Tutorial Brushless DC Motor Calculations

Brushless DC Motor
Calculations
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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
Enter the materials
Start Flux2D 3 Open the materials database 5 Add the magnetic material 6 Add the nonlinear steel material 9 Close the materials database 11
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
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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
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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
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
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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
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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
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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
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
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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
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 Display the isovalues plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
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
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Current in the B_COILB (PB) coil component . . . . . . . . . . . . . . . . . . . 350 Current in the B_COILC (MC) coil component . . . . . . . . . . . . . . . . . . . 352
Save and close PostPro_2D 354
No load startup with electromechanical coupling
359
Modify the physical properties 359

Start Preflu 9.1 360 Open the Constant Speed problem 361 Save your project with a new name 363 Define the no load characteristics 365
Edit the MOVING_ROTOR mechanical set . . . . . . . . . . . . . . . . . . . . . 365
Close and save the model 369
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 Display the isovalues plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
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
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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
Servo action with electromechanical coupling
415
Modification of physical properties 415

Start Preflu 9.1 416 Open the No Load problem 417 Save your project with a new name 419 Define the servo model characteristics 421
Edit the MOVING_ROTOR mechanical set . . . . . . . . . . . . . . . . . . . . . 421
Close and save the model 425
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
Display the isovalues plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
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
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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 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Enter the materials into the materials database (CSLMAT) Cogging torque computation (with batch file solution) Back EMF computation, with a 3-phase Wye external circuit Square wave motor: Constant speed (Torque ripples), with a square wave external circuit No load startup with electromechanical coupling, with the square wave external circuit from Chapter 4 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 Back EMF computation Constant speed computation No load startup computation Servo action computation Chapters 1 and 2 Chapters 1 and 3 Chapters 1 and 4 Chapters 1, 4 and 5 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.
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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
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
4
Choose Start, Programs, Cedrat (or your installation directory), Flux 9.1. Program Input Start Programs Cedrat Flux 9.1 The Flux Supervisor opens:
Start Flux2D
Flux Supervisor
Chapter
Enter the materials
Open the materials database
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
6
The Materials database (CSLMAT) opens:
Add the magnetic material
CSLMAT menu

Flux2D includes a linear model of magnets (constant permeability r and constant remanent flux density Br). Proceed as follows: Program Selected command Selected command Name of the material : Comment Input 1 Add 1 Material magnetpm magnetic material for brushless dc motor
Chapter
Enter the materials
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 To register, define at least one property Please select the property Select a model Value = 1 iso MU 1 scalar cst Input
Enter the materials
Chapter
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 Value = Select the line whose value is to be changed Please select the property Select a model Value = Select the line whose value is to be changed Please select the property Input 1.071 1 Validate 5 Magnet 1 scalar cst 0.401 1 Validate Quit
Chapter
Enter the materials

Next, add the nonlinear steel material. Proceed as follows: Program Input 1 Material Name of the material Comment To register, define at least one property Please select the property Select a model 1 iso MU B scalar a sat nlsteelpm nonlinear steel for laminations in brushless pm motor
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 Saturation magnetization Js = Tesla Initial relative slope a = Select the line whose value is to be changed
Input 1.99
7500
1 Validate
Enter the materials
Chapter
10
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.
Chapter
Enter the materials
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 Selected command Selected command The Flux Supervisor is displayed. You are now ready to begin creating the problem files to run the simulations. Quit Quit STOP
Enter the materials
Chapter
Chapter 2
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 Maximum value time step 0.5 s Minimum value time step 0.5 s Store automatically 1 on 1 Initial position of the rotor: Solve, Batch
61
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
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 preparationa finite element mesh and problem for each positionas 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 Flux2Ds 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.
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
Enter the physical properties
17

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
Chapter
18
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 Program icon on the toolbar Input click
Chapter
19
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 Look in File Name Input Brushless_V9 [your working directory brushless_3layer.flu [your name] Open
Chapter
20
The 3-layer geometry is shown in the following figure:
Save your project with a new name
The geometry (with 3-layer airgap) displayed in Preflu

