Tutorial Brushless DC Motor Calculations

Brushless DC Motor
Calculations
Copyright © 2005 Magsoft Corporation
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www.magsoft-flux.com
Cover illustration: Color shade plot of flux density on rotor, magnet, and stator from simulation
of motor at constant speed with external circuit coupling
Contents
1 About this document xv
What this document contains · · · · · · · · · · · · · · · · · · · · · · · · · xv
Chapters to complete for the different simulations · · · · · · · · · · xvi
For experienced users· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · xvi
1 Enter the materials 3
Start Flux2D · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3
Open the materials database · · · · · · · · · · · · · · · · · · · · · · · · · · 5
Add the magnetic material · · · · · · · · · · · · · · · · · · · · · · · · · · · 6
Add the nonlinear steel material· · · · · · · · · · · · · · · · · · · · · · · · 9
Close the materials database · · · · · · · · · · · · · · · · · · · · · · · · · 11
2 Cogging torque computation 15
Special considerations for simulation· · · · · · · · · · · · · · · · · · · · 15
Enter the physical properties · · · · · · · · · · · · · · · · · · · · · · · · · 17
Start Preflu 9.1 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 17
Open the 3-layer airgap problem · · · · · · · · · · · · · · · · · · · · · · · · · · · · 18
Save your project with a new name · · · · · · · · · · · · · · · · · · · · 20
Define as Transient Magnetic · · · · · · · · · · · · · · · · · · · · · · · · · 22
Change to the Physics context · · · · · · · · · · · · · · · · · · · · · · · · 23
iii
iv Contents
Physics context toolbars · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 24
Import materials from the materials database · · · · · · · · · · · · · 25
Assign materials and sources to the regions · · · · · · · · · · · · · · 27
Assign the windings of the stator slots · · · · · · · · · · · · · · · · · · · · · · · · 27
Assign WEDGE, AIR, STATOR_AIR, AIRGAP and SHAFT regions · · · · · · · 31
Assign STATOR and ROTOR regions · · · · · · · · · · · · · · · · · · · · · · · · · · 33
Assign the MAGNET · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 35
Creating and Assigning Mechanical Sets · · · · · · · · · · · · · · · · · 38
Creating Mechanical Sets· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 38
Create the MOVING_ROTOR Mechanical Set . . . . . . . . . . . . . . . . . . . . 39
Create the FIXED_STATOR Mechanical Set. . . . . . . . . . . . . . . . . . . . . 43
Create the ROTATING_AIRGAP Mechanical Set . . . . . . . . . . . . . . . . . . . 44
Assigning Mechanical Sets · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 45
Boundary conditions (Periodicity) · · · · · · · · · · · · · · · · · · · · · · 49
Check the physical model · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 51
Close Preflu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Solve (batch mode) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 54
Prepare the batch file · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 54
Close the solver · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 61
Start the batch computation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 62
Results · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 66
Display the full geometry· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69
Displaying isovalues (equiflux) lines at t = 1 s · · · · · · · · · · · · · · · · · · · 71
Change the default isovalues display . . . . . . . . . . . . . . . . . . . . . . . 71
Change the time to 1 s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Display the isovalues plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Contents v
Color shade of flux density on a group of regions · · · · · · · · · · · · · · · · · 75
Change the geometry display . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Change the time to 0.5 s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Create a group of the three regions . . . . . . . . . . . . . . . . . . . . . . . . 77
Display a color shade plot on the group of regions . . . . . . . . . . . . . . . . . 78
Create a path through the airgap · · · · · · · · · · · · · · · · · · · · · · · · · · · · 81
Normal component of flux density along the air gap path · · · · · · · · · · · 86
Superimpose the curves display · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 88
Spectrum analysis · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 91
Axis torque (full cycle) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 95
Save your analyses · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 98
Close PostPro_2D · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 99
3 Back EMF computation 102
Create the back EMF external circuit model · · · · · · · · · · · · · · 102
Conventions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 102
Back EMF circuit · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 104
Start ELECTRIFLUX · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 105
Open a new circuit problem · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 106
Using the icon in the toolbar. . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Using the menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
ELECTRIFLUX toolbar · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 109
ELECTRIFLUX menus · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 110
File menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Edit menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
View menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Circuit menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Sheet menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

vi Contents
Window menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
? (Help) menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Change the size of the sheet · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 113
Add coils for stator windings · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 117
Place the 4 coil components on the sheet . . . . . . . . . . . . . . . . . . . . 119
Rotate the 4 coils for proper orientation of the hot point. . . . . . . . . . . . . . 122
Add inductors · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 125
Place the 3 inductors on the sheet . . . . . . . . . . . . . . . . . . . . . . . . 126
Rotate the 3 inductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Add the open circuit loads · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 130
Place the 3 resistors on the sheet . . . . . . . . . . . . . . . . . . . . . . . . 132
Rotate the 3 resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Add the voltmeter· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 135
Place the voltmeter (R4) on the sheet . . . . . . . . . . . . . . . . . . . . . . 136
Rotate the voltmeter (R4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Save your circuit file · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 139
Connect (wire) the circuit components · · · · · · · · · · · · · · · · · · · · · · · 140
Define the resistors and inductors· · · · · · · · · · · · · · · · · · · · · · · · · · · 146
Define the resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Define the inductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Rename the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Analyze the circuit · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 152
Save and close the circuit file · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 154
Close ELECTRIFLUX· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 155
Enter the physical properties · · · · · · · · · · · · · · · · · · · · · · · · 156
Start Preflu 9.1· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 156
Open the 1-layer airgap problem · · · · · · · · · · · · · · · · · · · · · · · · · · · 157
Save your project with a new name · · · · · · · · · · · · · · · · · · · 159

Contents vii
Define as Transient Magnetic · · · · · · · · · · · · · · · · · · · · · · · · 161
Change to the Physics context · · · · · · · · · · · · · · · · · · · · · · · 162
Physics context toolbars · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 163
Import materials from the materials database · · · · · · · · · · · · 163
Import the problem circuit · · · · · · · · · · · · · · · · · · · · · · · · · · 165
Assign materials and sources to the regions· · · · · · · · · · · · · · 169
Assign the stator windings · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 169
Edit the PA region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Define the coil resistance · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 174
Assign WEDGE, AIR, AIRGAP and SHAFT regions · · · · · · · · · · · · · · · · 176
Assign STATOR and ROTOR regions · · · · · · · · · · · · · · · · · · · · · · · · · 177
Assign the MAGNET· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 179
Creating and Assigning Mechanical Sets · · · · · · · · · · · · · · · · 181
Creating Mechanical Sets · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 181
Create the MOVING_ROTOR Mechanical Set . . . . . . . . . . . . . . . . . . . 182
Create the FIXED_STATOR Mechanical Set . . . . . . . . . . . . . . . . . . . . 186
Create the ROTATING_AIRGAP Mechanical Set . . . . . . . . . . . . . . . . . . 187
Assigning Mechanical Sets · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 188
Boundary conditions (Periodicity) · · · · · · · · · · · · · · · · · · · · · 193
Check the physical model · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 194
Solve the back EMF problem · · · · · · · · · · · · · · · · · · · · · · · · 196
Check the version: Flux2D Standard · · · · · · · · · · · · · · · · · · · · · · · · · 196
Start the solver · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 197
Start the solver · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 198
Close the solver · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 202

viii Contents
Results from the Back EMF computation · · · · · · · · · · · · · · · · 203
Display the back EMF in R4 (the voltmeter) · · · · · · · · · · · · · · · · · · · · 205
Display a spectrum of the back EMF in R4 · · · · · · · · · · · · · · · · · · · · · 208
Voltage and current in coil B_MC (MC) · · · · · · · · · · · · · · · · · · · · · · · 213
Save and close PostPro_2D · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 214
4 Square wave motor: Constant speed (torque ripples) 217
Create the 3-phase bridge circuit · · · · · · · · · · · · · · · · · · · · · 218
Start ELECTRIFLUX · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 219
Create a new circuit problem · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 221
Using the icon in the toolbar. . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Using the menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Change the size of the sheet · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 223
Add the 6 switches · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 226
Place the 6 switches on the sheet . . . . . . . . . . . . . . . . . . . . . . . . 228
Rotate the 6 switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Add the 6 series voltages· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 236
Place the 6 series voltages on the sheet . . . . . . . . . . . . . . . . . . . . . 238
Rotate the series voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Add the main voltage source · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 243
Place the main voltage source . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Rotate the main voltage source . . . . . . . . . . . . . . . . . . . . . . . . . 245
Add the 3 coils · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 246
Place the 3 coil components on the sheet . . . . . . . . . . . . . . . . . . . . 248
Rotate the coil components . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Add the inductors · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 252
Place the 3 inductors on the sheet . . . . . . . . . . . . . . . . . . . . . . . . 254
Rotate the 3 inductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Contents ix
Add the voltmeter· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 257
Save your circuit· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 260
Connect (wire) the circuit components · · · · · · · · · · · · · · · · · · · · · · · 262
Define the circuit · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 266
Define the on/off resistance values for the switches . . . . . . . . . . . . . . . . 266
Define the inductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Define the voltmeter (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Rename the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Analyze the circuit · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 273
Save and close the circuit file · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 275
Close ELECTRIFLUX· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 276
Assign the physical properties · · · · · · · · · · · · · · · · · · · · · · · 277
Start Preflu 9.1· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 277
Open the Back EMF problem · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 278
Save your project with a new name · · · · · · · · · · · · · · · · · · · · · · · · · 281
Change the coupled circuit · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 283
Delete the existing circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Change to the Physics Context . . . . . . . . . . . . . . . . . . . . . . . . . 284
Import the Squarewave Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 284
Assign face regions to the circuit · · · · · · · · · · · · · · · · · · · · · · · · · · · 287
Assign the stator windings . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Edit the PA region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Edit the MA region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Edit the PB region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Edit the MC region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Define the coil resistance · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 291
Define the Voltage Sources · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 293
Define the Main Voltage Source . . . . . . . . . . . . . . . . . . . . . . . . . 293
Define the Series Voltage Sources . . . . . . . . . . . . . . . . . . . . . . . . 294

x Contents
Define the switches· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 295
Check the physical model · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 297
Close and save the model · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 298
Solve with user version · · · · · · · · · · · · · · · · · · · · · · · · · · · · 299
Select the user version · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 299
Start the solver · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 301
Verify the solving options· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 303
Start the computation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 305
Close the solver · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 307
Results: Constant speed computation · · · · · · · · · · · · · · · · · · 309
Display isovalues (equiflux) lines · · · · · · · · · · · · · · · · · · · · · · · · · · · 312
Set the properties for the display . . . . . . . . . . . . . . . . . . . . . . . . 312
Color shade plot on a group of regions · · · · · · · · · · · · · · · · · · · · · · · 318
Create the group of regions . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Set the properties for the display . . . . . . . . . . . . . . . . . . . . . . . . 319
Display the color shade plot . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Create a path through the airgap · · · · · · · · · · · · · · · · · · · · · · · · · · · 323
Flux density along the airgap path · · · · · · · · · · · · · · · · · · · · · · · · · · 328
Flux density: Normal component . . . . . . . . . . . . . . . . . . . . . . . . 328
Flux density: Tangential component . . . . . . . . . . . . . . . . . . . . . . . 329
Superimpose the normal and tangential flux density curves . . . . . . . . . . . . 330
Spectrum analysis · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 334
Time variation curve of axis torque · · · · · · · · · · · · · · · · · · · · · · · · · · 338
Waveforms of the electric quantities · · · · · · · · · · · · · · · · · · · · · · · · · 342
Voltage and current in the main voltage source (V7) . . . . . . . . . . . . . . . 343
Current in Switch1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Current in the B_COILA (PA) coil component . . . . . . . . . . . . . . . . . . . 348

Contents xi
Current in the B_COILB (PB) coil component . . . . . . . . . . . . . . . . . . . 350
Current in the B_COILC (MC) coil component . . . . . . . . . . . . . . . . . . . 352
Save and close PostPro_2D · · · · · · · · · · · · · · · · · · · · · · · · · 354
5 No load startup with electromechanical coupling 359
Modify the physical properties · · · · · · · · · · · · · · · · · · · · · · · 359
Start Preflu 9.1· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 360
Open the Constant Speed problem · · · · · · · · · · · · · · · · · · · · · · · · · · 361
Define the no load characteristics · · · · · · · · · · · · · · · · · · · · · · · · · · · 365
Edit the MOVING_ROTOR mechanical set . . . . . . . . . . . . . . . . . . . . . 365
Verify the user version: brushlike_921 · · · · · · · · · · · · · · · · · 370
Solve the no load startup problem · · · · · · · · · · · · · · · · · · · · 372
Choosing a time step· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 372
Start the solver · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 372
Results from no load startup · · · · · · · · · · · · · · · · · · · · · · · · 380
Display the isovalues (equiflux) lines at time step 100 (t = 0.05 s) · · · · 382
Select the 100th time step (0.05 s) . . . . . . . . . . . . . . . . . . . . . . . 383
Set the display properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Time variation analysis (2D Curves) · · · · · · · · · · · · · · · · · · · · · · · · · 390
Axis torque curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Angular velocity curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Rotor position curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Waveforms of electric quantities · · · · · · · · · · · · · · · · · · · · · · · · · · · · 399
Voltage and current in the main voltage source . . . . . . . . . . . . . . . . . . 400

xii Contents
Current in Switch1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Current in the B1 (PA) coil component . . . . . . . . . . . . . . . . . . . . . . 405
Voltage and current in the B2 (PB) coil component . . . . . . . . . . . . . . . . 407
Voltage and current in B3 (MC) coil component . . . . . . . . . . . . . . . . . . 409
Save and close PostPro_2D · · · · · · · · · · · · · · · · · · · · · · · · · 412
6 Servo action with electromechanical coupling 415
Modification of physical properties · · · · · · · · · · · · · · · · · · · · 415
Start Preflu 9.1· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 416
Open the No Load problem · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 417
Define the servo model characteristics · · · · · · · · · · · · · · · · · · · · · · · 421
Edit the MOVING_ROTOR mechanical set . . . . . . . . . . . . . . . . . . . . . 421
Transient startup of servo problem · · · · · · · · · · · · · · · · · · · · 426
Solve the servo simulation with user version · · · · · · · · · · · · · 428
Start the solver · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 429
Results from servo motor· · · · · · · · · · · · · · · · · · · · · · · · · · · 435
Display the isovalues (equiflux) lines· · · · · · · · · · · · · · · · · · · · · · · · · 438
Select the last time step (0.115 s) . . . . . . . . . . . . . . . . . . . . . . . . 438
Set properties for the isovalues display . . . . . . . . . . . . . . . . . . . . . 440
Color shade plot for stator, rotor, and magnet · · · · · · · · · · · · · · · · · · 444
Create a group of regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
Set the display properties for the color shade plot . . . . . . . . . . . . . . . . 446
Display the color shade plot . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Time variation results (2D curves) · · · · · · · · · · · · · · · · · · · · · · · · · · 449
Axis torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

Contents xiii
Angular velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Rotor position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Voltage and current in the main voltage source (V7) . . . . . . . . . . . . . . . 454
Current in Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Current in B1 (PA) coil component . . . . . . . . . . . . . . . . . . . . . . . . 459
Voltage and current in B3 (MC) coil component . . . . . . . . . . . . . . . . . . 461
Close PostPro_2D · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 464
Close Flux2D · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 465

Introduction
About this document

This tutorial, Brushless DC Motor: Calculations, is the second in the series featuring the model of
the brushless DC permanent magnet motor. The calculations presented in this document are
based on the models (geometry and mesh) created with Preflu, as explained in Brushless DC
Motor: Constructing the Model. You should already have completed and have saved two geometry
and mesh files for this model in your working directory.
For the first computation, the cogging torque (see Chapter 2), use the model with the 3-layer
airgap (BRUSHLESS_3LAYER).
For all the other computations, use the model with the 1-layer airgap (BRUSHLESS_1LAYER).
What this document contains

This tutorial shows you how to enter the required materials into the materials database
(CSLMAT) and then how to conduct a series of simulations with the brushless permanent
magnet motor.
In both Chapters 3 and 4, you create external circuits with the new ELECTRIFLUX module.
Chapter 1 Enter the materials into the materials database (CSLMAT)
Chapter 2 Cogging torque computation (with batch file solution)
Chapter 3 Back EMF computation, with a 3-phase Wye external circuit
Chapter 4 Square wave motor: Constant speed (Torque ripples), with a square wave
external circuit
Chapter 5 No load startup with electromechanical coupling, with the square wave
external circuit from Chapter 4
Chapter 6 Servo action with electromechanical coupling, with the square wave external
circuit from Chapter 4
xv
Chapters to complete for the different simulations
If you wish to do only some of the simulations described in this tutorial, the list below shows
which chapters to complete for each of the simulations.
Cogging torque computation Chapters 1 and 2
Back EMF computation Chapters 1 and 3
Constant speed computation Chapters 1 and 4
No load startup computation Chapters 1, 4 and 5
Servo action computation Chapters 1, 4, 5 and 6
The simulations in Chapters 4, 5 and 6 use the same external circuit, a square wave circuit shown
on page 218. For Chapter 5, you modify the physical properties of the problem from Chapter 4
to create and solve a new problem. For Chapter 6, you modify the physical properties for the
problem from Chapter 5 to create and solve a new problem.
For experienced users

If you are familiar with Flux2D, you may want to take advantage of the chapter summaries at the
beginning of each chapter. These sections list the physical properties and the solver and
postprocessor settings for each problem.
xvi
Chapter 1
Enter the materials

In this chapter you start Flux2D and use the Materials database module to create the
materials to be assigned to various parts of the model of the motor. These materials are
added to the materials database and can then be used for other problems also.
Start Flux2D
Open the Materials database (CSLMAT)
Add the magnetic material

iso MU
scalar constant
relative permeability of 1.071
magnet
scalar constant
remanent flux density of 0.401
Add the nonlinear steel material

iso MU
scalar a sat
Js = 1.99
Initial relative slope a = 7500
Close CSLMAT
1
2
Chapter 1
Enter the materials

For the brushless DC motor, you create two materials: (1) a magnetic material for the magnet
and (2) a nonlinear steel material for the rotor and stator laminations.
Start Flux2D
Start Flux2D from your Windows taskbar.
Starting Flux2D
3
4 Start Flux2D
Choose Start, Programs, Cedrat (or your installation directory), Flux 9.1.
Program Input
Start
Programs
Cedrat
Flux 9.1
The Flux Supervisor opens:
Flux Supervisor
Chapter 1 Enter the materials

Open the materials database 5
Open the materials database

To open the Materials database, in the Construction folder, double click Materials database.
Opening the materials database (CSLMAT)
Program Input
Double click Materials database
Enter the materials Chapter 1

6 Add the magnetic material
The Materials database (CSLMAT) opens:
CSLMAT menu
Add the magnetic material

Flux2D includes a linear model of magnets (constant permeability µr and constant remanent flux
density Br).
Proceed as follows:
Program Input
Selected command 1 Add
Selected command 1 Material
Name of the material : magnetpm
Comment magnetic material for brushless

dc motor

Add the magnetic material 7
Your screen should resemble the following figure:
Creating the magnet material (name and comment)
Next, enter two properties for the magnetic material:
1. the relative permeability (1.071) and

2. the remanent flux density (0.401).
Proceed as follows:
Program Input
To register, define at least

one property
Please select the property 1 iso MU
Select a model 1 scalar cst
Value =

8 Add the magnetic material
The field (a blue rectangle) where you enter the relative permeability is shown below:
Entering the relative permeability of the magnetic material
On some screens, stars (******) may be shown instead of the solid blue field. In this case, click
on the stars and then enter the relative permeability of the magnet (1.071).
Proceed as follows:
Program Input
Value = 1.071
Select the line whose value is 1 Validate

to be changed
Please select the property 5 Magnet
Select a model 1 scalar cst
Value = 0.401

to be changed
Please select the property Quit

Add the nonlinear steel material 9
Add the nonlinear steel material

Next, add the nonlinear steel material. Proceed as follows:
Program Input
1 Material
Name of the material nlsteelpm
Comment nonlinear steel for laminations

in brushless pm motor
To register, define at least

one property
Please select the property 1 iso MU
Select a model B scalar a sat
The scalar a sat model features an arc tangent formula to model the B-H curve. Enter the
saturation magnetization value (Js) and the initial relative slope (a) of the relative permeability.
Entering the saturation magnetization (Js) and initial relative slope (a) for the nonlinear steel
Program Input
Saturation magnetization 1.99

Js = Tesla
Initial relative slope 7500

a =

to be changed

10 Add the nonlinear steel material
When you choose Validate, a plot of the model is displayed:
B-H plot of the nonlinear steel
If you wish, you can modify the maximum value along the X axis with the Mod abscissa max
command or read the values at specific points along the curve with the Pick command.

