the wattage absorbed by the machine s fan in Watts per cubic rpm e Stator HF Loss Coef estimated high frequency eddy current loss in stator in Watts per cu
103. n 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help E me we Setting Design Run Results Field Explorer Manual Excitation C Existing Results Magnet Active lv Rotor Ang deg m 10 0 Magnet Temp 20 0 Wdg Current Dmp Bar Current Mechanical Degree Step Angle Repeat Angle Animation Speed Input the following parameters e Step Angle is the increment between each rotor position solution point p Ang p p e Repeat Angle is the total angle that BLDC will calculate to It will start at zero and calculate up to this point Once the two parameters have been entered click the Calculate button and BLDC will step through the desired positions calculating the field parameter chosen Upon completion you will see the screen below 94 BLDC Version 3 0 C Program Files WMagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help gt Emm Setting Design Run Results Field Explorer Manual Excitation C Existing Results Magnet Active lv Rotor Ang deg m 1160 Magnet Temp 20 0 Wdg Current Dmp Bar Current Mechanical Degree Step Angle 20 Repeat ngle 1180 ES Animation Speed lt q Stop Pause gt Click the Start Resume button to start and stop the animation being displayed You may use the Animation Speed scroll bar to speed up or slow down th
104. nd is defined by completing the following fields Temperatures Armature Temperature of armature in degrees Celsius Field Temperature of field in degrees Celsius Armature Current Style Rotor Position Dependant In this case the armature current is dependent upon the position of the rotor at any given time The details of the armature current waveform are entered and described below in the work sheet section Range Sweep In this case the armature current is dependent upon a set of fixed current values the details of which are entered and described below in the work sheet section Work Sheet This is the area where we describe the waveform and or magnitude value of the armature current 55 Style Used in the Rotor Position Dependant case to desctibe the waveform of the armature current choices are None Select when you wish to use the flux from the PM materials only and to ignore any armature reaction Sinusoidal Select when you wish to simulate using a sinusoidal armature current waveform in addition to the PM generated flux Square Select when you wish to simulate using a square wave armature current waveform in addition to the PM generated flux Ref Frame Specifies the frame of reference that the calculations and data file will be produced in Options are ABC refers to the normal time domain ABC reference frame Multiple values can be entered separated by a comma so that BLDC will calculate the magnetic parameters at e
105. nent is made You may move individual components or connection lines by simply clicking and dragging the component to its desired location BLDC Version 3 0 C Program Files WMagneForce bldc projects 1 50x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit Armature Excitation Inverter AN zl AJAA f amp Quick Parameter Set Invertor Advanced Firing 0 Degrees Invertor SW Dead Angle 0 1 Degrees Advantage of Symmetry Iv Phase to Phase Iv Bi Polar 3ph Y Arm Winding Select All Clear All Apply Cancel When all suitable connections and movements have been made select Apply at the bottom of the drawing area and your circuit will be saved At any time before you click Apply you can click Cancel and all changes in the drawing area since the last Apply will be erased To the left of the Apply and Cancel buttons are the Select all and Clear All buttons Use the Select All button to highlight all components on the drawing area You may then click and drag all the components as a group The Clear All button will clear the entire drawing area In the upper right hand corner of the drawing area there 1s a button labeled ROTOR ANG PWM This button allows access to the 3 different PWM control schemes that are part of BLDC The button is normally graded out until a PWM control scheme 1s selected in the attributes of at least one o
106. ngle is the total angle that BLDC will calculate to It will start at zero and calculate up to this point Once the two parameters have been entered click the Calculate button and BLDC will step through the desired positions calculating the field parameter chosen Upon completion you will see the screen below 109 BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help gt Emm Setting Design Run Results Field Explorer C Manual Excitation Existing Results Load Test Load 1 Rotor Ang deg e 1160 0101 Magnet Temp 40 00 W dg Current Dmp Bar Current Electrical Degree Step Angle 20 RepeatAngle 1180 ES Animation Speed lt q Stop Pause gt Click the Start Resume button to start and stop the animation being displayed You may use the Animation Speed scroll bar to speed up or slow down the animation You may also use the Red Arrows and the Pause button to step through each of the rotor positions manually When finished viewing the animation click the Exit button to return to the normal field explorer display 110