Save your project now with a specific name to indicate that you will be using this model for cogging torque calculations.
Chapter
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
Enter or verify the following: Program Save In: File Name: Input Brushless_v9 [working directory] cogging [your name] Save
Chapter
22
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.
Enter or verify the following: Program 2D domain type Length Unit Depth of the domain Input 2D plane MILLIMETER 50.308 OK
Chapter
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

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 Program
button to change to the Physics context. Input click
Chapter
24
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
Chapter
Import materials from the materials database
25
The following figures identify the Physics toolbar icons:

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
Chapter
26
The import material dialog appears.
Initial material import dialog
Click on the database.
icon next to the material database name to display the list of materials in the
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
Chapter
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

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.
Chapter
28
Proceed as follows: Program
Input
Click
Click
Click
Chapter
29
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
Chapter
30
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
Chapter
31
Next, accept your input.
Setting a vacuum property for the stator slots
Proceed as follows: Program Sub types: Input 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:
Chapter
32
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 Click Click Click Click
AIR AIRGAP + Ctrl SHAFT + Ctrl STATOR_AIR + Ctrl 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
Chapter
33
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
Chapter
34
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 Sub types: Material Input Select "Magnetic reg" Select "NLSTEELPM" OK
Chapter
35
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
Chapter
36
Proceed as follows: Program Type of region Material of the region
Input Magnetic region MAGNETPM OK
Now you must set the direction of the magnet. Select the magnet. Program Input Click
icon from the toolbar to orient the
If you prefer, choose Physics, Material, Orient material for face region from the menu. Program Input
Physics Material Orient material for face region
Chapter
37
The following figure shows the Orient Material window.
Setting the magnet to 45 degree orientation
Proceed as follows: Program Magnet...Angle Input 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
Chapter
38
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
Chapter
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 Mechanical set name Comment Type of mechanical set Rotation Axis Coordinate system Pivot point First coordinate Input moving_rotor the moving parts of the model Rotation around one axis Rotation around one axis parallel to Oz MAIN
Chapter
40
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 Type of kinematics Velocity (rpm) Position at time t=0s. (deg) Input Imposed Speed 1/6 0 Click "Internal characteristics" tab
Chapter
41
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 Type of load Moment of inertia Constant friction coefficient Viscous friction coefficient Friction coefficient proportional to the square speed Input Inertia, friction coefficients and spring 0 0 0 0
Chapter
42
Click "External characteristics" tab 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 MOVING_ROTOR Mechanical Set
Proceed as follows to define the External characteristics information. Click OK at the end to complete the definition of the mechanical set: Program Type of load Moment of inertia Constant friction coefficient Viscous friction coefficient Input Inertia, friction coefficients and spring 0 0 0
Chapter
43
Friction coefficient proportional to the square 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 Mechanical set name Comment Type of mechanical set Input fixed_stator the non-moving parts of the model Fixed OK
Chapter
44
Create the ROTATING_AIRGAP Mechanical Set
The New Mechanical set dialog closes briefly and then reappears. Enter the information to create the ROTATING_AIRGAP mechanical set.
Defining the information for the ROTATING_AIRGAP Mechanical Set
Proceed as follows: Program Mechanical set name Comment Type of mechanical set Used method to take the motion into account Input rotating_airgap the rotating airgap Compressible Remeshing of the air part surrounding the moving body OK
Chapter
45
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.
Chapter
46
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 Click Click Click
AIR MAGNET + Ctrl ROTOR + Ctrl 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 MECHANICAL_SET Input Select "MOVING_ROTOR" OK
Chapter
47
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 Click Click Click Click Click Click MA MC + Ctrl PA + Ctrl PB + Ctrl STATOR + Ctrl STATOR_AIR + Ctrl 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 MECHANICAL_SET Input Select "FIXED_STATOR" OK
Chapter
48
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
Chapter
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