Close the materials database 11
For example, the following figure shows the values at a point near the "knee" of the curve.
Reading values on the B-H curve with "Pick" command
Close the materials database

When you are ready, close the display and the materials database as follows:
Program Input
Quit
Quit
Please select the property Quit
Selected command Quit
Selected command STOP
The Flux Supervisor is displayed.
You are now ready to begin creating the problem files to run the simulations.

Chapter 2
Cogging torque computation

This chapter explains how to compute the cogging torque for the brushless DC motor.
Assign physical properties

Plane geometry, 50.308 depth, transient magnetic calculation
Materials and sources
All stator windings: vacuum, no source
Airgap: rotating airgap, constant angular velocity of 0.16666666 rpm, 2 pole pairs
Wedge, air, shaft: vacuum, no source
Stator, rotor: nonlinear steel, no source
Magnet: magnet material, constant direction 45 degrees, no source
Boundary conditions: Automatically assigned using periodicity
Solve with a batch file

Create a batch file with the following data:
Time step 0.5 s
Study time limit 100 s
Limit number of time steps 61
Maximum value time step 0.5 s
Minimum value time step 0.5 s
Store automatically 1 on 1
Initial position of the rotor: 0
Solve, Batch
13
Analyze results with PostPro_2D
Isovalues (equiflux) lines
Color shade plot over rotor, magnet and stator only
Analysis of quantities along a path through the airgap
Normal component of the flux density
Spectrum analysis of normal component of flux density
Axis torque over full cycle of the motor
Save and close PostPro_2D
14
Chapter 2
Cogging torque computation

The cogging torque in this brushless DC motor originates from variations in the reluctance of
the magnetic circuit due to slotting as the rotor rotates. The cogging torque becomes detectable
when the shaft is rotated slowly.
In other finite element packages, the cogging torque computation is generally performed as a
multi-static computation with different rotor positions. The multi-static approach to the cogging
torque computation requires a tremendous amount of effort in preparation—a finite element
mesh and problem for each position—as well as long computation times and tedious
postprocessing.
With its rotating airgap feature, Flux easily computes the cogging torque. Only one finite
element mesh is needed; only one problem is solved. Computation and postprocessing time is
greatly reduced compared to the multi-static method because in Flux, the rotor is rotated
automatically. There is no need to modify the geometry, mesh or physical properties, and a
torque value is stored for each position during the solving.
Special considerations for simulation

In general, cogging torque values are small. When one uses finite element methods to compute
the cogging torque, special consideration is needed to limit the influence of finite element
numerical errors due to the mesh.
With Flux2D’s moving airgap, you must make sure that the subdivisions on the boundaries of
the moving airgap from the current time step overlap the subdivisions of the next time step in
order to keep the mesh topology constant in the airgap. Flux computes the torque with the
virtual work method, based on the energy in the moving airgap. Thus, by keeping the mesh
topology the same at each position, the influence of finite element residual errors on the small
torque values is minimized.
F Be sure to use the model with the 3-layer airgap for this problem.
Please do not confuse this special 3-layer geometric division of the airgap with the number of
layers required by the Maxwell Stress Method to accurately compute the torque.
15
16 Special considerations for simulation
The reason for the three-layer structure, with the moving airgap placed between two outer layers
of air, is to evenly subdivide the boundary of the moving airgap. In this example, for one pole of
the motor, there are 180 subdivisions on the lower and upper boundaries of the airgap (0.5
degrees/subdivision). Because the rotor moves by a multiple of 0.5 degrees, the mesh topology
remains the same. The nodes from the current time step are overlapped by the nodes of the next
time step as the rotor rotates.
The airgap subdivided into 3 layers
A constant speed of 1/6 or 0.16666666 rpm is specified for the rotation of the rotor, because 1
second corresponds to 1 mechanical degree.
Before you proceed, be sure you have completed Chapter 1 and have added the two materials to
the Materials Database (CSLMAT).
Chapter 2 Cogging torque computation

Enter the physical properties 17
Enter the physical properties

To enter the physical properties, use the Preflu 9.1 application, the same application used to
create the geometry and mesh (in previous versions of Flux, a separate application, the Physical
Properties module, Prophy, was used).
Start Preflu 9.1
In the Flux Supervisor, in the Construction folder, double click Geometry & Physics:
Starting Preflu 9.1 to enter the physical properties
Program Input
Double click Geometry & Physics
Cogging torque computation Chapter 2

18 Enter the physical properties
The Preflu 9.1 application opens.
Preflu 9.1 screen
Open the 3-layer airgap problem
You can open an existing project either with the toolbar icon or the menu.
Using the icon in the toolbar
To open a new Flux project, click the icon on the toolbar
Program Input
click

Using the menu
If you prefer, choose Project, Open project from the menu:
Program Input
Project
Open project
The Open project dialog opens.
Enter or verify the following:
Program Input
Look in Brushless_V9 [your working

directory
File Name brushless_3layer.flu [your
name]
Open

20 Save your project with a new name
The 3-layer geometry is shown in the following figure:
The geometry (with 3-layer airgap) displayed in Preflu
Save your project with a new name

Save your project now with a specific name to indicate that you will be using this model for
cogging torque calculations.

Save your project with a new name 21
To save your project with a new name, choose Project, Save As… from the menu:
Program Input
Project
Save As…
The Save flux project dialog opens.
Saving the brushless 3-layer model as cogging
Program Input
Save In: Brushless_v9 [working directory]
File Name: cogging [your name]
Save

22 Define as Transient Magnetic
Define as Transient Magnetic

Define cogging as a transient magnetic problem using the Application menu:
Program Input
Application
Define
Magnetic
Transient Magnetic 2D
The Define Transient Magnetic 2D application dialog opens.
Program Input
2D domain type 2D plane
Length Unit MILLIMETER
Depth of the domain 50.308
OK

Change to the Physics context 23
Your screen should look like the following. Notice that there is a new context symbol,
representing the Physical model context.
The cogging problem after defining the physical model
Change to the Physics context

The Physics commands are available only in the Physics context. The following figure shows the
Physics context selected.
At the top of the data Tree, click the button to change to the Physics context.
Program Input
click

24 Change to the Physics context
The Physics context is shown in the following figure.
The cogging problem after going to the Physics context
Physics context toolbars
The Physics context includes some of the same icons and commands as the Geometry and Mesh
contexts. Most of the Display and Select icons are the same.
The following figures show the Physics toolbar icons:
Physics toolbar icons: Add, Check
Physics toolbar icons: Display, Select

Import materials from the materials database 25
The following figures identify the Physics toolbar icons:
Import materials from the materials database

Before we can assign materials we created in Chapter 1 to the different regions of our model, we
must import them. Use the menu, Physics, Material, Import material.
Program Input
Physics
Material
Import material

26 Import materials from the materials database
The import material dialog appears.
Initial material import dialog
Click on the icon next to the material database name to display the list of materials in the
database.
List of materials in the database displayed
Now scroll to find the two materials you want to import; MAGNETPM and NLSTEELPM.
Select both with the mouse using the Control key.
Proceed as follows:
Program Input
Click MAGNETPM
Click NLSTEELPM + Ctrl
Import

Assign materials and sources to the regions 27
After the import is complete, close the Import materials window.
Program Input
Close
If you expand the Materials in the data tree, you will see the two materials now included in the
project.
Materials imported into project
Assign materials and sources to the regions

Material and/or source assignment is done region by region. You can select the regions from the
screen, or choose the region names from the data tree on the left. You can use the Edit Array
command to assign the same properties to several regions at the same time.
Assign the windings of the stator slots
Begin by assigning the winding areas of the stator slots to a "vacuum" state. We will select the
stator slots from the data tree on the left. First expand the Face Region tree by clicking the
icon next to Physics, Regions, and Face region.

28 Assign materials and sources to the regions
Proceed as follows:
Program Input
Click
Click
Click

Next select the stator slots from the tree by selecting their names. Make sure you hold the
Control key when making multiple selections.
Program Input
Click MA
Click MC + Ctrl
Click PA + Ctrl
Click PB + Ctrl
Now click the right mouse button and select Edit Array.
Program Input
Right click, Edit array

The Edit Face Region window appears, and the stator slots are highlighted on the graphic.
Editing all stator slots using Edit Array function
Under the Modify All column, we will set all the stator slots at once to a vacuum region. First
select "Air or vacuum" in the Modify All column.
Select Air or Vacuum in the Modify All Column

Next, accept your input.
Setting a vacuum property for the stator slots
Proceed as follows:
Program Input
Sub types: Select "Air or vacuum"
OK
Assign WEDGE, AIR, STATOR_AIR, AIRGAP and SHAFT regions
Next, assign properties to the WEDGE, AIR, STATOR_AIR, AIRGAP and SHAFT regions as
a group:

Select the air regions from the tree by selecting their names. Make sure you hold the Control key
when making multiple selections.
Program Input
Click AIR
Click AIRGAP + Ctrl
Click SHAFT + Ctrl
Click STATOR_AIR + Ctrl
Click WEDGE + Ctrl
Under the Modify All column, we will set all these regions at once to a vacuum region.
Setting a vacuum property for the air regions
Proceed as follows:
Program Input
OK

Notice that the Console window displays a message confirming the assignment of the vacuum
region.
Console confirms region faces modified
Assign STATOR and ROTOR regions
Assign the NLSTEELPM material to the STATOR and ROTOR regions.
Select the stator and rotor regions (shown below in orange) from the graphic. Make sure you
hold the Control key when making the second selection.
Selecting the Stator and Rotor regions graphically

Once the regions are selected, right click the mouse and select Edit Array.
Edit the stator and rotor areas as a group
Under the Modify All column, we will set both of these regions to the NLSTEELPM material.
Setting the stator and rotor to NLSTEELPM
Proceed as follows:
Program Input
Sub types: Select "Magnetic reg"
Material Select "NLSTEELPM"
OK

Assign the MAGNET
Finally, assign the MAGNETPM material to the MAGNET region.
Select the magnet region graphically with the mouse, then right click the mouse and select Edit.
Selecting the magnet region, then selecting Edit
The Edit Face Region window appears.
Setting the magnet region to the MAGNETPM material

Proceed as follows:
Program Input
Type of region Magnetic region
Material of the region MAGNETPM
OK
Now you must set the direction of the magnet. Select the icon from the toolbar to orient the
magnet.
Program Input
Click
If you prefer, choose Physics, Material, Orient material for face region from the menu.
Program Input
Physics
Material
Orient material for face region

The following figure shows the Orient Material window.
Setting the magnet to 45 degree orientation
Proceed as follows:
Program Input
Magnet...Angle 45
OK
You have now assigned a material property to each region of the geometry.
Your screen should resemble the following figure.
The physical properties are assigned

38 Creating and Assigning Mechanical Sets
Creating and Assigning Mechanical Sets

Creating Mechanical Sets
New with Flux 9.1 is the existence of Mechanical Sets. Mechanical Sets are used whenever you
want motion in the model (either rotating or translating). Whenever there is motion in the
model, you must define 3 mechanical sets;
• Fixed - This defines the parts of the model that do not move
• Moving- This defines the parts of the model that move (either rotating or translating)
• Compressible- This defines the region between the moving and non-moving parts (and the
displacement regions, in the case of a translating motion)
We will first create these mechanical sets. Select Physics, Mechanical Set and New from the
menu.
Program Input
Physics
Mechanical set
New

Creating and Assigning Mechanical Sets 39
Create the MOVING_ROTOR Mechanical Set
The New Mechanical set dialog appears. Enter the information to create the
MOVING_ROTOR mechanical set.
Defining the Axis information for the MOVING_ROTOR

Mechanical Set
Proceed as follows to define the Axis information. Then go to the Kinematics tab.
Program Input
Mechanical set name moving_rotor
Comment the moving parts of the model
Type of mechanical set Rotation around one axis
Rotation Axis Rotation around one axis

parallel to Oz
Coordinate system MAIN
Pivot point
First coordinate 0

Second coordinate 0
Click on "Kinematics" tab
The Kinematics tab opens. Enter the information to define the General kinematics, then click on
the Internal characteristics tab.
Defining the General kinematics information for the

MOVING_ROTOR Mechanical Set
Proceed as follows to define the General kinematics information (rpm entered equals 1 degree of
rotation per second):
Program Input
Type of kinematics Imposed Speed
Velocity (rpm) 1/6
Position at time t=0s. (deg) 0
Click "Internal
characteristics" tab

The Internal characteristics tab opens. Enter the information to define the Internal kinematics
information, then click on the External characteristics tab.
Defining the Internal kinematics information for the MOVING_ROTOR

Mechanical Set
Proceed as follows to define the Internal characteristics information:
Program Input
Type of load Inertia, friction coefficients

and spring
Moment of inertia 0
Constant friction coefficient 0
Viscous friction coefficient 0
Friction coefficient 0
proportional to the square
speed

Click "External
The External characteristics tab opens. Enter the information to define the External kinematics
information, then click on OK button.
Defining the External kinematics information for the

Proceed as follows to define the External characteristics information. Click OK at the end to
complete the definition of the mechanical set:
Program Input

and spring
Moment of inertia 0

speed
OK
Create the FIXED_STATOR Mechanical Set
The New Mechanical set dialog closes briefly and then reappears. Enter the information to create
the FIXED_STATOR mechanical set.
Defining the information for the FIXED_STATOR

Mechanical Set
Proceed as follows:
Program Input
Mechanical set name fixed_stator
Comment the non-moving parts of the

model
Type of mechanical set Fixed
OK

Create the ROTATING_AIRGAP Mechanical Set
the ROTATING_AIRGAP mechanical set.
Defining the information for the ROTATING_AIRGAP

Mechanical Set
Proceed as follows:
Program Input
Mechanical set name rotating_airgap
Comment the rotating airgap
Type of mechanical set Compressible
Used method to take the motion Remeshing of the air part

into account surrounding the moving body
OK

The New Mechanical set dialog closes briefly and then reappears. Close the dialog by hitting the
Cancel button.
Close the Mechanical set dialog
Proceed as follows:
Program Input
Cancel
Assigning Mechanical Sets
Now assign the mechanical sets to the regions of your model. First assign the appropriate regions
to the MOVING_ROTOR mechanical set.

Select the AIR, MAGNET, ROTOR and SHAFT regions from the tree by selecting their names.
Make sure you hold the Control key when making multiple selections.
Program Input
Click AIR
Click MAGNET + Ctrl
Click ROTOR + Ctrl
Click SHAFT + Ctrl
Under the Modify All column, we will set all these regions at once to the MOVING_ROTOR
mechanical set.
Assigning regions to the MOVING_ROTOR mechanical set
Proceed as follows:
Program Input
MECHANICAL_SET Select "MOVING_ROTOR"
OK

Now assign regions to the FIXED_STATOR mechanical set. Select the MA, MC, PA, PB,
STATOR, STATOR_AIR and WEDGE regions from the tree by selecting their names. Make
sure you hold the Control key when making multiple selections.
Program Input
Click MA
Click MC + Ctrl
Click PA + Ctrl
Click PB + Ctrl
Click STATOR + Ctrl
Click STATOR_AIR + Ctrl
Click WEDGE + Ctrl
Under the Modify All column, we will set all these regions at once to the FIXED_STATOR
mechanical set.
Assigning regions to the FIXED_STATOR mechanical set
Proceed as follows:
Program Input
MECHANICAL_SET Select "FIXED_STATOR"
OK

Now assign the airgap region to the ROTATING_AIRGAP mechanical set. Select the AIRGAP
region from the tree by selecting its name.
Program Input
Click AIRGAP
Right click, Edit
The Edit Face region dialog appears. Click on the Mechanical Set tab to assign the mechanical set
to the AIRGAP region.
Click on the Mechanical Set tab

Boundary conditions (Periodicity) 49
Now select the ROTATING_AIRGAP mechanical set from the pull down menu.
Setting the AIRGAP region to the ROTATING_AIRGAP

mechanical set
Proceed as follows:
Program Input
Select "ROTATING_AIRGAP"
OK
Boundary conditions (Periodicity)

In previous versions of Flux, you needed to specify boundary conditions. With Flux 9.1,
boundary conditions are automatically created based on symmetry and periodicity.

50 Boundary conditions (Periodicity)
Since we have modeled one quarter, or 90 degrees, of the model, we need to define a periodicity
reflecting this. Select the icon from the toolbar to create a new periodicity.
Program Input
Click
If you prefer, you can select Geometry, Periodicity, New from the menu.
Program Input
Geometry
Periodicity
New

The New Periodicity dialog opens.
Defining a periodicity for the brushless DC motor
Proceed as follows:
Program Input
Geometrical type of the Rotation about Z axis with

periodicity angle of the domain
Included angle of the domain 90
Offset angle with respect to 0

the X line
Physical aspects of periodicity Odd (anticyclic boundary

conditions)
OK
Check the physical model
Now that all physical attributes have been assigned to our model, we should have Flux check it
before proceeding to solving.