107. nsity BrShad 96 In the box below the draw button you will have several options The first is Geometry Lines which is automatically selected This check box causes the machine s cross sectional geometty to be displayed to the right BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help C Manual Excitation Existing Results Load Test Load 1 Rotor Ang deg e 0 0 Magnet Temp 40 00 W dg Current Dmp Bar Current Draw Export Animate Display MV Geometry Lines Wire Mesh Material Shade Bmag Shade Br Shade Current Density Operational Iron Loss Density r of j le l gt e oo D The next option is the Wire Mesh check box which displays the finite element mesh used in the solution BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help WA C Manual Excitation Existing Results Load Test Load 1 Rotor Ang deg e 0 0 Magnet Temp 40 00 Wdg Current Dmp Bar Current XS peus s CAND ALS BE BASS as F ten A ae e gt m WENA AZ Nec Draw Export Animate Lap Display d A V Geometry Lines z CN lv Wire Mesh i p X X LF SCR ht AKA Lo n EAX m F ASSETS SOK Br Shade A Current Densit NOE perational i S N LT an Kc SO aN
108. of the armature winding in Celsius Below this area is a drop down box that specifies the finite element rotor positions per slot pitch This parameter is used to take advantage of machine symmetry so that the number of finite element calculations can be kept to a minimum and thus decrease simulation time To the right is a TOL CONTROL button that allows certain solution tolerances and simulation starting points to be changed The default values for these parameters should work in almost all cases therefore we do not recommend changing these values unless directed to by MagneForce technical support To the right are the APPLY and CANCEL buttons that allow you to commit or abandon your changes 48 LOAD TEST TAB BLDC Version 3 0 C Program Files MagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help mm s Setting Desian Field Explorer Parameters Load Test Transient Data Link Amb Temp 22 Vs Driven by Inverter Circuit vy 1 Use Tabular Input AF nge M Vs Ba m Inverter Ft Mechanical Output Demag Prediction Ckt Inverter local square voltage Load Pts Specify RPM v Wdg Temp Given 120 0 40 00 40 00 6000 96 00 40 00 40 00 Solver Progress Run Simulation Parameters Execute Load Test Transient FE rotor positions 15 0 per _ Abon per slot Sch E pole pitch Tol Control Apply Cancel The load test tab layout is similar to the parameters
109. opened projects is available under the File menu Click FILE then scroll down the option list and highlight and click the desired project T BLOC Version 3 0 C Program FilesWlagmeForceMsldchprajecteM 50xB mm 6pale 3ph bldc Design CErogram Flezihtagneforcelblde projects mm pole ph bik i Gireg am Piet PMagrpsior coe blc ur o ecco rin OOO 135 99 vit bic 3 Cipro amn Files MageeForcelbldcpnropect s 1505 TOnmm pole 3pihi birie CM pregram Files Mages ores ble e pec e nur ble S C Erir ars Fiber Pasce For c Lee o capes pie PH 150 EDmm fags pi bike Cilfrogram FlesiPageeForcelbldcpenjectst 1 61e T mm pole 3ph blde Exit Foot Thk fis Te Rad n5 Skt Te FR fi Shot Boite Pi 5 filed Wick Thk fi 57 m o j amp j amp dd Mosen 1a or t0 E E Ina Micro Du EZ ELEC Manual Micros 7 TIGER Hemicpihers 10 Chapter The Design Panel In this panel you will define the physical dimensions of the machine as well as select the armature and field materials plus define the windings Whenever you create or open a new or existing project you will first be placed at the design panel This panel has five tabs e Lamination Geometry Tab e Material Tab e Armature Winding Tab e Mechanical Tab e Drive Circuit Tab File Action Window Tools Help Setting Design Results Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit M Field ES je SE Dute
110. opy of the enclosed Software for the specified number of uses or until the trial expiration date has been reached in the materials accompanying the trial versions of the Software 1 if using the single user trial version on a computer used by a single individual Thereafter you may purchase the right to use the appropriate full version of either the single user or multi user versions of the Software which license terms are specified below by contacting MagneForce or your retailer You may not copy the printed materials accompanying the Software if any or print multiple copies of any user documentation BY YOUR USE OF THE TRIAL VERSION OF THE SOFIWARE YOU UNDERSTAND AND AGREE THAT AFTER A CERTAIN DATE YOU MAY NOT BE ABLE TO CONTINUE TO ACCESS AND OR USE THE SOFTWARE OR ANY DATA YOU HAVE ENTERED INTO SUCH SOFIWARE UNLESS YOU PURCHASE THE APPROPRIATE FULL VERSION OF THE SOFIWARE Single User Version If you purchased a full single user version of the Software you are granted a limited non exclusive license to use a copy of the enclosed Software on the computer s used by a single individual You may make one 1 backup copy of the Software for your own use You may not copy the printed materials accompanying the Software if any or print multiple copies of any user documentation General Making additional copies of the Software ot enabling others to use your registration code s license file s security key s or serial number s