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.
Chapter
50
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
Chapter
51
The New Periodicity dialog opens.
Defining a periodicity for the brushless DC motor
Proceed as follows: Program Geometrical type of the periodicity Included angle of the domain Offset angle with respect to the X line Physical aspects of periodicity Input Rotation about Z axis with angle of the domain 90 0 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.
Chapter
52
Select the Program icon from the toolbar to start the Physical Check. 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.
Chapter
53
Click on the Program
icon in the toolbar to exit Preflu. 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 Save current project before The Flux Supervisor is displayed. Input Yes
Chapter
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
Chapter
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 Look in File name
Input Brushless_V9[working directory] COGGING.TRA Open
Chapter
56
The solver opens as shown below.
Solve (batch mode)
Solver: Main data
Click the Prepare Batch button Program
to prepare the file for batch mode. Input click
Chapter
Solve (batch mode)
57
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 Restarting mode Time values Initial value of the time step Study time limit Limit number of time steps Maximum value of the time step Minimum value of the time step Storage of time steps 0.5 100 61 0.5 0.5 Input New computation
Chapter
58
Solve (batch mode)
Program one step on
Input 1 Ok
Your time data should be filled in as shown in the following figure:
Time data for the batch computation
Chapter
Solve (batch mode)
59
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 Initial position of the rotor 0. degrees
Input OK
Chapter
60
Solve (batch mode)
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.
Chapter
Solve (batch mode)
61
Close the solver

Choose File, Exit to close the solver. Program Input File
Exit
Chapter
62
Start the batch computation
In the Flux Supervisor, in the Solving process folder, double click Batch:
Solve (batch mode)
Starting the Solver for a batch computation
Program
Input Double click Batch
Chapter
Solve (batch mode)
63
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 Files COGGING.TRA Ready Yes
Input
COGGING.TRA Start
Chapter
64
The Solver window opens:
Solve (batch mode)
Batch computation in progress
Chapter
Solve (batch mode)
65
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 Batch COGGING.TRA The Flux Supervisor should still be open.
Input
Quit
Chapter
66
Results
To see your results, in the Flux2D Supervisor, in the Analysis folder, double click Results:
Results
Starting Results analysis from the Supervisor
Program
Input Double click Results
Chapter
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 Look in File name
Input Brushless_V9[working directory] COGGING.TRA Open
Chapter
68
PostPro_2D opens with a display of the model geometry at the first time step, 0.5 s.
Results
Model open in PostPro_2D
Chapter
Results
69
Display the full geometry