Select the icon from the toolbar to start the Physical Check.
Program Input
Click
If you prefer, you can select Physics, Check physics from the menu.
Program Input
Physics
Check physics
The console indicates that the physical check is completed.
Close Preflu
The model is ready for solving. Close the Preflu application.

Click on the icon in the toolbar to exit Preflu.
Program Input
Click
If you prefer, select Project, Exit from the menu.
Program Input
Project
Exit
When prompted, select to save your problem.
Proceed as follows:
Program Input
Save current project before Yes

54 Solve (batch mode)
Solve (batch mode)

For the cogging torque computation, Flux2D generates the torque waveform of 2 slot pitches.
For the 24-slot motor, 2 slot pitches corresponds to 30 mechanical degrees. The rotor rotates by
0.5 degrees for each time step. This results in a total of 60 time steps or positions for the cogging
torque computation. With the rotor speed at 1/6 rpm, 1 second corresponds to 1 mechanical
degree; thus the time step is 0.5 seconds.
Flux2D can solve directly (interactively) or in batch mode. For this problem, use batch mode to
reduce the solution time.
Prepare the batch file
To open the Solver, in the Flux Supervisor, in the Solving process folder, double click Direct.
Starting the solver

Solve (batch mode) 55
Program Input
Double click Direct
In the Open dialog, select the problem to be solved and click Open
Choosing the problem to solve
Program Input
Look in Brushless_V9[working directory]
File name COGGING.TRA
Open

The solver opens as shown below.
Solver: Main data
Click the Prepare Batch button to prepare the file for batch mode.
Program Input
click

Your screen should resemble the following figure.
Ready to enter data for batch file
In the “Definition of time data” dialog, enter or verify the information to prepare the batch file
as follows:
Program Input
Restarting mode New computation
Time values
Initial value of the time 0.5

step
Study time limit 100
Maximum value of the time 0.5

step
Minimum value of the time 0.5

step
Storage of time steps

Program Input
one step on 1
Ok
Your time data should be filled in as shown in the following figure:
Time data for the batch computation

After you click OK, the “Rotating air gap” dialog opens. Make sure that the initial position of the
rotor is 0 degrees. Then click OK.
Verifying the initial position of the rotor (0 degrees)
Program Input
Initial position of the rotor OK

0. degrees

Your screen should resemble the following figure. At the bottom of the screen, this message is
displayed: “COGGING: Preparation of the batch computation finished.”
Batch file completed
Flux2D has created a file called COGGING.DIF that will be used to start the batch solution.

Close the solver
Choose File, Exit to close the solver.
Program Input
File
Exit

Start the batch computation
In the Flux Supervisor, in the Solving process folder, double click Batch:
Starting the Solver for a batch computation
Program Input
Double click Batch

In the Batch window, problems with batch files prepared are indicated by Yes in the "Ready"
column, as shown in figure below.
Select the problem you wish to solve, e.g., “COGGING.TRA,” and click the Start button to
begin the batch computation:
Starting the batch computation
Program Input
Files Ready
COGGING.TRA Yes COGGING.TRA
Start

The Solver window opens:
Batch computation in progress

When the problem has finished solving, the Batch window is displayed again. Choose Quit to
close the Solver.
Closing the solver after batch computation
Program Input
Batch
COGGING.TRA Quit
The Flux Supervisor should still be open.

66 Results
Results
To see your results, in the Flux2D Supervisor, in the Analysis folder, double click Results:
Starting Results analysis from the Supervisor
Program Input
Double click Results

Results 67
From the Open dialog, choose the problem you want to analyze and click Open:
Opening the cogging torque problem for results analysis
Program Input
Look in Brushless_V9[working directory]
File name COGGING.TRA
Open

68 Results
PostPro_2D opens with a display of the model geometry at the first time step, 0.5 s.
Model open in PostPro_2D

Results 69
Display the full geometry
You can display various quantities as plots on the model geometry. If you wish, instead of the
model (¼ of the motor, in this case), you can display the full geometry.
To see the full geometry, in the toolbar, click the Full Geometry icon or choose Geometry,
Full Geometry from the menu:
Program Input
Geometry
Full geometry

70 Results
Your screen should resemble the following.
Model with full geometry displayed

Results 71
Displaying isovalues (equiflux) lines at t = 1 s
It is often useful to begin analysis with a display of the isovalues (equiflux) lines.
Change the default isovalues display
By default, PostPro_2D displays 11 equiflux (isovalues) lines. To display 21 isovalue lines over
the geometry, click the Results properties button or choose Results, Properties from the
menu.
Program Input
Results
Properties

72 Results
The Display properties dialog opens.
Results properties dialog for isovalues display
Make sure the Isovalues tab is on top (this is the default).
Then enter or verify the information in the dialog as follows:
Program Input
Isovalues
Analyzed quantity Equi flux
Support Graphic selection
Computing parameters
Quality Normal
Number 21

Results 73
Program Input
Scaling Uniform
OK
When you click OK, the properties dialog closes.
Change the time to 1 s
PostPro_2D opens with the model at the first time step, 0.5 s, and the rotor at 0 degrees. Look at
the isovalues with the rotor position at 1 degree, or time 1 s.
To do so, open the Parameters manager dialog by clicking the icon or by choosing
Parameters, Manager from the menu.
Program Input
Parameters
Manager
The Parameters dialog opens, as shown in the following figure.
Parameters dialog

74 Results
Choose 1 from the Values list and then close the Parameters dialog.
Program Input
Parameters
Values 1
click
Display the isovalues plot
To display the isovalues lines, click the Isovalues button in the toolbar or choose Results,
Isovalues from the menu.
Program Input
Results
Isovalues

Results 75
The isovalues (equi flux) lines are displayed:
Display of the flux density lines on the full geometry at 1 s.
Color shade of flux density on a group of regions
Next, look at a color shade plot of the flux density over the stator, rotor, and magnet regions of
the model only (not the full geometry) and at the initial time and position (0.5 s).
Change the geometry display
Click the Full Geometry button to deselect it.
Program Input
click

76 Results
Change the time to 0.5 s
Now change the time back to the initial value, 0.5 s. Open the Parameters manager with the
button, or choose Parameters, Manager from the menu.
Program Input
Parameters
Manager
In the Parameters dialog, choose 0.5 again and close the dialog.
Choosing 0.5 s (initial time step)
Program Input
Parameters
Values 0.5
click

Results 77
Create a group of the three regions
To place the three regions in a group, click the icon or select Supports, Group manager from
the menu.
Program Input
Supports
Group manager
The Group manager dialog opens.
Group manager dialog
In the Group manager, enter or verify the following:
Program Input
Filter Region
Objects available STATOR

MAGNET
ROTOR
Add -->

78 Results
Program Input
Current group STATOR

MAGNET
ROTOR
Group name Big3 [or your name]
Create
When you click the Create button, the dialog closes and the group is added to the supports list in
the problem's data tree.
Display a color shade plot on the group of regions
Now use the group for the display of the color shade plot.
Open the Results, Properties dialog by clicking the button or by choosing Results,
Properties from the menu.
Program Input
Results
Properties

Results 79
Properties for color shade plot on regions group
Click the Color Shade tab to bring it to the front. In the Color shade dialog, enter or verify the
following:
Program Input
click Color Shade tab
Analyzed quantity |Flux density|
Support Big3 [or your regions group]
Quality Normal
Scaling Uniform
OK
The Display properties dialog closes.

80 Results
To display the plot, click the color shade button in the toolbar.
Program Input
click
The plot on the group of regions is shown below:
Color shade plot of flux density on a group of regions

Results 81
Create a path through the airgap
Next examine the variation of several quantities along a path through the center of the airgap.
The following figure shows the path:
Location of path through airgap
To create this path through the airgap, open the Path manager.
Click the Path manager button or choose Supports, Path manager… from the menu:
Program Input
Supports
Path manager…

82 Results
The Path Manager dialog opens:
Path manager
You will be creating an arc path of 180 degrees through the center of the airgap. To verify the
coordinates for the path, with the Path manager open, move your cursor over the geometry
model.
The cursor looks like a cross with a trailing line or, when Arc is selected (as shown in the
previous figure), the cursor resembles a cross with a drawing compass .
Use the Zoom region button to enlarge the area around the bottom of the stator and the
airgap and move the cursor into the center of the airgap. The X and Y coordinates are shown at
the bottom of the PostPro_2D window.

Results 83
The following figure shows the Path manager, an enlargement of the airgap, and the coordinates
(here, for example, X= 25.4, so we used 25.4 for the X value):
Locating the coordinates for the center of the airgap path
In the Path Manager dialog, enter or verify the following:
Program Input
Path
Name CenterGap [or your choice]
Discretization 200
[default color] [new color, if desired]
Graphic section Arc
Numerical section New section

84 Results
When you click the New section button, the Section Editing dialog opens:
Section editing window to create paths
In the Section Editing dialog, enter or verify the following:
Program Input
Section type Arc start angle
Center point
X 0
Y 0
Origin point
X 25.4
Y 0
Length 180
OK

Results 85
The Section editing dialog closes and the path is displayed on the geometry, as shown (enlarged)
in the following figure.
Path through airgap
In the Path manager dialog, click the button to create the path and open the 2D Curves
manager at the same time.
Program Input
click

86 Results
Normal component of flux density along the air gap path
The 2D Curves manager is shown in the following figure.
Settings for flux density curves (normal component at 1 s, 2 s, and 3 s)
With the 2D curves manager, you can create and display curves of various quantities along paths;
with selected parameters (such as a series of time steps); or along shell (line) regions.

Results 87
Begin with curves of the normal component of the flux density along the path through the airgap
at times 1 s, 2 s, and 3 s.
F To select these times from the Parameter values list, click 1, hold down the Ctrl
key, and then select 2 and 3.
Enter the curve information as follows:
Program Input
Curve description
Name FDNorm [or your choice]
Path
First axis
X axis CenterGap
Second axis
Quantity Flux density
Components Normal component
Third data
Parameter Time
Parameter values 1 + Ctrl

2
3
Selection step 1
click
Clicking the button creates and displays the curve at the same time.

88 Results
A 2D curves sheet opens with the 3 curves “stacked,” as shown in the following figure:
Normal component of the flux density through the air gap at time steps 1, 2, and 3 s
Superimpose the curves display
To superimpose the curves, right click on the curves sheet, as shown in the previous figure.
From the context menu, choose Properties to open the properties dialog.
Program Input
Right click on curves sheet
Properties
The Curves properties dialog appears. Click the Display tab to bring it to the front.

Results 89
In the Display dialog, enter or verify the following:
Program Input
click Display tab
Display Superimposed
Gradations ON
X Axis
Range Automatic
Scale linear
Y Axis
Range Automatic
Scale linear
OK
When you click OK, the dialog closes.

90 Results
The following figure shows the curves superimposed:
Superimposed curves of normal component of flux density at times 1, 2, and 3 s

Results 91
Spectrum analysis
Next, use the Spectrum manager to display the harmonics of the normal component of the flux
density at 1 s.
Click the button or choose Computation, 2D Spectrum manager… from the menu.
Program Input
Computation
2D spectrum manager…
The Spectrum manager opens, as shown in the following figure:
Spectrum manager with settings for analysis of normal component of flux density at
1s

92 Results
Program Input
Analyzed curve FDNorm
Between 0
and 79.79644
Part of cycle described Full cycle
Create this original curve [check box to display flux

density curve with spectrum]
Spectrum
Harmonics number 30
Spectrum scale Linear
Display the DC component line [check to enable if desired]
Name SpectFDNorm [name]
click
Clicking the button creates and displays the spectrum and the curve on a new sheet.

Results 93
The flux density curve and the spectrum are shown below:
Spectrum analysis of normal component of flux density at 1 s
To clarify the spectrum display, you can change its properties. Right click on the legend of the
spectrum and choose Properties from the context menu.
Program Input
Right click on spectrum legend
Properties

94 Results
The previous spectrum plot, for example, uses a line width of 3, entered as shown below.
Properties dialog to modify individual curve settings, such as line form and width

Results 95
Axis torque (full cycle)
Finally, display the axis torque of the motor over the whole cycle of 61 time steps. Open the 2D
curves manager with the button, or choose Computation, 2D curves manager… from the
menu.
Program Input
click
The 2D curves manager for the axis torque curve is shown below:
Settings for curve of axis torque over the whole cycle

96 Results
Program Input
Curve description
Name AxisTorq [or your choice]
Parameter
First Axis
X axis Time
Parameter values 0.5 - 30.5
Selection step 1
Second axis
Quantity Mechanics
Component Axis torque
click

Results 97
The axis torque curve is shown in the following figure:
Time varying display of the axis torque
F Note: Since only ¼ of the motor is being modeled, the torque displayed will be ¼
of the total motor torque.

98 Save your analyses
To read values from the curve, from the 2D curves menu, select New cursor… and then position
the cursor.
Program Input
2D curves
New cursor…
For instance, the cursor in the previous figure is at X = 13.56537, showing a value of Y =
2.151964E-3 N.m for the axis torque.
Save your analyses

This concludes our analysis of the cogging torque. We encourage you to create other supports
(groups, paths, grids), plots, and curves on your own.
When you are ready, click the Save button to save your analysis work (the path, group, and
curves you created). If you prefer, choose File, Save from the menu.
Program Input
File
Save

Close PostPro_2D 99
Close PostPro_2D
Close PostPro_2D by selecting File, Exit from the menu:
Program Input
File
Exit

Chapter 3
Back EMF computation

This chapter explains how to compute the back EMF of the stator winding.
Create a 3-phase Wye connected no load circuit using ELECTRIFLUX

(see diagram on page 105)

Materials and sources
All stator windings: vacuum, external circuit
Airgap: rotating air gap, constant angular velocity of 500 rpm, 2 pole pairs
Wedge, air, shaft regions: vacuum, no source
Stator, rotor: nonlinear steel, no source
Magnet: magnet, radial +, no source
Boundary conditions: Accept default conditions
Link external circuit
Coil regions (PA, MA, MC, PB) to coil components (B_PA, B_MA, B_MC,
B_PB)
Define coil characteristics
B_PA, B_MA: Resistance total value, 10 turns, 0.0705 Ω
B_MC, B_PB: Resistance total value, 20 turns, 0.141 Ω
Solve with static initialization

Initial value of time step 0.00125s
Store 1 on 1 time steps

Waveforms of electric quantities (2D curves)
Voltage through resistor Res4
Spectrum analysis of Res4 voltage curve
Voltage for Res1
101
Back EMF computation
Flux2D computes the back EMF of the stator winding by connecting the stator winding power
supply to an open circuit load and rotating the rotor over one electric cycle. Line to line and
phase voltages with harmonics fully taken into account are readily available through the external
circuit model.
F For this simulation and for those described in Chapters 4, 5 and 6, be sure to use
the 1-layer airgap model.
Create the back EMF external circuit model

Conventions
The following conventions are used for the external circuit model.
The stator winding connections for the model (¼ of the motor, or 1 pole) are 3-phase Wye
connected. The phase diagram is shown in the following figure:
Phase diagram for the 3-phase Wye

connected windings
102
Create the back EMF external circuit model 103
For the circuit model, the hot point convention is also used .
The small squares beside the components indicate the “hot” points, shown in the following figure
at the top right of the coil.
Coil with "hot" point

at upper right
The “hot” point shows the side through which the current should enter the component to give a
positive voltage drop. The components must be oriented so that these “hot” points are on the
proper side. Thus, the position of the “hot” point is essential for the coils.
Back EMF computation Chapter 3

104 Create the back EMF external circuit model
Back EMF circuit
The following figure shows the components of the circuit as they should be placed on the screen.
Circuit components for back EMF simulation
Chapter 3 Back EMF computation

Start ELECTRIFLUX
To start ELECTRIFLUX, in the Flux Supervisor, in the Construction folder, double click
Circuit.
Starting the Circuit module (ELECTRIFLUX)
Program Input
Double click Circuit

ELECTRIFLUX opens, as shown below:
ELECTRIFLUX (Circuit) window
Open a new circuit problem
Open a new circuit problem, either with the toolbar icon or the menu.
Click the icon in the toolbar.
Program Input
click

Using the menu
If you prefer, choose File, New from the menu.
Program Input
File
New

New (blank) Circuit and Sheet windows open.
New Circuit and Sheet windows open in ELECTRIFLUX

ELECTRIFLUX toolbar
The ELECTRIFLUX toolbar includes icons for project management (New, Open, Save), as well
as special icons for managing components, selecting components, and viewing the sheet.
The following figure shows the ELECTRIFLUX toolbar.
The figures below identify the toolbar icons.

ELECTRIFLUX menus
Below are brief descriptions and illustrations of the ELECTRIFLUX menus.
File menu
The File menu includes commands to open, save, print, and import/export circuit files.
Edit menu
The Edit menu includes commands to manage components on the sheet, e.g., Cut, Copy, Paste,
Delete.

View menu
The View menu includes commands to change the appearance of the sheet. For example, you can
display or hide the circuit grid with View, Grid.
The Zoom commands are also accessible through the View menu.
Circuit menu
The Circuit menu includes commands to arrange components and connections, e.g., to insert
connection points, rotate elements, insert space between components, etc.
F "Automatic component skirting" is a setting that prevents circuit connections from

being made through or across components. This option is activated (checked) by
default.

Sheet menu
The Sheet menu includes commands to manage individual circuit sheets—to change the name of
the sheet, the background colors, the size of the sheet, the grid spacing, and so on.
Window menu
The Window menu includes commands for the display of the Circuit window (which includes
the Sheet window).
? (Help) menu
The ? (Help) menu includes commands to link to Flux online help (including a searchable
Index), the Flux User's Guide, and other documentation.

Change the size of the sheet
Before you proceed, if you wish, you can change the size of the sheet window.
To modify the sheet settings (size of sheet, etc.)
Right click anywhere on the sheet to open the context menu. Choose Sheet settings….
Program Input
Right click on the sheet
Sheet settings…

The Sheet properties dialog opens.
Modifying the sheet properties
Program Input
Sheet properties (Sheet_1)
Comment 3 phase wye delta
Squaring gap (pixels) 10
Line Width 1
Background color [white]
Line color [blue]
Selected line color [red]
Sheet Width 800
Sheet Height 600
OK

When you click OK, the dialog closes. Adjust the sheet window (if necessary) to show your new
sheet size.
New (larger) sheet with grid
Now you are ready to begin placing the circuit components on the sheet.

The following figure shows all the components in place for the circuit.
Circuit components placed on the sheet

Add coils for stator windings
First, add the coils for the stator windings.
To add the coils, click Coil conductor in the Components library.
Program Input
click Coil conductor

A red coil symbol is displayed in the upper left corner of the sheet.
Ready to place the coil components (stator windings)

Place the 4 coil components on the sheet
Move your cursor over the coil symbol, but do not click on the symbol yet. Drag the symbol
with the mouse until the coil is in the position shown in the following figure.
Moving Coil 1 into position
Then click to place the coil in that position (the coil symbol turns blue). As soon as you move
the cursor again, you will see a second (red) coil symbol.
Moving coil B2 into position

Move the cursor to place the three other coils, as shown (somewhat enlarged) in the following
figure.
Four coils placed on the sheet
Program Input
click to place B2 directly

below B1
click to place B3 below and to
the left of B2
click to place B4 to the right
of B3

Move your cursor off the sheet to stop adding coil components (the pointer changes to an arrow
shape).
To stop adding coil components to the sheet

Rotate the 4 coils for proper orientation of the hot point
Now rotate the coil components. For each component, complete the two steps below:
1. Click the component to select it (the component turns red).