111. ower e Field Explorer Panel The field explorer panel is used to display the machine geometry finite element mesh magnetic field density current density and iron loss density These fields can be displayed for any of the load solution points BLDC allows you to create a new project from a pre defined list modify the project and then save it under a different name In this way you can work with several design variations simultaneously Projects can be opened and saved at any time and the number of total projects is limited only to the size of yout hatd disk drive Chapter Minimum System Requirements BLDC zs a powerful finite element based electromagnetic modeling software package and as such it performs a large amount of mathematical computations The two largest factors affecting system performance in software of this type are the processor speed and available memory Often times users can gain a significant performance enhancement simply by adding RAM Accordingly MagneForce recommends you equip your computer with the maximum practical amount of RAM Pentium III Windows NT 2000 or XP 256 MB RAM 200 MB free hard drive space SVGA monitor operating at 1024 X 768 resolution or 800 X 600 resolution if using small fonts Mouse pointing device Chapter Installing BLDC Installing BLDC zs an easy multi part procedure Farst the software is installed Secondly the license txt file must be copied to the appropriate
112. per table which is the B H curve at 20 degrees Celsius The lower table is the temperature coefficient table which describes how the B H curve changes with increasing temperature The columns in this table C M and C H are temperature coefficients that are simply multiplied by the B H values at 20 degrees Celsius Doing so yields the successive curves in the graph at the tight You will notice that the number of curves in the graph equals the number of tabular entries in the temperature coefficient table Additionally as you highlight an entry in this table the corresponding cutve is accentuated The values in the two tables can be adjusted and the results reflected in the curves to the right Simply click on an entry and change it The table will be immediately sorted and the graph updated Additional data points can be added by using the scroll bars to position the cursor at the end of the table Simply enter your new values and the graph and table will again be immediately updated 38 The viewable size of the two tables and the graph area can be changed Simply position your cursor on the area between either the tables or between a table and the graph area and click and drag to the desired size After modifying the material properties you may click the SAVE button along the top of the settings panel Upon doing so the program will open a dialog box requesting you to save the material with a new name The system will not allow you to ov
113. quessedsssenheesse rede o Ghkqpessnessss File name Z Save as type Steel Material Type bhw Cancel adi o L gt f 9 1 4e 01 w 3n pu Ei E 850e 02 a 3D Field Correction 0 00 w Ww Inbox Outlook Express mw BLDC Manuali Micro gn Bldc In the upper right corner of the settings panel is the units selector drop down box This selector box allows you to view the B H curves and tables in the units of your choice The available selections ate Tesla amp A m amp Watts Ke or Tesla amp KA m amp Watts Kg or Tesla amp A m amp Watts Lb ot Gauss amp Oersted amp Watts Kg or KGauss amp KOersted amp Watts Kg or Gauss amp Oersted amp Watts Lb or KGauss amp KOersted amp Watts Lb Select the units with which you are most comfortable 45 Chapter The Run Panel Once you have selected and described a machine the run panel is used to select the type of simulation plus initiate the simulation process Choices of simulation include parameter load transient or data link Once a type is selected you may then select the number of data points associated load parameters and finally begin the simulation When first selected the run panel will be displayed BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Run File Action Window Tools Help E m m Setting Design Field Explorer Parameters Load Test Transient Data Link Amb Temp
