电摩500W直流无刷电机 ANSOFT 2D 仿真设计实例详解公开版

电摩500W直流无刷电机 ANSOFT 2D 仿真设计实例详解公开版电摩500W直流无刷电机 ANSOFT 2D 仿真设计实例详解公开版海文科技bso(mm)bs1(mm)bs2(mmrs(mm):Top Tooth Width(mm)Bottom Tooth Width(mm)Skew Width (Number of Slots)Length of Stator Core(mm)Stacking Factor of Stator CoreType of Stee:DW465_50//料库里没有B50W470导磁材料,这里使用一个接近的材料,不会带来太大的偏差Slot Insulation Thickness(mm)0.5Layer Insulation Thickness(mm): 0End Length Adjustment (mm): 7Number of parallel branches: 1Number of Conductors per Slot:/集中绕组一个线圈匝Type of coils: 21Average Coil Pitch: 1Number of wires per ConductorWire diameter(mm):■∥/这里使用两种线规共■跟线并绕,本案例糟满率相对较宽松,用的漆包线也能绕制1.ectWire sizePropertiesUnit SystemmmfameValueUnit EvaluaInput Half-turn LengthVire TypeC RoundC Rectangle End ExtensionfmmBase Inner Rafire diameter0690Tip Inner Di ameterEnd clearanceGaugeMIXEDnedge Thi ckmesDiameterNumberLayer InsulationLimited Fill Factor0.T5nindiErd/工 sulationWire Wrap Thickness(mm): 0.06Slot area(mm 2): 78.0978Net Slot area(mm 2): 73.9263Limited Slot Fill Factor(%: 75Stator slot fiⅢ I Factor(%}:53.2625/根据实际经验,用手工绕线这个槽满率比较合适Coil half- Turn Length(mm):45.5815/依据实际崁线时文测电阻调整半匝长ROTOR DATAMinimum Air Gap (mm):Outer Diameter(mm)Length of Rotor (mm)hailinTel:1515882153QQ:573059618海文科技ype of Steel: steel 1010Polar Arc Radius(mm): 299.5Mechanical pole embrace: 0.8Electrical pole embrace: 0,766702Max Thickness of Magnet (mm): 3Width of Magnet(mm)10.8781Type of magnet: N35SHi白 RotorProject2 ShaftPropertiesProiectamevalue Unit Evaluate PropertiesOuter Di ameter219mm219mmInner Di ameter199mm199mmNamevalueLength235mm23.5mmEmbrace0.8Steel TypeOffset200tStacking Factor0.95Magnet TypeNdFe30Pole TypeMagnet Thi cknessPERMANENT MAGNET DATA(注意,这里是工作温度下的数据)Residual flux Density(Tesla 1.1Coercive Force( kA/ m):838Maximum Energy density k/m3 230.45Relative recoil permeability: 1.0446Demagnetized flux density (tesla 0.692938Recoil residual Flux Density (Tesla 1.1Recoil Coercive Force( kA/m): 838MATERIAL CONSUMPTIONArmature Copper density(kg/m3): 8900Permanent Magnet density(kg/m3): 7550Armature Core Steel density(kg/m3): 7700Rotor Core Steel Density( kg/m/3)7872Armature Copper Weight(kg: 0.541546Permanent magnet Weight (kg 0.267291Armature Core Steel Weight( kg): 1.03178Rotor Core Steel Weight( kg 0.819333Total Net Weight(kg): 2.659952、空载磁路参数实际上这部分参数对确定槽形参数相当重要,对电摩这种低速永磁直流无刷驱动电机来说,运行时速度低(额定转速460转/分),使用电池供电,属于电压低,电hailinTe:1515882153QQ:573059618海文科技流比较大,所以通常铁耗占比小,即使取很人的空载磁负荷,相对一般的电机1.6T左右的齿磁通密度,可以取的齿磁密,这样额定点时铁耗只有50%左右,当转速在额定点附近减少时电流变大增大输岀转矩时仍然能保持相对宽的高效率调速区,改善马达的调速性能。