2. Click the Rotate icon the appropriate number of times to position the component.
To rotate coil B1
Each time you click the Rotate icon , the component rotates 90° clockwise. Note that coils
B2 and B4 must be rotated a total of 270° clockwise; thus, you need to click the Rotate icon
three (3) times to obtain the proper rotation for coils B2 and B4.
For example, the following figure shows coil B2 after its rotation. Look closely to see that the
"hot point" is at the lower left of the coil.

To rotate the coils, proceed as follows:
Program Input
click B1 symbol
B1 turns red
click once
B1 rotates 90° clockwise
click B2 symbol
B2 turns red
click three (3) times
click B3 symbol
B3 turns red
click once
click B4 symbol
B4 turns red

With the four coils properly rotated, your sheet should resemble the following:
Coils rotated (slightly enlarged)

Add inductors
Now add inductors to model the stator winding end turn inductances.
Click Inductor in the Components library.
Program Input
click Inductor
A red inductor symbol is displayed in the upper left corner of the sheet.
Ready to position inductors

Place the 3 inductors on the sheet
Move the cursor and click to place the 3 inductors on the sheet as shown in the following figure.
Placing the third inductor (L3) on the sheet
Proceed as follows:
Program Input
click to place L1 below B2

click to place L2 above B3
click to place L3 above B4
drag cursor off the sheet
Drag the cursor off the sheet to stop adding inductors.

With the inductors added, your sheet should resemble the following figure.
Inductors placed on sheet

Rotate the 3 inductors
Now rotate the 3 inductors for proper orientation. Inductors L2 and L3 must be rotated 270°
clockwise.
Proceed as follows:
Program Input
click L1 symbol
L1 turns red
click once
L1 rotates 90° clockwise
click L2 symbol
L2 turns red
click L3
L3 turns red

With the inductors properly rotated, your sheet should resemble the following figure.
Inductors oriented

Add the open circuit loads
Next, add the open circuit loads. These are three large resistors (100,000 Ω) connected in Wye.
The following figure shows the location of these three resistors.
Three resistors (open circuit loads) placed on the sheet

To add the resistors, click Resistor in the Components library.
Program Input
click Resistor
A red resistor symbol is displayed in the upper left corner of the sheet.
Ready to place resistor on the sheet

Place the 3 resistors on the sheet
Move the cursor and click to place 3 resistors on the sheet as shown in the following figure.
Resistors for open circuit loads placed on the sheet
Proceed as follows:
Program Input
click to place R1 at the top

right of the sheet
click to place R2 to the right
of coil B4
click to place R3 at the lower
right corner of the sheet

Move your cursor off the sheet to stop adding resistors for now.
Rotate the 3 resistors
Now rotate the 3 resistors for proper orientation of the "hot" point. Proceed as follows:
Program Input
click R1 symbol
R1 turns red
click once
R1 rotates 90° clockwise
click R2 symbol
R2 turns red
click R3
R3 turns red

With the three resistors properly rotated, your sheet should resemble the following.
Open circuit load resistors oriented

Add the voltmeter
Finally, add a large resistor between the phase C coil (B3) and the phase B coil (B4). This resistor
acts as a voltmeter to measure the line to line voltage.
Click Resistor again in the Components library.
Program Input
click Resistor
Again, the red resistor symbol is displayed in the upper left corner of your sheet.

Place the voltmeter (R4) on the sheet
Move your cursor with the resistor symbol and place it as shown in the following figure.
Placing the voltmeter (R4) on the sheet
Proceed as follows:
Program Input
click to place R4 between B3

and B4
Drag your cursor off the sheet to stop adding resistors.

Rotate the voltmeter (R4)
Now rotate the resistor (R4) as follows.
Program Input
click R4 symbol
R4 turns red
click twice

All the components should now be properly positioned on your sheet, as shown in the following
figure.
Components placed on sheet

Save your circuit file
Now is a good time to save your circuit file. Click the icon or choose File, Save from the
menu.
Program Input
File
Save
The "Choose a file name" dialog opens.
Saving the circuit file

The dialog shows your working directory in the "Save in" field (e.g., ours is "Brushless_V9" in the
previous figure). If you should wish to save the file to a different directory, click the button
and browse to the directory you wish.
When you are ready, proceed as follows:
Program Input
Save in Brushless_V9[working directory]
File name onedelta.ccs [or your name]
Save
Connect (wire) the circuit components
Now connect the components.
Place the cursor over the bottom pin of coil B1, so that the cursor changes to a bull's-eye
shape.
Starting to connect (wire) the components

Program Input
position cursor over bottom pin

of coil B1
Drag the cursor down to the top pin of coil B2 and click to complete the first connection.
Program Input
click pin at top of B2 to

complete the connection
Connect all the components in the same way.

Notice that with the "Automatic component skirting" option (the default option), you cannot
make an invalid connection, such as one that passes "through" or over a component. The cursor
changes to a hand as it passes over coil B2, as shown in the following figure.
You can make connections only when you see the bull's-eye cursor.

The following figure shows resistor R2 being connected to coil B4.
Connections for upper part of circuit

When you are making long connections, such as between resistor R3 and coil B3, you can click
on the grid itself (not on a component pin) to create an intermediate point or "corner" for the
connection, as shown in the following figure.
Adding an intermediate point for a connection

Such intermediate points may improve the legibility of your circuit diagram. For example, the
following figure shows what the connection might look like without the intermediate point.
Connecting R3 to B3 without intermediate point
You can also move connections. If necessary, click the icon in the toolbar to select entire
connections; the cursor changes to . Then click the connection line to select it and drag the
line until it assumes the shape you wish. For example, the following figure shows the last
connection selected (the lines of the connection are shown in red on the screen, and the number
5 is displayed over the line).
Connection selected (lines shown in red)

The following figure shows the connections for the whole circuit.
Circuit connections complete
Define the resistors and inductors
Now define the values of the resistors and inductors. You may use scientific notation to enter
the resistance and inductance values.
Use 100,000 Ω as the resistance value for all the resistors.
The design sheet value for the end turn inductance per phase is 0.031 mH/phase.

Define the resistors
Begin by defining the resistance value for each of the 4 resistors.
Double click R1, the symbol for the first of the open circuit loads.
Program Input
Double click R1
The symbol turns red, and the Resistor dialog opens.
Defining resistance for R1
If you wish, you can edit the name of the resistor and add a brief description in the Comment
field.
F The name of any resistor must begin with a capital R. The initial letter of any
component name cannot be changed.
In the dialog, enter or verify the following:
Program Input
Resistor
Name R1

Program Input
Characteristics
Name R(ohm)
Value 1e5
Ok
When you choose Ok, the dialog closes. Define the other 3 resistors, including the voltmeter, as
follows:
Program Input
Double click R2
1e5
Ok
Double click R3
1e5
Ok

Program Input
Double click R4
1e5
Ok
Define the inductors
In the same way, define the inductors. Double click L1, the symbol for the first inductor. The
symbol turns red and the Inductor dialog opens.
Defining inductance value for the first inductor (L1)

In the Inductor dialog, enter or verify the following:
Program Input
Inductor
Name L1
Characteristics
Name L(henry)
Value 3.1e-5
Ok
When you choose Ok, the dialog closes.
Define the other inductors as follows:
Program Input
Double click L2
3.1e-5
Ok
Double click L3
3.1e-5
Ok
Again, when you click Ok, the dialog closes.

Rename the coils
The coils can be named to reflect their use in the motor. Any name can be used for the coils as
long as the name starts with a "B". Rename the coils by editing each one (double clicking),
similar to the way the resistors and inductors were changed.
Program Input
Double click B1
B_PA
Ok
Double click B2
B_MA
Ok
Double click B3
B_MC
Ok

Double click B4
B_PB
Ok
Analyze the circuit
Analyze the circuit to check its connections and to create the *.CIF file to be used for
simulations. Choose Circuit, Analyse from the menu.
Program Input
Circuit
Analyse

The following dialog opens with a report of the analysis.
Analysis of the circuit
Click Exit to close the dialog.
Program Input
The circuit is connexe. Exit

Save and close the circuit file
The circuit and transmission files are now complete. Save the circuit file by clicking the icon
or by choosing File, Save from the menu.
Program Input
File
Save
Close the circuit by choosing File, Close.
Program Input
File
Close

The following dialog opens.
Confirming close of circuit
Click Yes to confirm:
Program Input
Close circuit? Yes
Close ELECTRIFLUX
Finally, close ELECTRIFLUX by choosing File, Exit.
Program Input
File
Exit

Enter the physical properties

Start Preflu 9.1
Starting Preflu 9.1 to enter the physical properties
Program Input

Preflu 9.1 screen
Open the 1-layer airgap problem
To open an existing Flux project, click the icon on the toolbar.
Program Input
click

Using the menu
Program Input
Project
Open project

Save your project with a new name 159
Program Input

directory]
File Name brushless_1layer.flu [your

name]
Open
The 1-layer geometry is shown in the following figure:
The geometry (with 1-layer airgap) displayed in Preflu

Save your project now with a specific name to indicate that you will be using this model for back
EMF calculations.

160 Save your project with a new name
Program Input
Project
Save As…
Saving the brushless 1-layer model as bemf
Program Input
Save In: Brushless_V9[working directory]
File Name: bemf [your name]
Save

Define as Transient Magnetic 161
Define as Transient Magnetic

Define bemf as a transient magnetic problem using the Application menu:
Program Input
Application
Define
Magnetic
Transient Magnetic 2D
The Define Transient Magnetic 2D application dialog opens. First, click on the "Coils
Coefficient" tab. In previous versions of Flux, when linking a circuit to a problem that was not
completely modeled (like this one, where only ¼ of the motor is represented), the values of the
circuit components needed to be adjusted for the amount of the problem represented. For
example, in the past, the values of the circuit inductors in this problem would be divided by 4.
Now, with Flux 9.1, the program takes the periodicity of the geometry into account and
internally divides the component values by 4. In this way, the same circuit can be used in
multiple models, regardless of how much of the problem is modeled.
Flux 9.1 automatically takes periodicity into account when using a circuit

162 Change to the Physics context
Now click back on the Definition tab to define the domain .
Program Input
2D domain type 2D plane
Length Unit MILLIMETER
Depth of the domain 50.308
OK
Notice on your screen that there is a new context symbol, representing the Physical model
context.
Change to the Physics context

The Physics commands are available only in the Physics context. At the top of the data Tree,
click the button to change to the Physics context.
Program Input
click

Import materials from the materials database 163
The Physics context is shown in the following figure.
The bemf problem after going to the Physics context
Physics context toolbars
Please refer to Chapter 2 for an explanation of the icons on the toolbar when the program is in
the Physics context.
Import materials from the materials database

Before we can assign materials we created in Chapter 1 to the different regions of our model, we
must import them. Use the menu, Physics, Material, Import material.

164 Import materials from the materials database
Program Input
Physics
Material
Import material
In the Import material dialog, click on the icon next to the material database to display the
list of materials in the database.
List of materials in the database displayed
Now scroll to find the two materials you want to import; MAGNETPM and NLSTEELPM.
Select both with the mouse using the Control key.

Import the problem circuit 165
Proceed as follows:
Program Input
Click MAGNETPM
Click NLSTEELPM + Ctrl
Import
After the import is complete, close the Import materials window.
Program Input
Close
Import the problem circuit

Before we can assign the coil conductors in the circuit we created earlier in this chapter to the
different regions of our model, we must import the circuit.
To import the circuit we created, click the icon on the toolbar.
Program Input
click

166 Import the problem circuit
If you prefer, choose Physics, Circuit, Import circuit from a CCS file from the menu:
Program Input
Physics
Circuit
Import circuit from a CCS file
The Import circuit dialog appears. Click on the browse file selector in the dialog box.
Program Input
click

Import the problem circuit 167
The Open circuit dialog appears.
Program Input
Look In: Brushless_V9 [your working

directory]
File Name: onedelta.ccs [your name]
Open
The circuit file name is transferred to the Import Circuit dialog box.
Selected circuit ready for import
Proceed as follows:
Program Input
Click OK

168 Import the problem circuit
The circuit is displayed on the screen. If you expand the data Tree under the Electric Circuit
node, you will see the components from the imported circuit.
Imported circuit displayed as a new "tab" in the graphics area
Click the GeometryFlux2DView tab at the bottom of the screen to return to the geometric view
of the model.
Program Input
Click GeometryFlux2DView

Assign materials and sources to the regions

Material and/or source assignment is done region by region. You can assign the same properties
to several regions at the same time with the Edit Array command.
Assign the stator windings
Each winding region (PA, MA, MC, PB) must be linked to a coil conductor (B_PA, B_MA,
B_MC, B_PB) in the circuit you created. Each region will be changed individually.
Edit the PA region
Expand the Face Regions in the Data tree. Select the PA region and right-click the mouse to
select Edit.
Proceed as follows:
Program Input
Click PA
Right-click, Edit

The Edit Face Region dialog opens.
Program Input
Type of region Coil conductor region type
Positive orientation of the

current
Number of turns of the 10

conductor
Coil conductor region component B_PA
Symmetries and periodicities All the symmetrical and

periodical conductors are in
series
OK

Similarly, select the MA region for editing (right-click on MA in the data Tree, select Edit)
Program Input

current

conductor
Coil conductor region component B_MA

series
OK

You can also select regions graphically. Click on one face of the MC region, then right-click and
select Edit.
Selecting the MC region for edit by selecting it graphically

The MC (B_MC) and PB (B_PB) regions each represent two windings. These regions are
considered compound surfaces. The number of turns for coils B_MC and B_PB is therefore
twice the value for one winding (20).Enter or verify the following:
Program Input

current

conductor
Coil conductor region component B_MC

series
OK
Finally select to edit the PB region (with either the tree or graphically).

Program Input

current

conductor
Coil conductor region component B_PB

series
OK
Define the coil resistance
According to the design sheet, the stator winding characteristics are 10 turns with a resistance
per phase value of 0.141Ω/phase.
For the PA (B_PA) and MA (B_MA) regions, the number of turns is 10. Their resistance must
be calculated, however. To obtain R/phase, divide 0.141Ω by 2 to obtain 0.0705Ω, because these
regions or coils represent only half of the complete winding. Since the B_PA and B_MA coils are
the same, we will use the Edit Array command to set the resistances to both coils at once.
Expand the data tree to display the coil conductors (under the Electric Circuit, then under the
Stranded Coil Conductor). Select the B_PA and B_MA coils using the mouse and Control key.
Proceed as follows:
Program Input
Click B_MA
Click B_PA + Ctrl
Right-click, Edit array

The Edit Stranded Coil dialog appears. In the Modify All column, enter the resistance.
Setting the resistance for coils B_MA & B_PA
Proceed as follows:
Program Input
Modify all - Resistance formula 0.0705
OK
Similarly, select the Edit Array command for the B_MC and B_PB coils.
The MC (B_MC) and PB (B_PB) regions each represent two windings. Their resistance is twice
the resistance for one winding. Thus, the resistance for B_MC and B_PB is 0.141 Ω. In the
Modify All column, enter the resistance.
Setting the resistance for coils B_MC & B_PB

Proceed as follows:
Program Input
OK
Assign WEDGE, AIR, AIRGAP and SHAFT regions
Assign properties to the WEDGE, AIR, AIRGAP and SHAFT regions as a group.
Select the air regions from the tree by selecting their names. Make sure you hold the Control key
when making multiple selections.
Program Input
Click AIR
Click AIRGAP + Ctrl
Click SHAFT + Ctrl
Click WEDGE + Ctrl
Under the Modify All column, we will set all these regions at once to a vacuum region.
Setting a vacuum property for the air regions

Proceed as follows:
Program Input
OK
Assign STATOR and ROTOR regions
Assign the NLSTEEL material to the STATOR and ROTOR regions.
Select the stator and rotor regions from the graphic. Make sure you hold the Control key when
making the second selection.
Selecting the Stator and Rotor regions graphically

Once the regions are selected, right click the mouse and select Edit Array.
Edit the stator and rotor areas as a group
Under the Modify All column, we will set both of these regions to the NLSTEEL material.
Setting the stator and rotor to NLSTEELPM
Proceed as follows:
Program Input
Sub types: Select "Magnetic reg"
Material Select "NLSTEELPM"
OK

Assign the MAGNET
Finally, assign the MAGNETPM material to the MAGNET region.
Select the magnet region graphically with the mouse, then right click the mouse and select Edit.
Selecting the magnet region, then selecting Edit
The Edit Face Region window appears.
Setting the magnet region to the MAGNETPM material

Proceed as follows:
Program Input
Type of region Magnetic region
Material of the region MAGNETPM
OK
Now you must set the magnet as a radial magnet. This is done by setting the magnet's
orientation. Select the icon from the toolbar.
Program Input
Click
The following figure shows the Orient Material window.
Setting the magnet to a positive radial magnet
Proceed as follows:
Program Input
Magnet...Oriented type Radial Positif
OK
You have now assigned a material property to each region of the geometry.