You can display various quantities as plots on the model geometry. If you wish, instead of the model ( 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 Full Geometry from the menu: Program Input or choose Geometry,
Geometry
Full geometry
Chapter
70
Your screen should resemble the following.
Results
Model with full geometry displayed
Chapter
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
Chapter
72
The Display properties dialog opens.
Results
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 Isovalues Analyzed quantity Support Computing parameters Quality Number Normal 21 Equi flux Graphic selection Input
Chapter
Results
73
Program Scaling
Input 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 Parameters, Manager from the menu. Program Input Parameters Manager icon or by choosing
The Parameters dialog opens, as shown in the following figure.
Parameters dialog
Chapter
74
Choose 1 from the Values list and then close the Parameters dialog. Program Parameters Values 1 click
Display the isovalues plot
Results
Input
To display the isovalues lines, click the Isovalues button Isovalues from the menu. Program Input
in the toolbar or choose Results,
Results Isovalues
Chapter
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 Program
to deselect it. Input click
Chapter
76
Change the time to 0.5 s
Results
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 Parameters Values
Input
0.5 click
Chapter
Results
77
Create a group of the three regions
To place the three regions in a group, click the the menu. Program
icon or select Supports, Group manager from
Input
Supports Group manager
The Group manager dialog opens.
Group manager dialog
In the Group manager, enter or verify the following: Program Filter Objects available Input Region STATOR MAGNET ROTOR Add -->
Chapter
78
Results
Program Current group
Input STATOR MAGNET ROTOR Big3 [or your name] Create
Group name
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 Properties from the menu. Program button or by choosing Results,
Input
Results
Properties
Chapter
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 Support Computing parameters Quality Scaling Normal Uniform OK The Display properties dialog closes. |Flux density| Big3 [or your regions group]
Chapter
80
To display the plot, click the color shade button Program in the toolbar. Input click
Results
The plot on the group of regions is shown below:
Color shade plot of flux density on a group of regions
Chapter
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 Program or choose Supports, Path manager from the menu: Input Supports Path manager
Chapter
82
The Path Manager dialog opens:
Results
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.
Chapter
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 Path Name Discretization [default color] Graphic section Numerical section CenterGap [or your choice] 200 [new color, if desired] Arc New section Input
Chapter
84
When you click the New section button, the Section Editing dialog opens:
Results
Section editing window to create paths
In the Section Editing dialog, enter or verify the following: Program Section type Center point X Y Origin point X Y Length Input Arc start angle
0 0
25.4 0 180 OK
Chapter
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 manager at the same time. Program
button to create the path and open the 2D Curves
Input click
Chapter
86
Normal component of flux density along the air gap path
The 2D Curves manager is shown in the following figure.
Results
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.
Chapter
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.
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 Curve description Name [default color] FDNorm [or your choice] [new color, if desired] Path First axis X axis Second axis Quantity Components Third data Parameter Parameter values Time 1 + Ctrl 2 3 1 click Clicking the button creates and displays the curve at the same time. Flux density Normal component CenterGap Input
Selection step
Chapter
88
A 2D curves sheet opens with the 3 curves stacked, as shown in the following figure:
Results
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.
Chapter
Results
89
In the Display dialog, enter or verify the following: Program Input click Display tab Display Gradations X Axis Range Scale Y Axis Range Scale Superimposed ON
Automatic linear
Automatic linear OK
When you click OK, the dialog closes.
Chapter
90
The following figure shows the curves superimposed:
Results
Superimposed curves of normal component of flux density at times 1, 2, and 3 s
Chapter
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 Program button or choose Computation, 2D Spectrum manager from the menu. 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
Chapter
92
Enter or verify the following: Program Analyzed curve Between and Part of cycle described Create this original curve Input FDNorm 0 79.79644 Full cycle
Results
[check box to display flux density curve with spectrum]
Spectrum Harmonics number Spectrum scale Display the DC component line Name [default color] 30 Linear [check to enable if desired] SpectFDNorm [name] [new color, if desired] click Clicking the button creates and displays the spectrum and the curve on a new sheet.
Chapter
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
Chapter
94
The previous spectrum plot, for example, uses a line width of 3, entered as shown below.
Results
Properties dialog to modify individual curve settings, such as line form and width
Chapter
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
Chapter
96
Enter or verify the following: Program Curve description Name [default color] AxisTorq [or your choice] [new color, if desired] Parameter First Axis X axis Parameter values Selection step Second axis Quantity Component Mechanics Axis torque click Clicking the button creates and displays the curve at the same time. Time 0.5 - 30.5 1 Input
Results
Chapter
Results
97
The axis torque curve is shown in the following figure:
Time varying display of the axis torque
Note: Since only of the motor is being modeled, the torque displayed will be of the total motor torque.
Chapter
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
Chapter
Close PostPro_2D
99
Close PostPro_2D
Close PostPro_2D by selecting File, Exit from the menu: Program Input
File
Exit The Flux Supervisor is displayed.
Chapter
Chapter 3
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) Assign physical properties
Plane geometry, 50.308 depth, transient magnetic calculation 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 B_MC, B_PB: Resistance total value, 20 turns, 0.141
Solve with static initialization

Initial value of time step Study time limit Limit number of time steps Store 1 on 1 time steps 0.00125s 100 s 49

Waveforms of electric quantities (2D curves) Voltage through resistor Res4 Spectrum analysis of Res4 voltage curve Voltage for Res1
101