NO-LOAD MAGNETIC DATAStator-Teeth Flux Density(Tesla)/对于电摩这类低速低电压马达,齿磁密左右能増大槽空间,提高导磁材料的利用率,同时可以实用比较大的导体,提高马达的出力Stator-Yoke flux density (tesla∥/比齿磁密稍低这样轭部的单位面积铁损耗教齿部低,这样齿部溫度比轭部低形成温度梯度便于槽內锎线铁损耗的热量顺杨的传导出米Rotor-Yoke Flux Density(tesla/这部分是轮毂上使用内嵌钢圈做导磁材料,通常是20#刚或者其他低碳钢,涡流损粔较大,必须取相对较低的磁负荷Air-Gap Flux Density (Tesla :0.85894Magnet Flux Density(Tesla :0.859576Stator-Teeth By-Pass Factor: 0.00538168Stator-Yoke By-Pass Factor: 8.1561e-005Rotor-Yoke By-Pass Factor: 5.46669e-005Stator-Teeth Ampere Turns(A T): 91.6933Stator-Yoke Ampere turns(A T):4.75193Rotor-Yoke Ampere Turns(AT): 3.2614Air-Gap Ampere Turns(AT):449.657Magnet Ampere Turns(A. T:-549477Armature Reactive Ampere Turnsat Start Operation(A T): 557.367Leakage-Flux Factor: 1Correction Factor for MagneticCircuit Length of Stator Yoke: 0.267538Correction Factor for MagneticCircuit Length of Rotor Yoke: 0.78224No-Load Speed (rpm): 514.76Cogging torque(N m 0.0003595123、使用一键有限元时用到的一些参数WINDING ARRANGEMENTThe 3-phase, 2-layer winding can be arranged in 51 slots as belowABYBCZCAXAXYBYZCZCAXABYBCZCZXAXYBYBCZCAXABYBYZCZXAXAngle per slot(elec degrees): 162.353Phase-A axis( elec degrees): 109.412hailinTel:1515882153QQ:573059618海文科技A相轴线角度,关于这个数据有专门宝贝介绍《永磁电机A相轴线和 ANSOFT仿真中的初始位置》,因为电机仿真瞬态分析时是以A相轴线和转子磁钢轴线对齐为起点的,这个参数对下面2D里的仿真时初始位置( nitial position)有影响。日5146*HO Maxwell2DDesi gn3 (Transient, XY)白-白MdelEO MotionSetup1 Motion Setup+-- Boundaries+A ExcitationsTypea MechanicalPerametersInitigl3734peral onsFirst slot center(elec degrees): 0TRANSIENT FEA INPUT DATAANSOFT MAXWELL2D里需要直接调用以下这几组 ANSOFT RMxprt里的计算数据For armature WindingNumber of turns: 119Parallel branches: 1erminal resistance(ohm): 0.125912End Leakage Inductance( H): 2.88149e-0062D Equivalent value:Equivalent Model depth(mm): 23.5Equivalent Stator Stacking Factor: 0.97Equivalent Rotor Stacking Factor: 0.95Equivalent Br(Tesla 1.1Equivalent Hc(kA/m):838Estimated Rotor Moment of Inertia(kg m2): 0.0283127、由 RMxprt直接生成 Maxwe l2D模型仿真的步骤详解ANSOFT支持由磁路到2D有限元模型的生成,完成材料类型的定义,完成各相绕组线圈的分组和电流正方向的定乂,完成电压源的加载,完成物理模型的网格剖分等等,而且可以直接进行仿真分析计算,降低了使用有限元进行电机电磁分析的门栏,让电机设计变得准确简单快捷。但在具体应用中还要对模型进行适当的修改,以达到更接近实际物理模型的目的,降低仿真结果和实际测试结果的误差。对本例而言,涉及到对磁钢的修改,符合不均匀气隙的物理模型实际,需要重新定义磁钢的充磁方向等。具体步骤如下:1、如下图所示,鼠标石键点击 Analysis-弹出 Add Solution Setup左键点击弹出Solution Setup,设定负载参数s。 lution Set日况Mpte31 gnl BRushless Permanent-Magnet DC Motor.)*General Defaults+-QMachineSetup Name: setupEnabledPasteCtrl+vo Add Solution Setup.per atl oIt lypeMotorhailinTel:1515882153QQ:573059618海文科技负载类型选择恒定转速,额定功率设定为500W,额定电压48V额定转速460转/分,作温度为75度,B级绝缘Solution SetupGeneral DefaultsSolution SetupSetup Name: Setup2Y EnabledGeneral DefaultsOperati on TypotorSetup Name: Setup2EnabledLoad tConst SpeedRated Output Powe500Operation IypMotorRated voltagLoad TypeConst speedRated SpeedIpmonsRated Output PoweConst PowerOperating Temperatu 75cel2、如卜图所示,右键点击 Setup弹出对话框—一点击 Create maxwell! Designb.x MmxprtDesi gn brushless permanent magne由QMachine日 A Analysi5网0pt电gopyCtrl+C回RPasteCtrl+v由口 DefinitRenameJectX DeleteDeletePropertiesrtesDisable SetupHameAnalyzeCreate Quick Report.ration iypePerformance.d typeDesign Sheet.ed Output PotCurveed voltageExport.Create Maxwell Design.3、弹出如下对话框—一点击oK开始自动生成 MAXWELL2D有限元分析模型Create Maxwell DesignTyp2D Designv Auto setupSolution Setup SetupVariationOKCancel如果在右上角 Auto setup前的小方框去掉黑色小v,那只是完成模型( Model)的建hailinTel:1515882153QQ:573059618海文科技立,材料属性的定义。