Creating and Assigning Mechanical Sets

Creating Mechanical Sets
New with Flux 9.1 is the existence of Mechanical Sets. Mechanical Sets are used whenever you
want motion in the model (either rotating or translating). Whenever there is motion in the
model, you must define 3 mechanical sets;
• Fixed - This defines the parts of the model that do not move
• Moving- This defines the parts of the model that move (either rotating or translating)
• Compressible- This defines the region between the moving and non-moving parts (and the
displacement regions, in the case of a translating motion)
We will first create these mechanical sets. Select Physics, Mechanical Set and New from the
menu.
Program Input
Physics
Mechanical set
New

Create the MOVING_ROTOR Mechanical Set
The New Mechanical set dialog appears. Enter the information to create the
Defining the Axis information for the MOVING_ROTOR

Mechanical Set
Proceed as follows:
Program Input
Mechanical set name moving_rotor
Comment the moving parts of the model
Type of mechanical set Rotation around one axis
Rotation Axis Rotation around one axis

parallel to Oz
Coordinate system MAIN
Pivot point
First coordinate 0

Second coordinate 0
Click on "Kinematics" tab
The Kinematics tab opens. Enter the information to define the General kinematics, then click on
the Internal characteristics tab.
Defining the General kinematics information for the

Proceed as follows to define the General kinematics information:
Program Input
Type of kinematics Imposed Speed
Velocity (rpm) 500
Position at time t=0s. (deg) 0
Click "Internal

The Internal characteristics tab opens. Enter the information to define the Internal kinematics
information, then click on the External characteristics tab.
Defining the Internal kinematics information for the MOVING_ROTOR

Mechanical Set
Proceed as follows to define the Internal characteristics information:
Program Input

and spring
Moment of inertia 0
speed

Click "External
The External characteristics tab opens. Enter the information to define the External kinematics
information, then click on OK button.
Defining the External kinematics information for the

Proceed as follows to define the External characteristics information:
Program Input

and spring
Moment of inertia 0

speed
OK
Create the FIXED_STATOR Mechanical Set
the FIXED_STATOR mechanical set.
Defining the information for the FIXED_STATOR

Mechanical Set
Proceed as follows:
Program Input
Mechanical set name fixed_stator
Comment the non-moving parts of the

model
Type of mechanical set Fixed
OK

Create the ROTATING_AIRGAP Mechanical Set
the ROTATING_AIRGAP mechanical set.
Defining the information for the ROTATING_AIRGAP

Mechanical Set
Proceed as follows:
Program Input
Mechanical set name rotating_airgap
Comment the rotating airgap
Type of mechanical set Compressible
Used method to take the motion Remeshing of the air part

into account surrounding the moving body
OK

The New Mechanical set dialog closes briefly and then reappears. Close the dialog by hitting the
Cancel button.
Close the Mechanical set dialog
Proceed as follows:
Program Input
Cancel
Assigning Mechanical Sets
Now assign the mechanical sets to the regions of your model. First assign the appropriate regions
to the MOVING_ROTOR mechanical set.
Select the AIR, MAGNET, ROTOR and SHAFT regions from the tree by selecting their names.
Make sure you hold the Control key when making multiple selections.

Program Input
Click AIR
Click MAGNET + Ctrl
Click ROTOR + Ctrl
Click SHAFT + Ctrl
Under the Modify All column, we will set all these regions at once to the MOVING_ROTOR
mechanical set.
Assigning regions to the MOVING_ROTOR mechanical set
Proceed as follows:
Program Input
MECHANICAL_SET Select "MOVING_ROTOR"
OK
Now assign regions to the FIXED_STATOR mechanical set. Select the MA, MC, PA, PB,
STATOR and WEDGE regions from the tree by selecting their names. Make sure you hold the
Control key when making multiple selections.

Program Input
Click MA
Click MC + Ctrl
Click PA + Ctrl
Click PB + Ctrl
Click STATOR + Ctrl
Click WEDGE + Ctrl
Under the Modify All column, we will set all these regions at once to the FIXED_STATOR
mechanical set.
Assigning regions to the FIXED_STATOR mechanical set

Proceed as follows:
Program Input
MECHANICAL_SET Select "FIXED_STATOR"
OK
Now assign the airgap region to the ROTATING_AIRGAP mechanical set. Select the AIRGAP
region from the tree by selecting its name.
Program Input
Click AIRGAP
Right click, Edit

The Edit Face region dialog appears. Click on the Mechanical Set tab to assign the mechanical set
to the AIRGAP region.
Click on the Mechanical Set tab
Now select the ROTATING_AIRGAP mechanical set from the pull down menu.
Setting the AIRGAP region to the ROTATING_AIRGAP

mechanical set

Proceed as follows:
Program Input
Select "ROTATING_AIRGAP"
OK
Boundary conditions (Periodicity)

In previous versions of Flux, you needed to specify boundary conditions. With Flux 9.1,
boundary conditions are automatically created based on symmetry and periodicity.
Since we have modeled one quarter, or 90 degrees, of the model, we need to define a periodicity
reflecting this. Select the icon from the toolbar to create a new periodicity.
Program Input
Click
The New Periodicity dialog opens.
Defining a periodicity for the brushless DC motor

Proceed as follows:
Program Input
Geometrical type of the Rotation about Z axis with

periodicity angle of the domain
Included angle of the domain 90
Offset angle with respect to 0

the X line
Physical aspects of periodicity Odd (anticyclic boundary

conditions)
OK
Program Input
Click

The model is ready for solving. Close the Preflu application.
Select Project, Exit from the menu.
Program Input
Project
Exit
Proceed as follows:
Program Input

196 Solve the back EMF problem
Solve the back EMF problem

You are now ready to solve the back EMF problem. Because this problem includes saturation and
inductances and is voltage based, numerical transients may occur before the steady state is
reached. Thus the problem will be solved using Flux's ability to automatically come to a steady
state at the start.
Check the version: Flux2D Standard
In the Flux2D Supervisor, make sure that Flux2D: Standard is shown in the Program manager at
the top of the Supervisor window.
If you do not see "Flux2D: Standard," choose Versions, Standard from the menu.
Program Input
Versions
Standard

Solve the back EMF problem 197
Start the solver
In Flux Supervisor, in the Solving process folder, double click Direct:
Starting the solver
Program Input
Double click Direct

In the Open dialog, select the problem to be solved and click Open.
Program Input
Look in: Brushless_V9[working directory]
File name: BEMF.TRA [your name]
Open
Start the solver
The solver screen will appear.
Click the Solve button to begin the computation.
Program Input
click

The Definition of time data dialog opens:
Definition of time data for back EMF computation
Enter or verify the following information:
Program Input

initialised by static
computation
Time values

step

Program Input
one step on 1
OK
Click OK to close the time data dialog. The following dialog opens:
Do not change the initial position of the rotor. Click OK and watch as the solution proceeds.
Program Input

0. degrees

When the computation stops, the following dialog opens:
End of back EMF computation
Click OK to close the dialog.
Program Input
Stop the solving process OK

Close the solver
Select File, Exit from the menu to close the solver.
Program Input
File
Exit

Results from the Back EMF computation 203
Results from the Back EMF computation

To see your results, in the Flux Supervisor, in the Analysis folder, double click Results.
Starting Results analysis (PostPro_2D)
Program Input

204 Results from the Back EMF computation
Select the problem to analyze and click Open:
Choosing the problem to analyze with PostPro_2D
Program Input
File name: BEMF.TRA [your name]
Open

PostPro_2D opens:
Opening PostPro_2D
Display the back EMF in R4 (the voltmeter)
Display a time variation curve of the back EMF or line to line no load voltage through the R4
resistor (the voltmeter).
Open the 2D curves manager with the button or choose Computation, 2D Curves
manager… from the menu:

Program Input
Computation
2D curves manager…
The 2D curves manager opens.
2D curves manager: Settings for time variation curve of back emf in R4

Enter the data for the curve as follows:
Program Input
Curve description
Name VoltRes4
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Components Voltage
Third data
Support R4
click

The voltage curve for the voltmeter (R4) is shown below:
Time variation circuit display of voltage in R4
To read specific values from the curve, in the 2D Curves menu, select New cursor….
Program Input
2D Curves
New cursor…
Then position the cursor as you wish. For instance, in the previous figure, the cursor is at X =
30.788E-3 s with a voltage value of Y = 3.379 Volts.
Display a spectrum of the back EMF in R4
To display a spectrum analysis of the voltage curve for R4, open the 2D Spectrum manager by
clicking the button or by choosing Computation, 2D spectrum manager… from the menu.

Program Input
Computation
The Spectrum manager opens, as shown in the following figure:
Settings for spectrum analysis of voltage curve for R4

Enter or verify the information as follows:
Program Input
Analyzed curve VoltRes4 [name of curve]
Between 1.25E-3
and 61.25E-3
Part of cycle described Full cycle [select]
Create this original curve [check to enable display of

voltage curve]
Spectrum
Harmonics number 30
Display the DC component line [check if desired]
Name SpectrVoltRes4
click
Clicking the button creates and displays the spectrum and the voltage curve at the same
time.

The spectrum and the voltage curve are shown below:
Time variation spectrum of voltage for R4

You can look at the back EMF or the line to line no load voltage through other components also.
Below, for example, is the voltage curve for Resis1:
Time variation voltage display for Resis1

Voltage and current in coil B_MC (MC)
You can also examine waveforms of electric quantities in any of the circuit components. For
example, the following figure shows both the voltage and current in coil B_MC (MC).
Voltage and current curves for coil B_MC (MC)
This concludes our analysis of the back EMF. We encourage you to explore other results in
PostPro_2D on your own.

When you finish, click the Save button to save your analysis (including all the curves you
have created).
Program Input
click
Close PostPro_2D by selecting File, Exit from the menu:
Program Input
File
Exit

Chapter 4
Square wave motor: Constant

speed (torque ripples)
This chapter shows you how to simulate constant speed operation of the motor at 500
rpm with inverter drives.
Create a 6-step inverter (3 phase bridge) circuit using ELECTRIFLUX

All stator windings: vacuum, external circuit
Airgap: rotating airgap, constant angular velocity of 500 rpm, 2 pole pairs
Wedge, air, shaft regions: vacuum, no source
Stator, rotor regions: nonlinear steel, no source
Magnet: magnet, radial +, no source
Boundary conditions: Accept default boundary conditions
Link the external circuit
Coil regions (PA, MA, MC, PB) to coil components (B_COILA, B_COILB,
B_COILC)
Define coil characteristics
B_COILA: Resistance total value, 10 turns, 0.141 Ω
B_COILB, B_COILC: Resistance total value, 20 turns, 0.141 Ω
Define voltage source: Constant time variation, 24 volts
Define the switches: User define, Time, 3 coefficients
Coefficients for SWC1: 15, 75, 180
215
Solve at constant speed
Select custom release (brushlike_921)
Solve, Direct
New computation
Initialized by static computation
Initial value of the time step 0.00125s
Store 1 on 1 time step
Initial rotor position 0

Isovalues (equi flux) lines at time step 1, 0.00125 s
Color shade plot on stator, rotor, magnet regions group
Analysis of quantities along a path through the air gap
Normal component of flux density
Tangential component of flux density
Spectrum analysis of normal component curve
Time variation of axis torque over one cycle
Waveforms of electric quantities
Voltage and current in voltage source
Current through Switch1
Current through B_COILA coil
Current through B_COILB coil
Current through B_COILC coil
216
Chapter 4
Square wave motor: Constant speed

(torque ripples)
For the square wave motor, you model a 3-phase bridge circuit (the freewheeling diodes are
neglected). Constant speed operation of the motor at 500 rpm with inverter drives is simulated
to yield motor torque ripples. The inverter switching scheme is rotor position dependent and is
modeled with switches that are controlled by the Flux2D user version "brushlike_921."
217
218 Create the 3-phase bridge circuit
Create the 3-phase bridge circuit

The following figure shows the complete circuit.
3-phase bridge circuit
Chapter 4 Square wave motor: Constant speed (torque ripples)

Create the 3-phase bridge circuit 219
Start ELECTRIFLUX
To start the circuit module, in the Construction folder, double click Circuit.
Starting the Circuit module (ELECTRIFLUX)
Program Input
Double click Circuit
Square wave motor: Constant speed (torque ripples) Chapter 4

ELECTRIFLUX opens:
ELECTRIFLUX (Circuit) window

Create a new circuit problem
First, open a new circuit problem, either with the toolbar icon or the menu.
Click the icon in the toolbar.
Program Input
click
Using the menu
If you prefer, choose File, New from the menu.
Program Input
File
New

New (blank) Circuit and Sheet windows open.
New Circuit and Sheet windows open
For a review of ELECTRIFLUX icons and menus, see page 109.

Change the size of the sheet
Before you proceed, if you wish, you can modify the size of the Sheet window.
To modify the sheet settings (size of grid, etc.)
Right click anywhere on the sheet to open the context menu and choose Sheet settings….
Program Input
Sheet settings…

The Sheet properties dialog opens.
Modifying the sheet properties
Program Input
Sheet properties (Sheet_1)
Comment 6-step inverter, 3-phase bridge
Squaring gap (pixels) 10
Line Width 1
Background color [white]
Line color [blue]
Selected line color [red]
Sheet Width 800
Sheet Height 600
Ok
When you click OK, the dialog closes. Adjust the sheet window to show the new size.

Now you are ready to begin placing the circuit components on the sheet. The following figure
shows all the components for the inverter circuit.
Inverter circuit components placed on circuit sheet

Add the 6 switches
First, add the 6 switches to the circuit sheet.
To add the switches, click Switch in the Components library.
Program Input
click Switch

A red switch symbol is displayed in the upper left corner of the circuit sheet.
Ready to place first switch component

Place the 6 switches on the sheet
Move your cursor over the switch symbol, but do not click on the symbol yet. Move the symbol
with the mouse until the switch is in the position shown in the following figure.
Moving Switch 1 into position
Then click to place the switch in that position (the switch symbol turns blue).
Program Input
click to place switch S1 at

upper left of circuit sheet

The following figure shows Switch 1 in position.
Switch 1 in place

Move the cursor again and you will see Switch 2, as shown in the following figure.
Moving Switch 2 into position
Place switch S2 below and to the right of S1.
Program Input
click to place switch S2 below

and to the right of S1

Place the remaining 4 switches as shown (slightly enlarged) in the following figure.
6 switches in place
Program Input
click to place switch S3 to the

right of S1
S1
click to place switch S5 to the
right of S3
S3

After you have placed Switch 6, drag the cursor off the sheet to stop adding switch components.
The cursor takes the shape of an arrow.
To stop adding switch components
Program Input
drag cursor off the circuit

sheet

Rotate the 6 switches
Now rotate each of the switches so that they are in the proper orientation. For each switch,
complete the two steps below:
1. Click Switch 1 to select it. The switch symbol turns red.

2. Then click the icon once.
To rotate Switch 1
Proceed as follows:
Program Input
click S1 symbol
S1 turns red
click once
S1 rotates 90° clockwise

The S1 symbol appears as shown (enlarged) here:
Notice that the "hot point" (the small square symbol) is at the upper right of the switch symbol.
This is the correct orientation for all 6 switches.
Follow the same procedure to rotate the remaining switches:
1. Select the switch (the symbol turns red).

2. Click the icon once (the symbol turns 90° clockwise).
Proceed as follows:
Program Input
click S3 symbol
S3 turns red
click once
click S5 symbol
S5 turns red
click once
click S4 symbol

Program Input
S4 turns red
click once
click S6 symbol
S6 turns red
click once
click S2 symbol
S2 turns red
click once

After you finish rotating the switches, your display should resemble the following figure:
Switches rotated
Add the 6 series voltages
To model the commutation behavior of the switches, add 6 series voltages. A voltage source is
placed underneath each of the six switches, as shown in the following figure.
Six series voltages (placed under each switch)

To add the first series voltage, click Voltage source in the Components library.
Program Input
click Voltage source
A red voltage symbol is displayed in the upper left corner of the sheet.
Ready to place the first series voltage

Place the 6 series voltages on the sheet
Move the symbol directly underneath the first switch, and click to place the voltage source
symbol:
First series voltage in position
Program Input
click to place V1 below S1

Move the cursor and place the 5 other series voltages, as shown in the following figure:
Series voltages in position
Program Input

When you have placed the last series voltage, drag the cursor off the sheet to stop adding voltages
for now.

Rotate the series voltages
Now rotate the series voltages. As you did for the switches, click the symbol to select it; the
symbol turns red; then click the icon once to rotate the symbol 90° clockwise.
Proceed as follows.
Program Input
click V1 symbol
V1 turns red
click once
V1 rotates 90° clockwise
The following figure shows V1 in the correct orientation.
Series voltage VS1 rotated

Rotate each series voltage 90° clockwise.
Program Input
click V3 symbol
click once
click V5 symbol
click once
click V4 symbol
click once
click V6 symbol
click once
click V2 symbol
click once

The following figure shows the series voltages in the proper orientation.
Six series voltages rotated

Add the main voltage source
Now add the main DC voltage source.
Click Voltage source in the Components library.
Program Input
click Voltage source
The red voltage source symbol is displayed in the upper left corner of the sheet, as before.

Place the main voltage source
Move the cursor and place the main voltage source to the left of the first switch, as shown in the
following figure.
Placing main voltage source (VS7) on the sheet
Program Input
click to place V7 to the left

of S1
To stop adding voltage components, drag your cursor off the sheet.

Rotate the main voltage source
Now rotate the main voltage source, as before.
Proceed as follows:
Program Input
click V7 symbol
V7 turns red
click once
V7 rotates 90° clockwise
The main voltage source V7 is correctly oriented in the following figure.
Main voltage source rotated

Add the 3 coils
Next, add 3 coils for the stator windings.
Click Coil conductor in the Components library.
Program Input
click Coil conductor

A red coil symbol is displayed in the upper left corner of the sheet.
Ready to place the first coil component

Place the 3 coil components on the sheet
Move the coil component symbol to a position underneath and to the right of series voltage V4:
Coil 1 (B1) placed on the sheet
Program Input
click to place B1 below and to

the right of V4

Move the cursor to place the other 2 coils, as shown in the following figure.
Three coils placed on sheet
Program Input
click to place B2 below and

right of V6
click to place B3 below and
right of V2
To stop adding coil components, drag the cursor off the sheet.

Rotate the coil components
Now rotate the coil components. Each coil must be rotated 90 degrees; you will need to click the
Rotate icon once for the proper rotation, as shown in the following figure. Notice that the "hot
point" symbol is at the upper right of the coil.
Proceed as follows:
Program Input
click B1 symbol
B1 turns red
click once
click B2 symbol
B2 turns red
click once
click B3 symbol
B3 turns red

Program Input
click once
With the three coils properly oriented, your sheet should resemble the following figure:
Coils oriented (after rotation)

Add the inductors
Now add inductors to model the stator winding end turn inductances.
Click Inductor in the Components library.
Program Input
click Inductor

A red inductor symbol is displayed in the upper left corner of your sheet.
Ready to position inductors

Place the 3 inductors on the sheet
Move the cursor and click to place the 3 inductors on the sheet, as shown in the following figure.
Placing 3rd inductor (L3) on the sheet
Program Input
click to place L1 under coil B1

To stop adding inductors, drag the cursor off the sheet.

With the inductors added, your display should resemble the following figure:
Inductors placed on circuit sheet

Rotate the 3 inductors
Now rotate the 3 inductors for proper orientation.
Proceed as follows:
Program Input
click L1 symbol
L1 turns red
click once
click L2 symbol
L2 turns red
click once
click L3 symbol
L3 turns red
click once

With the inductors properly oriented, the lower part of your sheet should resemble the following
figure.
Inductors oriented
Add the voltmeter
Next, add a large resistor between V3 and V5. This resistor acts as a voltmeter to measure the
line to line voltage. The following figure shows the location for the resistor.
Resistor R1 (voltmeter) being placed on the sheet

To add the resistor, click Resistor in the Components library.
Program Input
click Resistor

A red resistor symbol is displayed in the upper left corner of the sheet.
Ready to place resistor on the sheet
Move the cursor over the resistor symbol and then place the symbol on the sheet, as shown in
the following figure.
Resistor R1 being placed on the sheet

Proceed as follows:
Program Input
click to place R1 between V3

and V5
Drag the cursor off the sheet to stop adding resistors.
Save your circuit
Now is a good time to save your circuit. Click the icon or choose File, Save from the menu.
Program Input
File
Save

Saving the circuit file
Program Input
Save in Brushless_V9 [working directory]
File name squarewave [or your name]
Save

Connect (wire) the circuit components
Now connect the circuit components.
Place your cursor over the top pin of the main voltage source, V7, until the cursor changes to a
bull's-eye shape.
Ready to start wiring the circuit
Program Input
position cursor over top pin of

voltage source V7
Drag the cursor over to the top pin of switch S1 and click to complete the first connection.