114. r Dia 74 4 Inner Dia po 1 Num Poles 6 X Magnet Arc Style poo Magnet Thk 24 Magnet WwW pes Armature ES Type tvpe 703 Duter Dia m Inner Dia 78 Num Slots 18 Tooth Width S Yoke Width g Slot Open 25 Tip Def E Tip Thickness n5 Foot Thk 1 5 Tip Rad 0 5 Slot Top A E Slot Bottom A 15 Slot Wedge Thk 1 57 Stack 80 Weight 1 141 Skew fo weight 5 833 LAMINATION GEOMETRY TAB BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit Field Armature Tye Type Outer Dia 44 Duter Dia i555 Inner Dia o Inner Dia 78 Num Poles Num Slots ig Magnet Arc Style is Tooth Width lar Yoke Width B o Magnet Thk 24 Slot Open 5 Magnet w 266 Tip Def 1 Tip Thickness 5 o FotThk i5 Tip Rad 5 Slot Top R n Slot Bottom R 5 Slot Wedge Thk 1 57 Stack 80 Skew Weight 1 141 Weight 5 833 AJAJAJ gt Modiy Draw Air gap 1 700 This tab has sections on the left that describe the physical dimensions of the field armature and machine in general On the right is a cross sectional drawing of the machine The field parameters will vary depending upon the exact rotor geometry chosen The following is for
115. rameter and when selected displays the residual flux density in the permanent magnets 85 BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Field Explorer Manual Excitation Existing Results Magnet Active M Rotor Ang deg m joo Magnet Temp 20 0 W dg Current Dmp Bar Current Draw Export Animat Display amp V Geometry Lines Wire Mesh Material Shade Flux Lines Bmag Shade iv Br Shade Current Density perational Iron Loss Den sity Br Shade l l l l lelle The scale of the flux density can be changed by double clicking the legend and changing the settings as desired C BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Manual Excitation Existing Results Magnet Active M i V Auto Scale Rotor Ang deg m joo I From o Magnet Temp 20 0 To W dg Current Dmp Bar Current 3 D Steps 10 s c Draw Export Animate Display NV Geometry Lines Wire Mesh Material Shade Flux Lines Bmag Shade v Br Shade Current Density Operational Iron Loss Density Br Shade il le le sooo The final parameter that can be displayed 1s the Current Density which when selected will show the current density in
116. ree and certify that neither the MagneForce Software nor any direct product thereof is being or will be used for any purpose prohibited by the Acts You agree and certify that you are not a citizen ot permanent resident of the following countries Cuba Iran Iraq North Korea Libya Sudan or Syria General Provisions This Agreement sets forth MagneForce s and its Representatives entire liability and your exclusive remedy with respect to the Software You acknowledge that this Agreement is a complete statement of the agreement between you and MagneForce with respect to the Software and that there are no other prior or contemporaneous understandings promises representations or descriptions with respect to the Software This Agreement shall govern any services or content related to the Software unless such services or content are subject to a separate written agreement between you and MagneForce or its Representatives However the limitations of liability and disclaimer of warranties in this Agreement shall apply to MagneForce and its Representatives with respect to such content or services except to the extent provided otherwise in a separate written agreement approved by MagneForce between you and MagneForce or the applicable Representative s This Agreement does not limit any rights that MagneForce may have under trade secret copyright patent or other laws The Representatives of MagneForce are not authorized to make modification
117. ribed in the next section e Magnetization Orientation describes how the permanent magnets are magnetized Choose radial if the magnetic field emanates radially from the rotor or parallel if the field lines are parallel to each other e Center Offset is active only when radial orientation is chosen It is the angle at which the field differs from straight radial e Relative Angle is active only when parallel orientation is chosen It is the angle that the field differs from straight parallel e Magnet Vol is a calculated value of the permanent magnet volume measured in cubic millimeters 16 The Lamination parameters are e Field Lam is the type of steel the field stack is constructed from please select from the drop down list 5 e Armature Lam is the type of steel the armature stack is constructed from please select from the drop down list Please note that if your particular steel does not appeat in the list you will have a chance to add it utilizing the settings panel which will be explained in the next section The damper bar parameters are e Bar Ohm Per Meter is the resistance of the bar material measured in ohms per meter e End Ring Ohm Per Meter is the resistance of the end ring material measured in ohms per meter e Bar Risa calculated parameter and is the actual machine bar resistance in ohms e End Ring Rd is a calculated parameter and is the d axis resistance parameter of the end ring e End Ring Rq is a