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.
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 ( 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
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.
Chapter
104
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
105
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
Chapter
106
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.
Using the icon in the toolbar
Click the Program
icon in the toolbar. Input click
Chapter
107
Using the menu
If you prefer, choose File, New from the menu. Program Input
File New
Chapter
108
New (blank) Circuit and Sheet windows open.
New Circuit and Sheet windows open in ELECTRIFLUX
Chapter
109
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.
Chapter
110
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.
Chapter
111
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.
"Automatic component skirting" is a setting that prevents circuit connections from being made through or across components. This option is activated (checked) by default.
Chapter
112
Sheet menu
The Sheet menu includes commands to manage individual circuit sheetsto 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.
Chapter
113
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
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The Sheet properties dialog opens.
Modifying the sheet properties
Enter or verify the following: Program Sheet properties (Sheet_1) Comment Squaring gap (pixels) Line Width Background color Line color Selected line color Sheet Width Sheet Height 3 phase wye delta 10 1 [white] [blue] [red] 800 600 OK Input
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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.
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The following figure shows all the components in place for the circuit.
Circuit components placed on the sheet
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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
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A red coil symbol is displayed in the upper left corner of the sheet.
Ready to place the coil components (stator windings)
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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
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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 below B1 click to the left click to of B3 place B2 directly place B3 below and to of B2 place B4 to the right
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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
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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.
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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
B4 turns red click three (3) times
B4 rotates 270 clockwise
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With the four coils properly rotated, your sheet should resemble the following:
Coils rotated (slightly enlarged)
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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
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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.
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With the inductors added, your sheet should resemble the following figure.
Inductors placed on sheet
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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 three (3) times
L2 rotates 270 clockwise click L3
L3 turns red click three (3) times
L3 rotates 270 clockwise
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With the inductors properly rotated, your sheet should resemble the following figure.
Inductors oriented
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Add the open circuit loads
Next, add the open circuit loads. These are three large resistors (100,000 ) connected in Wye. The following figure shows the location of these three resistors.
Three resistors (open circuit loads) placed on the sheet
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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
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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 drag cursor off the sheet
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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 three (3) times
R2 rotates 270 clockwise click R3
R3 turns red click three (3) times
R3 rotates 270 clockwise
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With the three resistors properly rotated, your sheet should resemble the following.
Open circuit load resistors oriented
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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.
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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 cursor off the sheet
Drag your cursor off the sheet to stop adding resistors.
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Rotate the voltmeter (R4)
Now rotate the resistor (R4) as follows. Program Input click R4 symbol
R4 turns red click R4 rotates 180 clockwise twice
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All the components should now be properly positioned on your sheet, as shown in the following figure.
Components placed on sheet
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Save your circuit file

Now is a good time to save your circuit file. Click the menu. Program Input File icon or choose File, Save from the
Save
The "Choose a file name" dialog opens.
Saving the circuit file
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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 Save in File name Input Brushless_V9[working directory] 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
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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.
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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.
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The following figure shows resistor R2 being connected to coil B4.
Connections for upper part of circuit
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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
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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)
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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 as the resistance value for all the resistors. The design sheet value for the end turn inductance per phase is 0.031 mH/phase.
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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.
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 Resistor Name R1 Input
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148
Program Characteristics Name Value
Input
R(ohm) 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
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149
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)
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In the Inductor dialog, enter or verify the following: Program Inductor Name Characteristics Name Value L1
Input
L(henry) 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.
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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
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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
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The following dialog opens with a report of the analysis.
Analysis of the circuit
Click Exit to close the dialog. Program The circuit is connexe. Input Exit
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Save and close the circuit file
The circuit and transmission files are now complete. Save the circuit file by clicking the or by choosing File, Save from the menu. Program Input File
icon
Save
Close the circuit by choosing File, Close. Program Input File
Close
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The following dialog opens.
Confirming close of circuit
Click Yes to confirm: Program Close circuit? Input Yes
Close ELECTRIFLUX
Finally, close ELECTRIFLUX by choosing File, Exit. Program Input File
Exit
The Flux Supervisor is displayed.
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Start Preflu 9.1

Starting Preflu 9.1 to enter the physical properties
Program
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157
Preflu 9.1 screen
Open the 1-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 an existing Flux project, click the Program icon on the toolbar. Input click
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159
Enter or verify the following: Program Look in File Name Input Brushless_V9 [your working directory] 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.
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160
To save your project with a new name, choose Project, Save As from the menu: Program Input
Project
Save As
Saving the brushless 1-layer model as bemf
Enter or verify the following: Program Save In: File Name: Input Brushless_V9[working directory] bemf [your name] Save
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161

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

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
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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.