Program Input
click pin at top of S1 to

complete the connection
Connect the remaining components as shown in the following figures.
The switches, series voltages, and voltmeter are connected as shown in the following figure.
Connections for upper part of circuit

The coils and inductors are connected as shown below.
Connections for lower part of circuit

The following figure shows the connections for the whole circuit:
Circuit connections completed

Define the circuit
The components that must be defined are the switches, the resistor, and the inductors.
According to the design sheet, the value of the end turn inductance per phase is 0.031 mH/phase.
Even though we are modeling only ¼ of the motor, we can define the components to their full
value and Flux will internally scale them to the correct value.
Define only the voltmeter (the resistor), the inductors, and the on/off resistance values for the
switches now. (These characteristics can also be defined or modified during the physical
properties definition. You will use the Preflu module to complete the definition of the circuit in
the next section.)
Define the on/off resistance values for the switches
Begin by defining the on/off resistance values for the switches.
Double click S1, the symbol for Switch 1.
Program Input
Double click S1
The symbol turns red, and the following dialog opens.
Defining on/off resistance for Switch 1 (S1)

If you wish, you can edit the name of the switch and add a description in the Comment field.
F The name of any switch must begin with a capital S. The initial letter of any
component name cannot be changed.
In the dialog, enter or verify the following:
Program Input
Switch
Name S1
Ron(ohm)
Value 1e-4
Roff(ohm)
Value 10000
Ok
When you choose Ok, the dialog closes.
F The default Roff value is 10000 Ω; you do not need to re-enter this value. You
should verify it, however.
Define Ron and Roff for the remaining switches as follows:
Program Input
Double click S2
1e-4
10000
Ok

Program Input
Double click S3
1e-4
10000
Ok
Double click S4
1e-4
10000
Ok
Double click S5
1e-4
10000
Ok

Program Input
Double click S6
1e-4
10000
Ok
Define the inductors
In the same way, define the inductors. Double click L1, the symbol for the first inductor.
Program Input
Double click L1
The symbol turns red, and the Inductor dialog opens.
Defining inductance value for the first inductor (L1)

In the Inductor dialog, enter or verify the following:
Program Input
Name L1
Characteristics
Name L(henry)
Value 3.1e-5
Ok
Define the other inductors as follows:
Program Input
Double click L2
3.1e-5
Ok
Double click L3
3.1e-5
Ok

Define the voltmeter (R1)
Finally, define the voltmeter, the resistor R1. Double click the R1 symbol.
Program Input
Double click R1
The resistor symbol turns red, and the Resistor dialog opens.
Defining the voltmeter (resistor R1)
In the Resistor dialog, enter or verify the following:
Program Input
Name R1
Comment voltmeter
Characteristics
Name R(ohm)
Value 1e5
Ok
When you click Ok, the dialog closes.

Rename the coils
The coils can be named to reflect their use in the motor. Any name can be used for the coils as
long as the name starts with a "B". Rename the coils by editing each one (double clicking),
similar to the way the resistors and inductors were changed.
Program Input
Double click B1
B_COILA
Ok
Double click B2
B_COILB
Ok
Double click B3
B_COILC
Ok

Analyze the circuit
Analyze the circuit to check its connections and to create the *.CIF file to be used for
simulation.
Choose Circuit, Analyse from the menu.
Program Input
Circuit
Analyse

The following dialog opens with a report of the analysis.
Analysis of the circuit
Click Exit to close the dialog.
Program Input
The circuit is connexe. Exit

Save and close the circuit file
The circuit and transmission files are now complete. Save the circuit by clicking the icon or
choosing File, Save from the menu.
Program Input
File
Save
Close the circuit by choosing File, Close.
Program Input
File
Close

Confirmation to close circuit
Click Yes to confirm the close of the circuit:
Program Input
Close circuit? Yes
Close ELECTRIFLUX
Finally, close ELECTRIFLUX by choosing File, Exit.
Program Input
File
Exit

Assign the physical properties 277
Assign the physical properties

Start Preflu 9.1
Starting the Preflu module

278 Assign the physical properties
Program Input
Preflu 9.1 screen
Open the Back EMF problem
This constant speed model is similar to the model generated in the previous chapter to study
back EMF. The geometry, materials and mechanical sets are the same; just the drive circuit is
different. It will be easiest to start with the back EMF model to create this new model of a
constant speed brushless motor.

Program Input
click
Using the menu
Program Input
Project
Open project

Opening the Back EMF project
Program Input

directory]
File Name bemf.flu [your name]
Open

The geometry of the Back EMF model (1 layer airgap) is displayed:
Back EMF project is opened
Save your project now with a specific name to indicate that you will be using this model for
constant speed analysis.

Program Input
Project
Save As…
Saving the bemf model as constspeed
Program Input
File Name: constspeed [your name]
Save

Change the coupled circuit
The constant speed model is identical to the Back EMF model except for the circuit coupled to
the geometry. To create this model, you need to delete the current circuit, import the new
circuit, and assign the new circuit to regions in the model.
Delete the existing circuit
To delete the circuit currently coupled to the problem (onedelta.ccs), choose Physics, Circuit,
Delete electrical circuit from the menu.
Program Input
Physics
Circuit
Delete electrical circuit
A confirmation dialog appears. Click OK to delete the circuit.
Confirmation to delete the circuit
Program Input
Delete electrical circuit? OK

Change to the Physics Context
The Physics commands are available only in the Physics context. At the top of the data Tree,
click the button to change to the Physics context.
Program Input
Click
Import the Squarewave Circuit
To import the circuit we created, click the icon on the toolbar.
Program Input
Click
If you prefer, choose Physics, Circuit, Import circuit from a CCS file from the menu:
Program Input
Physics
Circuit
Import circuit from a CCS file

The Import circuit dialog appears. Click on the browse file selector in the dialog box.
Program Input
Click
The Open circuit dialog appears.
Selecting the squarewave circuit to import
Program Input
Look In: Brushless_V9 [your working

directory]
File Name: squarewave.ccs [your name]
Open

The circuit file name is transferred to the Import Circuit dialog box.
Selected circuit ready for import
Proceed as follows:
Program Input
Click OK
The squarewave circuit appears. Your display should resemble the following:
The constspeed problem after importing the squarewave circuit

Assign face regions to the circuit
Assign the stator windings
Each winding region (PA, MA, MC, PB) must be linked to a coil conductor (B_COILA,
B_COILB, B_COILC) in the circuit you created. Each region will be changed individually.
Edit the PA region
Expand the Face Regions in the Data tree (under Physics, Regions). Select the PA region and
right-click the mouse to select Edit.
Proceed as follows:
Program Input
Click PA
Right-click, Edit

Program Input
Material of the region <verify selection is blank>

current

conductor
Coil conductor region component B_COILA

series
OK
Edit the MA region
Similarly, select the MA region for editing (right-click on MA in the data Tree, select Edit)

Enter or verify the following. Note that the MA ("minus A") region uses the same coil conductor
(B_COILA) as the PA region, but the orientation of the current is set to Negative:
Program Input
Negative orientation of the

current

conductor
Coil conductor region component B_COILA

series
OK
Edit the PB region
Now, select the PB region for editing (right-click on PB in the data Tree, select Edit).

Program Input

current

conductor
Coil conductor region component B_COILB

series
OK
Edit the MC region
Now, select the MC region for editing (right-click on MC in the data Tree, select Edit).

Enter or verify the following. Note that the current orientation needs to be set to Negative, since
the orientation of all the coil conductors are the same in relation to the voltage sources in the
circuit.
Program Input
Negative orientation of the

current

conductor
Coil conductor region component B_COILC

series
OK
Define the coil resistance
According to the design sheet, the stator winding characteristics are 10 turns with a resistance
per phase value of 0.141Ω/phase. Since the B_COILA, B_COILB and B_COILC coils are the
same, we will use the Edit Array command to set the resistances to all coils at once.
Expand the data tree to display the coil conductors (under the Electric Circuit, then under FE
Coupling Components, then under the Stranded Coil Conductor). Select the B_COILA,
B_COILB and B_COILC coils using the mouse and Shift key.

Proceed as follows:
Program Input
Click B_COILA
Click B_COILC + Shift
The Edit Stranded Coil dialog appears. In the Modify All column, enter the resistance.
Setting the resistance of all the coils
Proceed as follows:
Program Input
OK

Define the Voltage Sources
Define the Main Voltage Source
The design value for the power supply is 24 volts. Expand the data tree to display the voltage
sources (under the Electric Circuit, then under the Voltage/current sources). Select the voltage
source, V7, from the data tree to set this voltage.
Proceed as follows:
Program Input
Click V7
Right click, Edit
The Edit voltage source dialog appears.
Changing the power supply voltage to 24v.

Proceed as follows:
Program Input
Value 24
OK
Define the Series Voltage Sources
The design value for the series voltages is 3.2 volts. Since they are all the same, we will use the
Edit Array command to set all voltage sources at once.
Select the V1 to V6 voltage sources using the mouse and Shift key.
Proceed as follows:
Program Input
Click V1
Click V6 + Shift
The Edit Voltage Source dialog appears. In the Modify All column, enter the voltage.
Setting all series voltages supplies

Proceed as follows:
Program Input
Modify all - RMS_MODULUS 3.2
OK
Define the switches
Next, define the switches. They are on or off depending on the rotor position.
The switches are time dependent and are defined with 3 coefficients:
1. Coefficient 1: ON angle in mechanical degrees

2. Coefficient 2: OFF angle in mechanical degrees
3. Coefficient 3: switch’s cycle in mechanical degrees
Expand the data tree to display the switches (under the Electric Circuit, then under the
Switches/semiconductors). Select switch S1 from the tree to set the switch timing.
Proceed as follows:
Program Input
Click S1
Right click, Edit

The Edit switch dialog appears. To access the switch timing, click on the Turn On Command
tab.
Clicking the tab to go set the switch timing.
Proceed as follows:
Program Input
Click Turn on command
Now change the switch timing using the format shown. Again, the first coefficient is the ON
angle in mechanical degrees, the second coefficient is the OFF angle, and the third coefficient is
the switch's cycle in degrees.
Setting the timing for switch S1

Proceed as follows:
Program Input
Command by formula
Expression USER(15,75,180)
OK
The other 5 switches can be defined similarly. The table below shows the characteristics for all 6
switches. You have already entered the characteristics for Switch 1, so that row is crosshatched.
Switch characteristics for user version brushlike_921
SW ON Angle OFF Angle Switch Cycle

No.
1 15 75 180
2 45 105 180
3 75 135 180
4 105 165 180
5 135 15 180
6 165 45 180
Program Input
Click

Close and save the model
The model is ready for solving. Close the Preflu application. Select Project, Exit from the menu.
Program Input
Project
Exit
Proceed as follows:
Program Input

Solve with user version 299
Solve with user version

You are now ready to solve the constant speed problem. Because this problem includes saturation
and inductances and is voltage based, numerical transients may occur before the steady state is
reached. Thus the problem will be solved using Flux's ability to automatically come to a steady
state at the start.
Select the user version
The switches of the external circuit are rotor position dependent and are controlled by the
Flux2D user version "brushlike_921."
To select the user version, choose Versions, brushlike_921 from the menu.
Program Input
Versions
brushlike_921

300 Solve with user version
You should see "Flux2D: brushlike_921" at the top of the Program manager, as shown in the
following figure:
Flux2D custom version (brushlike_921)
F Make sure the appropriate user version (brushlike_921) is selected before you
start the solver.

Start the solver
To start the solver, in the Solving process folder, double click Direct:
Starting the solver with a user version (includes user subroutine)
Program Input
Double click Direct

In the Open dialog, select the problem to be solved and click Open:
Program Input
File name: CONSTSPEED.TRA
Open

Verify the solving options
In the Solver window, click the Options tab to bring it to the front:
Checking the solving options
Enter or verify the options as follows:
Program Input
click Options tab
Magnetic, Electric iterations
Number of iterations 50
Requested precision 1.e-004
Thermal iterations
Required precision 1.e-004

Program Input
Magnetic updatings to coupled

problem
Minimal number of updatings 1
Maximal number of updatings 5
Progressive Newton Raphson Disabled

algorithm
Be sure that the Newton-Raphson algorithm is “Disabled,” as shown in the figure below:
Enter or verify the accuracy, solver type and priority for the computation, and click Apply to
apply the solving options.
Program Input
Accuracy definition Automatic accuracy
Solver type SuperLU (9.20)
Priority associated to the Priority normal

computation
Apply

Start the computation
Click the Solve button to begin the computation.
Program Input
click
The Definition of time data dialog opens, as shown in the following figure:
Definition of time data

Enter or verify the following information. Solve the problem with a time step that is 4 time steps
per slot pitch (1 time step every 3.75 degrees) over one electric cycle (180 mechanical degrees).
The resulting time step is 0.00125 seconds
Program Input
computation
Time values

step
one step on 1
OK
Before the computation begins, the following dialog opens:
Verifying the initial position of the rotor (0)
Do not change the initial position of the rotor. Click OK to close this dialog and watch as the
solution proceeds.

Program Input

0. degrees
When the computation is finished, the following dialog opens:
End of computation
Program Input
Close the solver
Then close the solver by selecting File, Exit from the menu:

Program Input
File
Exit

Results: Constant speed computation 309
Results: Constant speed computation

In the Flux Supervisor, make sure the brushlike_921 version is still selected; otherwise, you will
not be able to proceed.
In the Supervisor, in the Analysis folder, double click Results.
Starting Results analysis from the Supervisor with user version (brushlike_921)
Program Input

310 Results: Constant speed computation
In the Open dialog, choose the problem to be analyzed and click open:
Choosing the problem to analyze
Program Input
File name: CONSTSPEED.TRA
Open

PostPro_2D opens with a display of the model geometry at the first time step (0.00125 s):
Constant speed problem ready for analysis in PostPro_2D

Display isovalues (equiflux) lines
Begin with an isovalues (equiflux) plot on the model geometry at time step 1 (0.00125 s).
Set the properties for the display
Open Results, Properties by clicking the icon or by choosing Results, Properties from the
menu:
Program Input
Results
Properties

The Display properties dialog opens, as shown in the following figure:
Properties dialog for equiflux lines (Isovalues) display
Make sure the Isovalues tab is on top. Then enter or verify the following settings:
Program Input
Isovalues
Quality Normal
Number 21
Scaling Uniform

Program Input
Display characteristics
Write numbers [check to enable, if desired]
OK
When you click OK, the properties dialog closes.
To display the plot, click the Isovalues button in the toolbar, or choose Results, Isovalues
from the menu.
Program Input
Results
Isovalues

The isovalues plot is shown below:
Display of flux density lines at time step 0.00125
If you wish, you can change the display of the isovalues plot.
Right click anywhere on the sheet and choose Properties from the context menu:

Program Input
Right click on isovalues sheet
Properties
The Geometry properties dialog opens:
Removing the legend from the isovalues display
For instance, to remove the legend from the sheet, click the Sheet tab to bring it to the front,
clear the “With legend” checkbox, and click OK to close the dialog.

You should then see the isovalues plot as shown in the following figure:
Isovalues plot
You can adjust the displays in many other ways. Remember to right click on the sheet to open
the properties dialog.

Color shade plot on a group of regions
Next, display a color shade plot for only the stator, rotor, and magnet regions.
Create the group of regions
Create a group of these three regions with the Group manager. Open the Group manager dialog
by clicking the button or by choosing Supports, Group manager from the menu:
Program Input
Supports
Group manager
The Group manager dialog opens:
Group manager dialog
Enter or verify the information in the Group manager as follows:
Program Input
Filter Region
Objects available ROTOR

MAGNET
STATOR

Program Input
Add ->
Current group: ROTOR

MAGNET
STATOR
Create
Click the Create button to create the group and close the Group manager dialog.
Set the properties for the display
Now use the group for the display of the color shade plot. Open the Results, Properties dialog
again by clicking the button or by choosing Results, Properties from the menu.
Program Input
Results
Properties

Properties for color shade display
Click the Color shade tab to bring it to the front. Then enter or verify the information as
follows:
Program Input
Analyzed quantity |Flux density|
Support Big3 [group name]
Quality Normal
Scaling Uniform
OK

When you click OK, the Display properties dialog closes.
Display the color shade plot
To display the plot, click the color shade button in the toolbar or choose Results, Colour
shade from the menu.
Program Input
Results
Colour shade

You will see the color shade plot on your group of regions:
Color shade plot of flux density on a group of regions
The saturation values are not high (maximum of 1.5 T). These results are in the linear part of the
B-H curve, as can be seen during the solving process, where each time step requires only 2
Newton-Raphson iterations to achieve convergence—at an accuracy level of 1e-4.

Information about the iterations for each time step is available under the *log_res file tab at the
bottom of the PostPro_2D screen.
Information about solving at time 0.055 s, Computation 44
Create a path through the airgap
To create a path through the center of the airgap, open the Path manager.
Click the Path manager icon or choose Supports, Path manager… from the menu:
Program Input
Supports
Path manager…

The Path manager dialog opens.
Path manager
You will be creating an arc of 180 degrees through the center of the airgap. To verify the
coordinates for the path, with the Path manager open, move your cursor over the geometry
model.
The cursor appears in the shape of a drawing compass (when Arc is selected, as shown in the
figure above).