118. rmance Esport Rpn Hz V Number of poles 6 T 7000 350 86 9 3 60 Losses and Parameters Outer diameter 165 5 6000 300 68 2 3 43 Stack length 80 Armature skew in slots 0 xY Curves Fld lam 1 Grade M19 0 50mm Performance Export Total field lam weight 1 141 Waveforms rm lam 1 Grade M19 0 50mm Total armature lam weight 5 833 Fld mag 1 Grade TDK f b9b Total volume 1 48e405 omega t Armature lam dimensions Type Outer_Dia Inner_Dia OF OF Nw O ES e The name of the specific Load Test which was executed on the Run Panel will appear at the top of the data selection area Below this is the Tables area that contains two choices and an export button e Performance when this is selected the performance parameters will be displayed in the tabular data output area to the right e Loss Separation when this is selected the loss parameters will be displayed in the tabular data output area to the right e Export button is used to export the performance loss data and or project design data sheet The output can be in either Microsoft Notepad or Excel 71 T BLDC Version 3 0 C Virogram FilesVdagneF orcelbide projects 1 x Umm amp pele 3ph bldc Hesulls Tables F Ped Lobie and Parbet AU Danes C Petomarce Exar f Waveho Arm lam i Total armatus Fld mag 1 se omega 1 1 5 Oot Oman pole Iph pm _fisid A 165 5 Total volume 2 Padum nce Tabl
119. s and should be treated as such Copyright c 2002 MagneForce Software Systems Inc All rights reserved P O Box 4652 Timonium MD 21094 Table of Contents CHAPTER 1 CHAPTER 7 About BLDC l The Run Panel Parameters Tab CHAPTER 2 Load Test Tab Minimum System Requirements 3 Transient Tab Data Link Tab CHAPTER 3 Message Box Installing BLDC 4 Run Simulation Check Box CHAPTER 4 CHAPTER 8 Starting BLDC 6 The Results Panel Parameters Tab CHAPTER 5 Load Test Tab The Design Panel 11 Transient Tab Lamination Geometry Tab 12 Materials Tab 16 CHAPTER 9 Armature Winding Tab 18 The Field Explorer Panel Mechanical Tab 21 Manual Excitation Drive Circuit Tab 23 Existing Results CHAPTER 6 The Settings Panel 34 FE Solver amp Mesh Control 35 User Defined Coefficients amp Functions 36 Permanent Magnet Material 37 Steel Lamination Material 40 46 47 49 52 54 63 64 65 67 71 77 81 82 96 Chapter About BLDC BLDC zs a brushless DC simulation environment It is designed for quick learning ease of use and the ability to provide powerful results The goal of this software is to allow the designer to experiment with such things as materials geometries and winding configurations without ever having to build a prototype The results provided by BLDC are as good as test data but achievable in a much shorter time frame and at lower cost As you will see BLDC provides parameterized results such as voltages currents
120. s book Limit of Liability Disclaimer of Warranty MaeneForce has used its best efforts in preparing this software and manual MagneForce makes no representations or warranties with respect to accuracy or completeness MagneForce Software Systems Inc 2002 Software License Agreement Software is defined as the MagneForce Software Systems Inc MagneForce computer program with which this Software License Agreement is included and any updates or maintenance releases thereto The use by You of any services or content accessible through the Software may be subject to your acceptance of separate agreements with MagneForce or third parties This Agreement applies to all standard versions of the Software and other branded or customized versions unless otherwise agreed Do not use the Software until you have carefully read the following Agreement This Agreement sets forth the terms and conditions for licensing of the Software from MagneForce to you and installing and using the Software indicates that you have read and understand this Agreement and accept its terms and conditions If you do not agree with this Agreement promptly return the Software and accompanying items to the place of purchase or as provided below within sixty 60 days of purchase for a full refund License and Certain Restrictions Trial Versions If this Agreement is included with the trial versions of the Software you are granted a limited non exclusive license to use a c
121. s in the run panel As you would expect output data belonging to the parameter test will be found on the parameter tab of this panel and load test results will be found on the load tab All tabs have essentially the same format 65 The left portion of the tab from top to bottom is the data selection area it allows you to select the specific parameters you would like to view ot export This area has two sections one entitled Tables and the other X Y Curves The Tables section controls what will be seen in the tabular data output atea to the right while the X Y Curves section controls what will be graphed in the area below The remaining portion of this tab contains a project design data sheet tabular data output area and a graphical data output area The design data sheet is a listing of all important design parameters entered previously on the settings and design panels The tabular and graphical data output areas are where the selected results will be displayed in tabular and graphical format BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Results File Action Window Tools Help Save i Field Explorer Parameters Load Test Transient Inverter Driven Test Design Sheet for project 150x80mm 6pole 3ph Inverter Driven Test Performance Table 150x80mm Tables Performance Export C Losses and Parameters Field type pm field M Freq Vli Hz Number of poles 6 1 56 70