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.
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164
Program
Input
Physics Material
Import material
In the Import material dialog, click on the list of materials in the database.
icon next to the material database to display the
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.
Chapter
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

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 Program icon on the toolbar. Input click
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166
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 Program Input click
in the dialog box.
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167
The Open circuit dialog appears.
Enter or verify the following: Program Look In: File Name: Input Brushless_V9 [your working directory] 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
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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
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169

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
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The Edit Face Region dialog opens.
Enter or verify the following: Program Type of region Input Coil conductor region type Positive orientation of the current Number of turns of the conductor Coil conductor region component Symmetries and periodicities 10 B_PA All the symmetrical and periodical conductors are in series OK
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171
Similarly, select the MA region for editing (right-click on MA in the data Tree, select Edit)
Enter or verify the following: Program Type of region Input Coil conductor region type Positive orientation of the current Number of turns of the conductor Coil conductor region component Symmetries and periodicities 10 B_MA All the symmetrical and periodical conductors are in series OK
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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
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173
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 Type of region Input Coil conductor region type Positive orientation of the current Number of turns of the conductor Coil conductor region component Symmetries and periodicities 20 B_MC All the symmetrical and periodical conductors are in series OK Finally select to edit the PB region (with either the tree or graphically).
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Enter or verify the following: Program Type of region
Input Coil conductor region type Positive orientation of the current
Number of turns of the conductor Coil conductor region component Symmetries and periodicities
20 B_PB All the symmetrical and periodical conductors are in 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 0.141/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 0.141 by 2 to obtain 0.0705, 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
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175
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 Modify all - Resistance formula Input 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 . In the Modify All column, enter the resistance.
Setting the resistance for coils B_MC & B_PB
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176
Proceed as follows: Program Modify all - Resistance formula
Input 0.141 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
AIR AIRGAP + Ctrl SHAFT + Ctrl 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
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177
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
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178
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 Sub types: Material Input Select "Magnetic reg" Select "NLSTEELPM" OK
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179
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
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180
Proceed as follows: Program Type of region Material of the region
Input Magnetic 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 Magnet...Oriented type Input Radial Positif OK You have now assigned a material property to each region of the geometry.
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181

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
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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: Program Mechanical set name Comment Type of mechanical set Rotation Axis Coordinate system Pivot point First coordinate Input moving_rotor the moving parts of the model Rotation around one axis Rotation around one axis parallel to Oz MAIN
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183
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: Program Type of kinematics Velocity (rpm) Position at time t=0s. (deg) Input Imposed Speed 500 0 Click "Internal characteristics" tab
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184
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 Type of load Moment of inertia Constant friction coefficient Viscous friction coefficient Friction coefficient proportional to the square speed Input Inertia, friction coefficients and spring 0 0 0 0
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185
Click "External characteristics" tab 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 MOVING_ROTOR Mechanical Set
Proceed as follows to define the External characteristics information: Program Type of load Moment of inertia Constant friction coefficient Viscous friction coefficient Input Inertia, friction coefficients and spring 0 0 0
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186
Friction coefficient proportional to the square 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 Mechanical set name Comment Type of mechanical set Input fixed_stator the non-moving parts of the model Fixed OK
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187
Create the ROTATING_AIRGAP Mechanical Set
The New Mechanical set dialog closes briefly and then reappears. Enter the information to create the ROTATING_AIRGAP mechanical set.
Defining the information for the ROTATING_AIRGAP Mechanical Set
Proceed as follows: Program Mechanical set name Comment Type of mechanical set Used method to take the motion into account Input rotating_airgap the rotating airgap Compressible Remeshing of the air part surrounding the moving body OK
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188
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.
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189
Program
Input
AIR MAGNET + Ctrl ROTOR + Ctrl 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 MECHANICAL_SET Input 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.
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190
Program
Input Click Click Click Click Click Click MA MC + Ctrl PA + Ctrl PB + Ctrl STATOR + Ctrl 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
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191
Proceed as follows: Program MECHANICAL_SET Input 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
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192
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
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193
Proceed as follows: Program Input Select "ROTATING_AIRGAP" OK

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
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194
Proceed as follows: Program Geometrical type of the periodicity Included angle of the domain Offset angle with respect to the X line Physical aspects of periodicity Input
Rotation about Z axis with angle of the domain 90 0 Odd (anticyclic boundary conditions) OK

Now that all physical attributes have been assigned to our model, we should have Flux check it before proceeding to solving. Select the Program icon from the toolbar to start the Physical Check. Input Click
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195
The model is ready for solving. Close the Preflu application. Select Project, Exit from the menu. Program Input
Project
Exit
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196
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
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197
Start the solver

In Flux Supervisor, in the Solving process folder, double click Direct:
Starting the solver
Program
Input Double click Direct
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198
In the Open dialog, select the problem to be solved and click Open.
Program Look in: File name:
Input Brushless_V9[working directory] BEMF.TRA [your name] Open
Start the solver