Click the button and drag the cursor to enlarge the bottom of the airgap between the air and
the stator regions. Then position the cursor to see the coordinates (we used X=25.4).
Checking coordinates for path through airgap
Then in the Path manager dialog, enter or verify the information as follows:
Program Input
Name CenterGap [or your choice]
Discretization 200
[default color] [new color if desired]
Graphic section Arc
Numerical section New section

When you click the New section button, the Section Editing dialog opens.
Section Editing dialog to create path
In the Section Editing dialog, enter or verify the information as follows:
Program Input
Section type Arc start angle
Center point
X 0
Y 0
Origin point
X 25.4
Y 0
Length 180
OK

Click OK to close the Section Editing dialog. The path to be drawn through the airgap is
displayed:
Path through the airgap (enlarged)
In the Path manager dialog, click the button to create the path and open the 2D Curves
manager at the same time.
Program Input
click

Flux density along the airgap path
The 2D curves manager is shown in the following figure.
Settings for flux density curve (normal component)
Flux density: Normal component
First, create a curve of the normal component of the flux density along the airgap path at the first
time step. Enter or verify the following:
Program Input
Curve description
Name FDNorm
Path
First axis
X axis CenterGap [path name]
Second axis

Program Input
Components Normal component
Third axis
Parameter Time
Parameter values 0.00125
Selection step 1
Create
Click the Create button to create the curve of the normal component of the flux density. You
will not see the curve displayed, but you should see the name listed at the bottom of the 2D
Curves manager.
Normal component curve created
Flux density: Tangential component
Now create a similar curve for the tangential component of the flux density. The 2D Curves
manager should show a new default name for the curve and a new color. You should be able to
enter a new name (and color, if you wish), change the component, and create the second curve.
For the tangential component curve, enter or verify the information as follows:
Program Input
Curve description
Name FDTang
Path
First axis
X axis CenterGap [path name]

Program Input
Second axis
Components Tangent component
Third axis
Parameter Time
Parameter values 0.00125
Selection step 1
Create
When you click the Create button, the tangential component curve is added to the list, but you
will not see the curves yet.
Superimpose the normal and tangential flux density curves
To create a superimposed display of these two curves, proceed as follows:
Click the icon to open a blank curves sheet.
Program Input
click
Then right click anywhere on the blank curve sheet, and open the properties dialog.
Program Input
click
Properties

In the properties dialog, make sure the Selection tab is on top.
Curves properties Select dialog; choose curves to display
Enter or verify the following in the Selection dialog:
Program Input
Curves filter Computation
Curves available FDNorm

FDTang
Add -->
Displayed curves FDNorm

FDTang

Click the Display tab to bring it to the front.
Settings for superimposed curves display
Enter or verify the following information in the Display dialog:
Program Input
click Display tab
Display Superimposed
Gradations ON
X Axis
Range Automatic
Scale linear
Y Axis
Range Automatic

Program Input
Scale linear
OK
The two curves superimposed are shown below.
Superimposed curves of normal and tangential flux density (with cursor)
If you wish, display a cursor by choosing 2D curves, New cursor… from the menu.
Program Input
2D Curves
New cursor…

Spectrum analysis
Next, use the Spectrum manager to display the harmonics of the normal component of the flux
density. Proceed as follows:
Click the button or choose Computation, 2D Spectrum manager… from the menu.
Program Input
Computation
The Spectrum manager opens.
Spectrum manager

Enter or verify the following for the spectrum analysis:
Program Input
Analyzed curve FDNorm
Between 0
and 79.79644
Part of cycle described Full cycle
Create this original curve [check box to enable display of

normal component curve]
Spectrum
Harmonics number 30
Display the DC component line [check to enable if desired]
Name SpectFDNorm [or other name]
click
Clicking the button creates and displays the spectrum with the curve on a new sheet.

The spectrum and the normal component curve are shown below:
Spectrum analysis of normal component of flux density
To clarify the spectrum display, you can change its properties. Right click on the legend of the
spectrum and choose Properties from the context menu.
Program Input
Right click on spectrum legend
Properties

The Curves properties dialog opens.
Sample of settings for spectrum display
In the properties dialog, you can change, for example, the legend text, the form of the curve, the
line width and color. Make the settings you wish (our previous figure uses a line width of 3; the
default line width is 1). Click OK to apply your changes and close the dialog.

Time variation curve of axis torque
Finally, display a curve of the axis torque of the motor over the whole cycle.
Open the 2D curves manager with the button or choose Computation, 2D curves
manager… from the menu.
Program Input
Computation
The 2D Curves manager opens.
Settings for AxisTorque curve

Program Input
Curve description
Name AxisTorque
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Mechanics
Components Axis torque
Third data
click
Clicking the button creates and displays the curve.

The axis torque curve is shown below:
Axis torque over one cycle
To read values from the curve, from the 2D curves menu, select New cursor….
Program Input
2D Curves
New cursor…
Position the cursor as you wish. For instance, in the figure above, the cursor is at X = 0.026 s,
and the axis torque value (Y) is 623.105 N.m.

You can record the values from the curve in various ways. For example, from the 2D Curves
menu, choose Analysis, Write all mean values:
Program Input
2D Curves
Analysis
Write all mean values
The mean values are written into the “Review file” tab at the bottom of the window.
Mean values from axis torque curve
The average torque is given for all 1 pole (0.694 N.m.). The design value is 0.585 N.m.

Waveforms of the electric quantities
Next, look at curves of electric quantities. Use the 2D Curves manager, as before. Open the
curves manager by clicking the button or by choosing Computation, 2D curves manager…
from the menu.
Program Input
Computation
Settings for curve of voltage in the main voltage source (V7)

Voltage and current in the main voltage source (V7)
To create a curve of the voltage in the main voltage source (V7), enter or verify the settings as
follows:
Program Input
Curve description
Name V7Voltage
Parameter
First axis
X axis Time
Second axis
Quantity Circuit
Components Voltage
Third data
Support V7
Create
Click the Create button to create the curve. (The curve will not be displayed.)
In the same way, create a curve of the current in the voltage source. The 2D Curves manager
should still be open. You should be able to change only the name, the color (if you wish) and the
component to create the V7 current curve.
Program Input
Curve description
Name V7Current
Parameter
First axis

Program Input
X axis Time
Second axis
Quantity Circuit
Components Current
Third data
Support V7
Create
Click the Create button to create the time variation curve of the current in the voltage source.
(Remember, the curve will not be displayed.)
Close the 2D curves manager with the button.
Program Input
2d curves manager
click

Superimpose the V7 voltage and current curves for a display like the following (we used the
"Automatic" setting for the Y axis):
Voltage and current in the voltage source
Current in Switch1
Now create a curve of the current through Switch1.
Click the button to open the 2D curves manager.
Program Input
click

Program Input
Curve description
Name CurrSW1
Parameter
First axis
X axis Time
Second axis
Quantity Circuit
Components Current
Third data
Support S1
click

The curve of the current for Switch 1 is shown below.
Current in Switch 1

Current in the B_COILA (PA) coil component
Next, create and display a curve for the current in the B_COILA (PA) component. Click the
button to open the 2D curves manager.
Program Input
click
Program Input
Curve description
Name CurrB1(PA)
Parameter
First axis
X axis Time
Second axis
Quantity Circuit
Components Current
Third data
Support B_COILA
click

The curve of the current in the B_COILA coil component is shown below:
Current in coil component B_COILA (PA, positive phase A)

Current in the B_COILB (PB) coil component
In the same way, create a curve of the current in coil component B_COILB (PB, positive phase
B). Click the button to open the 2D curves manager.
Program Input
click
Program Input
Curve description
Name CurrB2(PB)
Parameter
First axis
X axis Time
Second axis
Quantity Circuit
Components Current
Third data
Support B_COILB
click

The curve of the current in coil component B_COILB (PB) is shown in the following figure:
Current in coil component B_COILB (PB, positive phase B)

Current in the B_COILC (MC) coil component
Finally, create a curve of the current in coil component B_COILC (MC, minus phase C). Click
the button to open the 2D curves manager.
Program Input
click
Program Input
Curve description
Name CurrB3(MC)
Parameter
First axis
X axis Time
Second axis
Quantity Circuit
Components Current
Third data
Support B_COILC
click

The curve of the current in B_COILC (MC) is shown below:
Current in coil component B_COILC (MC, negative phase C)

354 Save and close PostPro_2D

This concludes our analysis of the motor at constant speed.
To save the analysis supports and the curves you have created, click the icon or choose File,
Save from the menu.
Program Input
File
Save

Save and close PostPro_2D 355
Then close PostPro_2D by choosing File, Exit.
Program Input
File
Exit


Chapter 5
No load startup with

electromechanical coupling
In this chapter you modify the constant speed problem to simulate the no load startup.
Modify physical properties of constant speed problem

Airgap
Rotating airgap
Mechanic values
Moment of inertia: 3.8675e-5
Viscous friction coefficient: 0.005
Keep "squarewave" circuit
Set release to custom (brushlike_921)
Solve, Direct
Time data
New computation
Initial value of time step 5e-4 s
Store 1 on 1
Initial position of the rotor 0
357
Isovalues (equi flux) lines at time step 100 (time 0.05 s)
Time variation analyses (2D curves)
Axis torque
Angular velocity
Rotor position
Current in Switch1
Current in B_COILA coil component
Voltage and current in B_COILB coil component
Voltage and current in B_COILC coil component
358
Chapter 5
No load startup with

With the constant speed problem already defined, you can easily modify the physical properties
to simulate the no load startup.
F If you do not have the constant speed file, you must define all the physical
properties and link the external circuit as described in the previous chapter
(beginning on page 277). The only difference for this problem is in the definition of
the moving mechanical set.
Basically, for each time step, Flux2D computes the electromagnetic torque, solves the mechanical
equation to yield the angular acceleration, speed and displacement, then rotates the rotor and
repeats the process.
Modify the physical properties

Be sure you have the CONSTSPEED.TRA and squarewave.ccs files in your working directory.
To modify the physical properties, use the Preflu 9.1 application.
359
360 Modify the physical properties
Start Preflu 9.1
Program Input
Chapter 5 No load startup with electromechanical coupling

Modify the physical properties 361
The initial Preflu screen
Open the Constant Speed problem
This no load model is similar to the model generated in the previous chapter. We simply need to
modify the moving mechanical set.
Program Input
click
No load startup with electromechanical coupling Chapter 5

Using the menu
Program Input
Project
Open Project
Opening the Constant Speed project

Program Input

directory]
File Name constspeed.flu [your name]
Open
The geometry of the Constant Speed model (1 layer airgap) is displayed.
The constspeed project is opened
Save your project now with a specific name to indicate that you will be using this model for no
load analysis.

Program Input
Project
Save As…
Saving the constspeed project as noload
Program Input
File Name: noload [your name]
Save

Define the no load characteristics
The no load model is identical to the constant speed model except for the definition of the
Edit the MOVING_ROTOR mechanical set
Expand the Mechanical Set in the Data tree. Select the MOVING_ROTOR mechanical set and
Proceed as follows:
Program Input
Click MOVING_ROTOR
Right-click, Edit

The Edit Mechanical Set dialog appears. To enter the no load characteristics, click on the
Kinematics tab at the top.
Going to the Kinematics tab
Proceed as follows:
Program Input
Click Kinematics

Change the type of kinematics problem to a "Coupled Load" problem. Then go to enter the
internal characteristics.
Going to the Internal Characteristics tab
Proceed as follows:
Program Input
Type of kinematics Coupled load
Velocity at time t=0s (rpm) 0
Position at time t=0s (deg) 0
Click Internal characteristics

Now enter the characteristics needed to do the No Load analysis.
*PI()/180
Entering the No Load Internal Kinematic characteristics
Program Input

and spring
Moment of inertia 3.8675e-5
Viscous friction coefficient 0.005*PI()/180
Friction coefficient proport… 0
Click External characteristics
F Note: Since only ¼ of the motor is being modeled, the value you enter for the
moment of inertia is ¼ of the inertia of the entire motor.

Enter the external kinematic characteristics.
Entering the No Load External Kinematic characteristics
Program Input

and spring
Moment of inertia 0
OK

370 Verify the user version: brushlike_921
Program Input
Project
Exit
Proceed as follows:
Program Input
Verify the user version: brushlike_921

Because the motor has rotor position dependent switches, you must use the brushlike_921
custom version, as you did with the constant speed problem.

Verify the user version: brushlike_921 371
Be sure you see Flux2D: brushlike_921 at the top of the Program manager.
If you do not, choose Versions, brushlike_921 from the menu.
Program Input
Versions
brushlike_921

372 Solve the no load startup problem
Solve the no load startup problem

You are now ready to solve the motor at no load start up.
Choosing a time step
Choose a time step that is also valid at synchronous speed.
For example, if we estimate the synchronous speed to be 500 rpm, a time step of 0.5 ms will
rotate the rotor 6 degrees every time step (the slot pitch is 15 degrees). Therefore, a time step of
0.5 ms is appropriate for this problem.
Start the solver
Starting the solver with the brushlike_921 release (user subroutine)

Solve the no load startup problem 373
Program Input
Double click Direct
In the Open dialog, select the problem to be solved and click Open:
Program Input
File name: NOLOAD.TRA
Open

In the Solver window, click the Options tab to bring it to the front:
Setting the general solving options
The most important option to check is that the Progressive Newton Raphson algorithm is
disabled, as shown below:
Verify the options as follows:
Program Input
click Options tab
Magnetic, Electric iterations

Program Input
Thermal iterations
Magnetic updatings for coupled

problem
Minimal number of updatings 1
Maximal number of updatings 5
Progressive Newton Raphson Disabled

algorithm
Accuracy definition Automatic accuracy
Solver type SuperLU (9.20)
Priority associated to the Priority normal

computation
Apply
Click Apply to confirm the options.

Then click the Solve icon to begin the computation.
Program Input
click
Definition of time data for no load startup

Program Input
computation
Time values
Initial value of the time 5e-4

step
one step on 1
OK
Click OK to close the dialog. Before the computation begins, the following dialog opens:
Initial rotor position for rotating air gap
Do not change the rotor position. Click OK to close the dialog and watch as the computation
proceeds.
Program Input

0. degrees

End of solving (time steps completed)
Click OK to close the dialog and stop the computation.
Program Input

Close the solver by selecting File, Exit from the menu:
Program Input
File
Exit

380 Results from no load startup
Results from no load startup

Make sure the Flux2D version is still brushlike_921; otherwise, you will not be able to proceed.
In the Flux Supervisor, in the Analysis folder, double click Results:
Starting Results analysis with customized release
Program Input

Results from no load startup 381
In the Open dialog, choose the problem to be analyzed and click Open.
Choosing no load problem to analyze
Program Input
File name: NOLOAD.TRA
Open

Display the isovalues (equiflux) lines at time step 100 (t = 0.05 s)
PostPro_2D opens with the model geometry at the first time step, 0.0005 s.
No load problem open in PostPro_2D
Begin your analysis with a display of the isovalues (equi flux) lines at time step 100, or time =
0.05 s.

Select the 100th time step (0.05 s)
To select the 100th time step, click the Parameters manager button or choose Parameters,
Manager… from the menu:
Program Input
Parameters
Manager…
The Parameters dialog opens:
Choosing time step 100 from the Samples number list
From the Values list, choose 0.05, the time at the 100th time step. Then close the Parameters
dialog.
Program Input
Parameters
Values 0.05
click

You should see the model geometry with the rotor at approximately 256 degrees:
Rotor position at time step 100 (0.05 s)

Set the display properties
Set the display for 21 isovalue lines (the default is 11).
Click the Results, Properties icon or choose Results, Properties from the menu.
Program Input
Results
Properties

The Display properties dialog opens:
Settings for display of 21 equiflux lines
Make sure the Isovalues tab is on top. Then enter or verify the following:
Program Input
Isovalues
Quality Normal
Number 21
Scaling Uniform

Program Input
Display characteristics
Write numbers [check to enable if desired]
OK
Click OK to apply the settings and close the dialog.
To display the plot, click the Isovalues button or choose Results, Isovalues from the menu.
Program Input
Results
Isovalues

The isovalues plot at t = 0.05 s is shown below:
Isovalues at time step 100 (0.05 s)
If you wish, display this plot on the full geometry. Click the icon in the toolbar or choose
Geometry, Full geometry from the menu.
Program Input
click

The plot on the full geometry is shown below.
Isovalues plot on full geometry (t = 0.05 s)

Time variation analysis (2D Curves)
Now look at the time variation results, such as torque, speed, voltages, currents, etc. Look first at
a curve of the axis torque.
Open the 2D Curves manager by clicking the button or by choosing Computation, 2D

Curves manager… from the menu.
Program Input
Computation

The 2D curves manager opens:
Properties for time variation curve of axis torque
Axis torque curve
Enter or verify the following to create a curve of the axis torque:
Program Input
Curve description
Name AxisTorque
Parameter
First axis
X axis Time
Selection step 1
Second axis

Program Input
Quantity Mechanics
click
Clicking the icon creates and displays the curve.
The axis torque curve is shown below:
Axis torque
F The axis torque shown is the resulting torque from the electromagnetic torque,
friction torque and load torque. At synchronous speed, the average torque is
almost zero. The torque values you see during the solving process are the
electromagnetic torque computed by the virtual work method.

Angular velocity curve
Create a curve of the angular velocity next. Open the 2D curves manager again with the
button.
Program Input
click
Program Input
Curve description
Name AngVel
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Mechanics
Component Angular velocity
click

The angular velocity curve is shown below:
Angular velocity curve

Superimpose the axis torque and angular velocity curves on the same sheet. Use the “Stretched”
option for the Y axis.
Your curves display should resemble the following:
Axis torque and angular velocity curves superimposed

Rotor position curve
Look next at a curve of the rotor position. Open the 2D curves manager again with the
button.
Program Input
click
Program Input
Curve description
Name Position
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Mechanics
Components Position
click

The curve of the rotor position is shown below:
Position curve

Superimpose the position and angular velocity curves (with "Stretched" Y axis) for a display like
the following:
Position and angular velocity curves superimposed

Look next at the waveforms of the electric quantities. Click to open the 2D curves manager
again.
Program Input
click
To create a curve of the voltage in the main voltage source (V7)

Voltage and current in the main voltage source
To create a curve of the voltage in the main voltage source (V7), enter or verify the following:
Program Input
Curve description
Name VoltV7
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Voltage
Third data
Support V7
Create
Click the Create button to create this curve. You will not see the curve displayed yet. The 2D
curve manager should remain open, with the new curve added to the list of curves in the Name
field at the bottom.
Curves listed in 2D Curves manager

For a curve of the current in the main voltage source, enter or verify the following:
Program Input
Curve description
Name CurrV7
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Current
Third data
Support V7
Create
Click the Create button to create the current curve. Again, you will not see these curves
displayed yet.

Open a new 2D curves sheet and superimpose the V7 voltage and current curves (use the
"Stretched" option for the Y axis):
Superimposed display of voltage and current curves for V7 (main voltage source)

Current in Switch1
Now create a curve of the current in Switch1 (S1). Click to open the 2D curves manager.
Program Input
click
Program Input
Curve description
Name CurrS1
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Current
Third data
Support S1
click

The curve of the current in SWITCH1 is shown below:
Current in Switch1

Current in the B1 (PA) coil component
Next create a curve of the current in the B1 (PA, positive phase A) coil component. Open the
2D Curves manager with the icon.
Program Input
click
Program Input
Curve description
Name CurrB1-PA
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Current
Third data
Support B_COILA
click

The current curve for coil component B1 (PA) is shown below.
Current in B1 (PA) coil component

Voltage and current in the B2 (PB) coil component
Next create curves of the voltage and current in the B2 (PB, positive phase B) coil component.
Click the button to open the 2D Curves manager and
Program Input
click
Enter or verify the following for a curve of the voltage in B2:
Program Input
Curve description
Name VoltB2-PB
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Voltage
Third data
Support B_COILB
Create
Click the Create button to create the voltage curve for the B2-PB component. Remember, you
will not see the curve displayed yet.
After the curve is created, the 2D Curves manager displays a new default curve name and color.
You should need only to enter a new name (and color, if you wish) for the curve and to select
Current as the Component.