122. s to this Agreement or to make any additional representations commitments or warranties binding on MagneForce other than in writing signed by an officer of MagneForce Accordingly such additional statements are not binding on MagneForce and you should not rely upon such statements If any provision of this Agreement is invalid or unenforceable under applicable law then it is to that extent deemed omitted and the remaining provisions will continue in full force and effect The validity and performance of this Agreement shall be governed by Maryland law without reference to choice of law principles except as to copyright and trademark matters which are covered by federal laws This Agreement is deemed entered into at Timonium Maryland and shall be construed as to its fair meaning and not strictly for or against either party Consumer Information and Privacy For details about MagneForce s privacy policies please refer to the MagneForce Privacy Statement contained either in the Software or on a website designated by MagneForce MagneForce the MagneForce logo BLDC and BLDC among others are tegistered trademarks and or registered service marks of MagneForce Inc in the United States and other countries MagneForcess com among others is a trademark and or service mark of MagneForce Software Systems Inc in the United States and other countries Other parties trademarks or service marks are the property of their respective owner
123. suitable to drive the selected armature Each individual component in this preconfigured inverter is selectable and its attributes modifiable by right clicking the component itself BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Design File Action Window Tools Help Field Explorer Lamination Geometry Material Armature Winding Mechanical Drive Circuit Armature Excitation Inverter a AN Al Zl ie EET e Quick Parameter Set Invertor Advanced Firing 0 Degrees Invertor SW Dead Angle 0 1 Degrees Advantage of Symmetry Iv Phase to Phase Iv Bi Polar At B C N 3ph Y Am Winding Select All Clear All Apply Cancel 25 Once the above three major components are placed onto the schematic drawing surface any additional components such as filter capacitors or inductors shut resistors extra switches or diodes may be placed onto the drawing surface Each individual component will have a specific set of attributes detailed below available for setting and accessed by right clicking the component itself Each component s attribute box will allow the component to be scaled in size or rotated on the page e Resistor attributes include name and resistance The resistor name is automatically generated sequentially however it may be changed if desired and the resistance value is set in Ohms e Inductor attributes include name and inductance The inductor name is automat
124. urrent Dmp Bar Current 6 Draw Export Animate Display V Geometry Lines Wire Mesh Material Shade Flux Lines Bmag Shade Br Shade Iv Current Density perational Iron Loss Density The scale of this parameter can also be adjusted by double clicking the legend and adjusting the parameters as appropriate BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help Em C4 Setting Design C Manual Excitation Existing Results Load Test Load V Auto Scale Rotor Ang dege 0 0 From 340000 Magnet Temp 40 00 To EET Wdg Current Dmp Bar Current d Steps 10 Draw Export Animat Display QJ E H m E Iv Geometry Lines Wire Mesh Material Shade Flux Lines Bmag Shade Br Shade Iv Current Density Operational Iron Loss Density 101 The final parameter is the Iron Loss Density which when selected will display the iron loss density in Watts Kilogram in any lamination material BLDC Version 3 0 C Program Files WMagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help 1 my m mmm us V2 AU Design Run Results Field Explorer Manual Excitation Existing Results Load Test Load 1 M Rotor Ang deg e 0 0 Magnet Temp 40 00 Wdg Current Dmp Bar Current Draw E