并不能直接进行仿真分析,还需要运动设置( Motion Setup)、设置边界条件( Boundaries),加激励源( Excitations等。这部分网上能找到很多文档,为突出重点,这部分本宝贝不进行具体描述、 Maxwell! DDesign瞬态模型接下来分析上面第三步骤产生的 Maxwel2 DDesign瞬态模型:1、模型(Mode)部分右键点击Mode,弹出如下对话, ANSOFT已经完成运动设置,指定了BandAssign Band2Set Symmetry Multplier. Delete Allect厂 Model Depthvisualization下图可以看到转了蓝色部分区域表示指定的Band覆盖了仿真计算中的转动部件区域Project Manager白 Model日 Moti onSetup1M Moving-白? Boundaries中不 ExcitationsParameters图Mesh0 perati onsT ength ailProject下图表示模型的长度也就是铁心长度,这里说明下,马达实际铁长为24mm,考虑到通常叠压系数为0.97左右,对这类型的马达仿真,我选取的铁长少一片冲片,即原有铁长24-0.5=235mm。这样仿真电流结果和实测电流值在输出转矩一样时略小,不会相差太大,剩余相差部分由于控制器换向或者其他原因带米的波形畸变导致,在计算铜耗时需要考虑补偿这部分。Project ManagerDesign SettingsPreserve Transient Solution日合!List.Advanced Product CouplingBackgroundAssign Material.Material ThresholdsSymmetry MultiplierModel DepthMotion Setup中心E1 Set Symmetry MultiplierParModelSet Model Depth日蹰Meslhailinel:1515882153QQ:573059618海文科技下图为模型( Model)设置初始位置和转速部分,连续点击下列图标 Motion Setup1白 Maxwe12 DEsig3〔 Trans白白Mode1+o Moti onSetupl弹出如下对话框,对旋转电机一键有限元部分会自动设定如图所示 Rotation、初始位置角初始位置角 Initial position和转速设定Motion SetupMotion SetupMotion SetupType Data I MechanicallTDateMechanicalType Data MechanicaMotionC Translatio工 nitial3734T Consider Mechenical Transc Rotati on厂 Rotate LimiAngular velocity: 460rpm2、设定边界条件因为51槽46极只有一个单元札,且每极每相槽数为17/46,分母为偶数,所以最小的对称求解区域就是一个完整的模型只需设定转子外圈导磁材料边界为0矢量即可如果最小对称区域不是一个完整的模型,需要设定 Master和Save主从边界。Lu10.00d Boundariesop VectorPotenti allE-A Excitations Vector Potential Boundary中 PhaseAPhaseBGeneral DefaultsIIII DLlectNameectorPotentiallrtiesPerametersNameValuevalue项 External circuit,点击右边小三角形图标弹出 Edit External Circuit选相,"外电路选3、设定激励 Excitation,右键点击 Excitation,弹出如下对话框,用光标选屮白 VectorPotenti a11白心中山Assign由山List由Ⅲ assignAP Delete AllVisualizationSet Default Base NamectExternal CircuitEdit External Circuit.左键点击弹出如下对话框hailinTel:1515882153QQ:573059618海文科技Edit External Circuitinding Information Available Inductors Source Typ. ParameterBelow is list of, the externally connected windings you haveWinding Name Has Inductor in Circui t Inductor NamePhaseALPhascAPhaseBPHasedPhasePHaserEd1tC⊥xg⊥t工 mport Circuit.」点击 Edit circuit选项进入到如卜外电路编辑设定界面M Ansoft Maxwell Circuit Editor -51_46_2-51_46_2-SchematicEditor-[51-46_2-51_46_2-Schematic1 File Edit View Project Draw Schematic Maxwell Circuit Tools Window Help自哆自X≌cs2目1A=50置国面F1a日回费Project Manager51_462因为分辨率的关系,无法看到外电路图,需要左键点击上图右上角图标将外电路图放置到界面合适大小处a Ansoft Maxwell Circuit Editor -51_46_2-51_46_2-SchematicEditor -[51_46_2-51_46_2-Schematicla File Edit View Project Draw Schematic Maxwell Circuit Tools Window HelpD哆副自X≌C1回号50x皿Fl@ag目1o、oaAsProjectManager51462Project components+Proper tiesValue Unit IE立太:本:zNew PageVariable直流无刷使用两两导通换相,每相导通120度电角度,60度电角度换一次相,这样个电周期进行6次换相,实现这个换相是通过上述图中石下角那6个独立的电压源供电。在一个电周期内没60度电角度轮流按照即定的相序轮流导通,控制 ANSOFThailinTe:1515882153QQ:573059618