Enter or verify the settings for the curve of the current in B2, as shown below.
Program Input
Curve description
Name CurrB2-PB
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Current
Third data
Support B_COILB
Create
Click the Create button to create the current curve for coil B2. (Remember that the curve will
not be displayed.)

Superimpose the B2 voltage and current curves (with "Stretched" Y axis) for a display like the
following:
Superimposed display of voltage and current curves for coil component B2 (PB)
Voltage and current in B3 (MC) coil component
Next, create and superimpose voltage and current curves for coil component B3 (MC, minus
phase C).
Click to open the 2D curves manager once again.
Program Input
click

Enter or verify the following for the voltage curve for coil component B3:
Program Input
Curve description
Name VoltB3-MC
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Voltage
Third data
Support B_COILC
Create
Click Create to create the B3 voltage curve (it will not be displayed yet).
With the 2D curves manager still open, enter or verify the following for the B3 current curve:
Program Input
Curve description
Name CurrB3-MC
Parameter
First axis
X axis Time
Selection step 1

Program Input
Second axis
Quantity Circuit
Component Current
Third data
Support B_COILC
Create
Again, click Create to create the B3 current curve.
Superimpose the curves on a new sheet ("Stretched" Y Axis) for a display like the following:
Superimposed display of voltage and current curves in B3 coil component
This concludes our analysis of the no load problem. We encourage you to explore other results
on your own.


When you have finished your analysis, click the Save button to save the analysis supports
and curves you have created.
Program Input
click
Close PostPro_2D by choosing from File, Exit from the menu:
Program Input
File
Exit

Chapter 6
Servo action with

You can easily modify the no load startup problem to simulate servo action, just by
adding a load.
Modify the physical properties of the no load startup problem

Plane geometry, 50, 308 depth
Airgap
Rotating airgap
Moment of inertia (default): 0.38765e-4
Viscous friction coefficient: 0.005
Constant friction coefficient: 0.3
Keep "squarewave" circuit
Solve, Transient startup

Problem: SERVO
Initialization: NOLOAD
Start from previous time step
Step to use: 100
Verify Flux version (brushlike_921)
413
Solve with transient startup and user version
Restart at time step: Step1:time=0.05s
Keep previous time steps
Time data
Initial value of time step 1e-3 s
Store 1 on 1

Isovalues (equi flux) lines at last time step, 0.115 s
Color shade plot of flux density on stator, rotor, magnet regions group
Time variation analyses (2D curves)
Axis torque
Angular velocity
Rotor position
Current in Switch1
Current in B1 coil component
Voltage and current in B3 coil component
Close Flux2D
414
Chapter 6
Servo action with electromechanical

coupling
With the no load startup problem already defined, you can easily modify the physical properties
to simulate the servo action just by adding a load.
F You must have already solved the no load startup problem in order to modify it for
the servo simulation. The only difference between these two problems is that the
value of the load or "constant friction coefficient" for the servo problem is no
longer zero.
Once the servo problem is defined, use Flux2D’s transient startup feature to designate the last
time step of your no load startup as the initial time step of your servo problem. Then start the
simulation.
If you have not completed the no load problem, you must define all the physical properties as
described for the constant speed problem (see page 277). Then define the moving airgap
(mechanical coupling with constant friction coefficient of 0.3 N.m.) as described in this chapter
on page 424. Solve as for the no load problem (page 372).
Modification of physical properties

Make sure the no load problem files (NOLOAD.TRA and squarewave.ccs) are in your working
directory.
415
416 Modification of physical properties
Start Preflu 9.1
Program Input
Chapter 6 Servo action with electromechanical coupling

Modification of physical properties 417
The initial Preflu screen
Open the No Load problem
This Servo model is similar to the model generated in the previous chapter. We simply need to
modify the moving mechanical set.
Program Input
click
Servo action with electromechanical coupling Chapter 6

Using the menu
Program Input
Project
Open Project
The Open Project dialog opens.
Opening the No Load project

Program Input

directory]
File Name noload.flu [your name]
Open
The geometry of the No Load model (1 layer airgap) is displayed.
The Noload project is opened.
Save your project now with a specific name to indicate that you will be using this model to
simulate servo action.

Program Input
Project
Save As…
Saving the noload project as servo
Program Input
File Name: servo [your name]
Save

Define the servo model characteristics
The servo model is identical to the no load model except for the definition of the
Edit the MOVING_ROTOR mechanical set
Expand the Mechanical Set in the Data tree. Select the MOVING_ROTOR mechanical set and
Proceed as follows:
Program Input
Click MOVING_ROTOR
Right-click, Edit

The Edit Mechanical Set dialog appears. To enter the servo characteristics, click on the
Kinematics tab at the top.
Going to the Kinematics tab
Proceed as follows:
Program Input
Click Kinematics

Now go to define the Internal Characteristics of the kinematics.
Going to the Internal Characteristics tab
Proceed as follows:
Program Input
Click Internal characteristics

Change the constant friction coefficient value.
*PI()/180
Defining MOVING_ROTOR for servo model
Program Input

and spring
Moment of inertia 3.8675e-5
Constant friction coefficient 0.3
Viscous friction coefficient 0.005*PI()/180
OK

Program Input
Project
Exit
Proceed as follows:
Program Input
Now you can define the transient startup of the servo motor.

426 Transient startup of servo problem
Transient startup of servo problem

The transient startup feature enables you to use a solution from one problem as the initial time
step of a transient problem. The necessary conditions are the same finite element mesh (number
of nodes, elements and regions); the same number of components (but not necessarily the same
circuit); and the same number of mechanical equations (whether they involve motion or not).
For the servo problem, the no load startup solution satisfies all the above conditions. Make sure
your servo problem and your no load startup problem are both in your working directory.
In the Flux Supervisor, in the Solving process folder, double click Transient Startup:
Starting the Transient Startup module

Transient startup of servo problem 427
Program Input
Double click Transient startup
The Transient starting (DEMEVO) module opens:
Transient startup (DEMEVO) screen
Prepare for the transient startup as follows:

428 Solve the servo simulation with user version
Program Input
Problem name servo
Name of the problem containing NOLOAD

the initialization (MS, MD, or
ME) :
looking for the number of time

steps
Number of time steps in the

file: 100
Number of the time step to use 100

as initial value (default
100_0.1)
Results are stored in the

output file
Memory size reached 184 k.

words
The Transient starting module closes and the Flux2D Supervisor is displayed. The solution at
time step 100 of the no load start up problem now becomes the first time step of the servo
problem.
Solve the servo simulation with user version

Now you are ready to solve the servo problem.
F Make sure the correct user version of Flux2D (brushlike_921) is shown at the
top of the supervisor window.
User version of Flux2D
Choose a time step that is also valid at the new synchronous speed with the load. The no load
synchronous speed is 1200 rpm. With the load, the new speed is smaller, so a time step of 1 ms is
satisfactory for the computation.

Solve the servo simulation with user version 429
Start the solver
Starting the solver for the servo problem (with customized release)
Program Input
Double click Direct

In the Open dialog, select the problem to be solved and click Open.
Choosing the servo problem to solve
Program Input
File name: SERVO.TRA
Open
In the Solver window, click the Solve icon to start the computation.
Program Input
click

Because the transient startup is based on the no load problem, which has already been solved, the
following dialog opens.
Notice of previous results for servo problem (transient startup)
Click Yes to continue.
Program Input
Do you want to continue ? Yes

Defining the time data for the SERVO problem
Program Input
Restarting mode Restart at time step
Step1: time = 5.e-002 s
Keep the previous time steps
Time values
Value of the time step 1e-3

Program Input
Number of additional time 65

steps
one step on : 1
OK
Click OK to close the dialog and watch as the solution proceeds.
End of SERVO computation

Click OK to close the dialog and stop the computation.
Program Input
Close the solver by selecting File, Exit from the menu:
Program Input
File
Exit

Results from servo motor 435
Results from servo motor

Make sure the Flux version is still brushlike_921; otherwise, you will not be able to proceed.
In the Analysis folder, double click Results:
Starting Results analysis with customized version
Program Input

436 Results from servo motor
In the Open dialog, choose the problem to be analyzed and click Open:
Choosing SERVO problem to be analyzed
Program Input
File name: SERVO.TRA
Open

PostPro_2D opens with a display of the model at the first time step (0.05 s).
Servo model open in PostPro_2D

Display the isovalues (equiflux) lines
Begin your analysis with a display of 21 equiflux lines at the last time step, 0.115 s.
Select the last time step (0.115 s)
To select the last time step, click the Parameters manager button or choose Parameters,
Manager from the menu:
Program Input
Parameters
Manager
The Parameters dialog opens:
Choosing time 0.115 in the Parameters dialog
From the Samples number list, choose 0.115, the value of the last time step, and then close the
dialog.
Program Input
Parameters
Values 0.115
click

You should see the geometry with the rotor at approximately 800 degrees:
Model at last time step, time 0.115 s

Set properties for the isovalues display
Now set the display properties for 21 isovalue lines.
Click the Results, Properties icon or choose Results, Properties from the menu.
Program Input
Results
Properties

Settings to display 21 equiflux lines
Make sure the Isovalues tab is on top. Then enter 21 as the number of lines and click OK to close
the dialog.
Program Input
Isovalues
Number 21
OK

To display the plot, click the Isovalues icon in the toolbar.
Program Input
click
The isovalues plot is shown below:
Equiflux (isovalues) lines at time 0.115 s
F You may want to see this plot over the full geometry.
To display the full geometry, click the icon in the toolbar, or choose
Geometry, Full geometry from the menu.

The isovalues plot over the full geometry is shown below:
Isovalues at t = 0.115 (full geometry)

Color shade plot for stator, rotor, and magnet
Now display a color shade plot for only the stator, rotor, and magnet regions.
Display this plot over the full geometry. If you have not already done so, choose the Full
Geometry icon in the toolbar.
Program Input
click
Create a group of regions
First, create a group of the three regions. Click the Group manager icon or choose Supports,
Group manager from the menu:
Program Input
Supports
Group Manager
The Group manager dialog opens:
Settings to create display group for color shade plot

Program Input
Filter Region
Objects available ROTOR

MAGNET
STATOR
Add -->
Current group ROTOR

MAGNET
STATOR
These regions are displayed on the model geometry:
Creating a regions group for color shade display

Click Create to create the group and close the Group manager dialog.
Program Input
Create
Set the display properties for the color shade plot
Now click the properties icon or choose Results, Properties from the menu.
Program Input
Results
Properties

Setting properties for color shade plot on group
Click the Color Shade tab to bring it to the front. Select the group you have just created as the
Support and click OK to close the dialog.
Program Input
Support Big3 [your regions group]
OK

Display the color shade plot
To display the plot, click the Color shade icon in the toolbar.
Program Input
click
The color shade plot is shown below:
Color shade plot of flux density on group of regions (rotor, magnet, and stator)

Time variation results (2D curves)
Now look at the time variation results such as torque, speed, voltages, currents, etc.
Axis torque
Begin by creating a curve of the axis torque.
Open the 2D curves manager by clicking the icon or by choosing Computation, 2D curves
manager… from the menu.
Program Input
Computation
The 2D curves manager opens. Enter or verify the following:
Program Input
Curve description
Name AxisTorque
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Mechanics
Create
Click Create to create the axis torque curve (you will not see the curve yet).

The 2D curves manager should still be open with the Axis torque curve listed in the field at the
bottom.
Settings for curve of angular velocity
Angular velocity
Enter or verify the following information to create a curve of the angular velocity. You should
need only to enter a new name for the curve and to choose Angular velocity from the
Components list:
Program Input
Curve description
Name AngVel
Parameter
First axis
X axis Time

Program Input
Selection step 1
Second axis
Quantity Mechanics
Components Angular velocity
click
Superimpose the axis torque and angular velocity curves using “Stretched” for the Y-axis. Your
display should resemble the following:
Superimposed display of axis torque and angular velocity curves
F The axis torque shown is the resulting torque from the electromagnetic torque,
friction torque and load torque. At synchronous speed, the average torque is
almost zero. The torque values you see during the solving process are the
electromagnetic torque computed by the virtual work method.

Rotor position
Next, create a curve of the rotor position. Click to open the 2D curves manager.
Program Input
click
Program Input
Curve description
Name Position
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Mechanics
Component Position
click
Click the button to create and display the position curve.

Superimpose the position and angular velocity curves ("Stretched" Y axis) for the following
display:
Superimposed display of position and angular velocity curves
You can quickly see values on a curve by placing the arrow cursor on the curve and checking the
values at the bottom of the screen. The 2D Cursor feature, however, shows the values on both
curves at the cursor position, and offers the additional possibilities of writing the values to a file,
displaying the mean values, and so on.

Voltage and current in the main voltage source (V7)
Look now at waveforms of electric quantities. Begin with curves of the voltage and current in the
main voltage source, V7.
Click to open the 2D Curves manager.
Program Input
click
Program Input
Curve description
Name VoltV7
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Voltage
Third data
Support V7
Create
Click Create to create the curve. The 2D Curves manager should remain open.

For a curve of the current in the voltage source, enter or verify the following:
Program Input
Curve description
Name CurrV7
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Current
Third data
Support V7
click
Click the button to create and display the V7 current curve.

Superimpose the voltage and current curves (with "Stretched" Y axis) for a display like the
following:
Superimposed display of voltage and current curves for voltage source

Current in Switch 1
Next, create a curve of the current in SWITCH1. Click to open the 2D Curves manager.
Program Input
click
Program Input
Curve description
Name CurrS1
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Current
Third data
Support S1
click
Click the button to create and display the curve.

The SWITCH1 current curve is shown below:
Current in Switch1

Current in B1 (PA) coil component
Next look at a curve of the current in the B1 (PA) coil component. Click to open the 2D
Curves manager.
Program Input
click
Program Input
Curve description
Name CurrB1-PA
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Current
Third data Electrical component
Support B_COILA
click
Click the button to create and display the curve.

The B1-PA current curve is shown below:
Current in the PA coil component (positive phase A)

Voltage and current in B3 (MC) coil component
Finally, look at the voltage and current in the B3 (MC) coil component. Click to open the
2D Curves manager.
Program Input
click
Program Input
Curve description
Name VoltB3-MC
Parameter
First axis
X axis Time
Selection step 1
Second axis
Quantity Circuit
Component Voltage
Third data
Support B_COILC
Create
Click Create to create the B3-MC voltage curve.

Then, still in the 2D Curves manager, enter the information for the B3-MC current curve:
Program Input
Curve description
Name CurrB3-MC
Parameter
First axis
X axis Time
Parameter values 0.05 - 0.115 [select all]
Selection step 1
Second axis
Quantity Circuit
Component Current
Third data
Support B_COILC
click
Click to create and display the B3-MC current curve.

Superimpose the B3-MC voltage curve ("Stretched" Y axis) for a display like the following:
MC voltage and current curves
This concludes our analysis of the servo motor. We encourage you to look at other results as you
wish.

464 Close PostPro_2D
Close PostPro_2D
When you are ready, close PostPro2D by choosing File, Exit from the menu:
Program Input
File
Exit
Saving analysis file
Choose Yes to save your analysis.
Program Input
Do you want to save SERVO Yes

Close Flux2D 465
Close Flux2D
Choose File, Quit to close Flux2D:
Program Input
File
Quit
Congratulations! You have now completed the simulations for the brushless DC motor.
We hope you have enjoyed your analyses with Flux2D.

Tutorial Brushless DC Motor Calculations

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Brushless DC Motor

1 About this document xv

What this document contains · · · · · · · · · · · · · · · · · · · · · · · · · xv

Chapters to complete for the different simulations · · · · · · · · · · xvi

For experienced users· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · xvi

1 Enter the materials 3

Open the materials database · · · · · · · · · · · · · · · · · · · · · · · · · · 5

Add the magnetic material · · · · · · · · · · · · · · · · · · · · · · · · · · · 6

Add the nonlinear steel material· · · · · · · · · · · · · · · · · · · · · · · · 9

Close the materials database · · · · · · · · · · · · · · · · · · · · · · · · · 11

2 Cogging torque computation 15

Special considerations for simulation· · · · · · · · · · · · · · · · · · · · 15

Enter the physical properties · · · · · · · · · · · · · · · · · · · · · · · · · 17

Start Preflu 9.1 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 17

Open the 3-layer airgap problem · · · · · · · · · · · · · · · · · · · · · · · · · · · · 18

Save your project with a new name · · · · · · · · · · · · · · · · · · · · 20

Define as Transient Magnetic · · · · · · · · · · · · · · · · · · · · · · · · · 22

Change to the Physics context · · · · · · · · · · · · · · · · · · · · · · · · 23

Physics context toolbars · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 24

Import materials from the materials database · · · · · · · · · · · · · 25

Assign materials and sources to the regions · · · · · · · · · · · · · · 27

Assign the windings of the stator slots · · · · · · · · · · · · · · · · · · · · · · · · 27

Assign WEDGE, AIR, STATOR_AIR, AIRGAP and SHAFT regions · · · · · · · 31

Assign STATOR and ROTOR regions · · · · · · · · · · · · · · · · · · · · · · · · · · 33

Assign the MAGNET · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 35

Creating and Assigning Mechanical Sets · · · · · · · · · · · · · · · · · 38

Creating Mechanical Sets· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 38

Create the MOVING_ROTOR Mechanical Set . . . . . . . . . . . . . . . . . . . . 39

Create the FIXED_STATOR Mechanical Set. . . . . . . . . . . . . . . . . . . . . 43

Create the ROTATING_AIRGAP Mechanical Set . . . . . . . . . . . . . . . . . . . 44

Assigning Mechanical Sets · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 45

Boundary conditions (Periodicity) · · · · · · · · · · · · · · · · · · · · · · 49

Check the physical model · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 51

Solve (batch mode) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 54

Prepare the batch file · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 54

Close the solver · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 61

Start the batch computation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 62

Display the full geometry· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 69

Displaying isovalues (equiflux) lines at t = 1 s · · · · · · · · · · · · · · · · · · · 71

Change the default isovalues display . . . . . . . . . . . . . . . . . . . . . . . 71

Change the time to 1 s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Display the isovalues plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Color shade of flux density on a group of regions · · · · · · · · · · · · · · · · · 75

Change the geometry display . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Change the time to 0.5 s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Create a group of the three regions . . . . . . . . . . . . . . . . . . . . . . . . 77

Display a color shade plot on the group of regions . . . . . . . . . . . . . . . . . 78

Create a path through the airgap · · · · · · · · · · · · · · · · · · · · · · · · · · · · 81

Normal component of flux density along the air gap path · · · · · · · · · · · 86

Superimpose the curves display · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 88

Axis torque (full cycle) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 95

Save your analyses · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 98

3 Back EMF computation 102

Create the back EMF external circuit model · · · · · · · · · · · · · · 102

Back EMF circuit · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 104

Start ELECTRIFLUX · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 105

Open a new circuit problem · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 106

Using the icon in the toolbar. . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Using the menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

ELECTRIFLUX toolbar · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 109

ELECTRIFLUX menus · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 110

File menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Edit menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

View menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111