125. x An information box will be displayed that contains parameter information about two different nodes labeled PO and P1 and you will be allowed to click on the wire mesh The most recently clicked node is P1 and the node clicked just prior 1s PO In the nodal information box the x y r Theta and Az parameters ate listed Just below this 1s the differential information between PO and P1 Listed here are Delta x Delta y Delta Az as well as the Vector Length and Direction Below this 1s a Flux calculator that will give you the flux in Webers for a given depth between P1 and PO BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x80mm 6pole 3ph bldc Field Explorer File Action Window Tools Help 3a Field Explorer C Manual Excitation Existing Results Load Test Load Rotor Ang deg e 0 0 Magnet Temp 40 00 Wdg Current Dmp Bar Current AX o o V Leng 7 700 A NE V y ce dis AY 7 700 V Direc 20 00 7 S TES i ME Del Az 31 86e 3 A VAT ce ANZ Ws X Pa ux web 294 Je A SOE KD X XOU Draw Export Animate ms Pii 6 NOSSA o A y MET 1 NS e Display AN 3 V Geometry Lines mm deg Web m V Wire Mesh 5 Flux Lines BmagShade BrShade Current Density Operational Iron Loss Density s l Fe olo 103 Under the nodal information button is a button labeled E which is the elemental information button This
126. xist within each phase Wire Size 1 amp Wire Size 2 is the gauge of the wire used to wind the coils Select these from the table by clicking the select button to the left of the name Also included in this table 1s the Parallel Strands parameter This parameter specifies the numbet of parallel strands that the winding is composed of The reason there are two Wire Size parameters is so that a winding may be composed of two wires of different sizes The actual existence of each size is specified in the winding table below Based upon your input several parameters are calculated Ra is the phase resistance as viewed from the machine s terminals Min Slot Area is cross sectional area of the slot measured in square millimeters Max Slot Fill is the percentage fill of the fullest slot Copper Weight is the weight in kg of the copper winding specified in the winding table Wdg Symmetry in Number of Poles is the symmetry if any that exists in the winding as related to the number of poles This parameter can help spot an unintentionally unbalanced winding and is used to determine how the machine is solved For example a 60 degree phase belt winding can be solved in one pole while a 120 degree phase belt winding must be solved in two poles The table below these parameters together with the drawing to the right describe exactly how the coils are wound within the slots of the armature The table lists the coils which are calculated based upon
127. xport Animate Display iM Geometry Lines Wire Mesh Material Shade Flux Lines J Bmag Shade Br Shade Current Density Operational Iron Loss Density The scale of this parameter can also be adjusted by double clicking the legend and adjusting the parameters as approptiate BLDC Version 3 0 C Program Files WagneForce bldc projects 1 50x60mm 6pole 3ph bldc Field Explorer File Action Window Tools Help 3 m des J Emm u Vj j Ae Design Run Results Field Explorer C Manual Excitation Existing Results Load Test w Load 1 vV Auto Scale Rotor Ang deg e 0 0 Fomo Magnet Temp 40 00 To W dg Current Dmp Bar Current Steps Draw Export Animate Display iW Geometry Lines Wire Mesh Material Shade Flux Lines Bmag Shade Br Shade Current Density Operational v Iron Loss Density 102 To the right of these check boxes are several sizing and information buttons To zoom in on the image use the Plus button or to zoom out click the Minus button to normalize the image size click the Normalize button or to shift the image click the 4 Arrows button then move your cursor to the drawing area and click and drag the image the desired distance The button labeled N is the nodal button which when clicked displays information about the nodes This button is most often used in conjunction with the wire mesh check bo
128. y state calc D ju Total Steps Specify RPM W dg Temp 40 00 40 00 Monitor Pause Run Simulation Parameters EXHEU B Load Test Transient Tol Control Apply Cancel rs The transient tab is similar to the load test tab in that it simulates machine performance under load however it uses a time stepping solution method that is capable of accurately calculating transient machine performance The solution technique used here will allow accurate calculation of the actual machine parameters both during and after the transient has occutred This simulation will require more solution time therefore it is not recommended for solution of a machine operating simply under steady state conditions The parameters on this tab include e Amb Temp which is the ambient temperature of the machine e End Time is the ending time of the simulation in seconds Be sure to set this point an adequate amount beyond the Start Time of the last load in the load point table below e Max Step Size is the maximum width in seconds of the time interval used during the simulation e Display Progress Every N Steps is a parameter used to control how often data points are output to the screen when monitoring the solution progress e Rotor Cycles for Steady State Calc specifies the number of AC cycles at the end of each load point from which the steady state parameters for that load point will calculated For instance setting this parameter to 2 wil

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