The solver screen will appear. Click the Solve button Program to begin the computation. Input click
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199
The Definition of time data dialog opens:
Definition of time data for back EMF computation
Enter or verify the following information: Program Restarting mode Input New computation initialised by static computation
Time values Initial value of the time step 0.00125
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200
Program Study time limit Limit number of time steps Storage of time steps one step on
Input 100 49
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 Initial position of the rotor 0. degrees Input OK
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201
When the computation stops, the following dialog opens:
End of back EMF computation
Click OK to close the dialog. Program Stop the solving process Input OK
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202
Close the solver
Select File, Exit from the menu to close the solver. Program Input File
Exit
Chapter
Results from the Back EMF computation
203

To see your results, in the Flux Supervisor, in the Analysis folder, double click Results.
Starting Results analysis (PostPro_2D)
Program
Chapter
204
Select the problem to analyze and click Open:
Choosing the problem to analyze with PostPro_2D
Input Brushless_V9[working directory] BEMF.TRA [your name] Open
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205
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 manager from the menu: button or choose Computation, 2D Curves
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206
Program
Input Computation
2D curves manager
The 2D curves manager opens.
2D curves manager: Settings for time variation curve of back emf in R4
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207
Enter the data for the curve as follows: Program Curve description Name [default color] VoltRes4 [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Components Third data Support R4 click Clicking the button creates and displays the curve at the same time. Circuit Voltage Time 0.00125 - 0.06125 1 Input
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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.
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209
Program
Input Computation
2D spectrum manager
The Spectrum manager opens, as shown in the following figure:
Settings for spectrum analysis of voltage curve for R4
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210
Enter or verify the information as follows: Program Analyzed curve Between and Part of cycle described Create this original curve Input
VoltRes4 [name of curve] 1.25E-3 61.25E-3 Full cycle [select] [check to enable display of voltage curve]
Spectrum Harmonics number Spectrum scale Display the DC component line Name [default color] 30 Linear [check if desired] SpectrVoltRes4 [new color, if desired] click Clicking the time. button creates and displays the spectrum and the voltage curve at the same
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211
The spectrum and the voltage curve are shown below:
Time variation spectrum of voltage for R4
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212
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
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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.
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When you finish, click the Save have created). Program
button to save your analysis (including all the curves you
Input click
Close PostPro_2D by selecting File, Exit from the menu: Program Input
File
Exit
Chapter
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 Assign physical properties
Plane geometry, 50.308 depth, transient magnetic calculation 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 B_COILB, B_COILC: Resistance total value, 20 turns, 0.141 Define voltage source: Constant time variation, 24 volts Define the switches: User define, Time, 3 coefficients Coefficients for SWC1: 15, 75, 180 Coefficients for SWC2: 45, 105, 180 Coefficients for SWC3: 75, 135, 180 Coefficients for SWC4: 105, 165, 180 Coefficients for SWC5: 135, 15, 180 Coefficients for SWC6: 165, 45, 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 Study time limit Limit number of time steps Store 1 on 1 time step Initial rotor position
0.00125s 100 s 49 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
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
The following figure shows the complete circuit.
3-phase bridge circuit
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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
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220
ELECTRIFLUX opens:
ELECTRIFLUX (Circuit) window
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221
Create a new circuit problem

First, open a new circuit problem, either with the toolbar icon or the menu.
Using the icon in the toolbar
Click the Program
icon in the toolbar. Input click
Using the menu
If you prefer, choose File, New from the menu. Program Input
File New
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222
New (blank) Circuit and Sheet windows open.
New Circuit and Sheet windows open
For a review of ELECTRIFLUX icons and menus, see page 109.
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223
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 Right click on the sheet Sheet settings
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224
The Sheet properties dialog opens.
Modifying the sheet properties
Enter or verify the following: Program Sheet properties (Sheet_1) Comment Squaring gap (pixels) Line Width Background color Line color Selected line color Sheet Width Sheet Height 6-step inverter, 3-phase bridge 10 1 [white] [blue] [red] 800 600 Ok When you click OK, the dialog closes. Adjust the sheet window to show the new size. Input
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225
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
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226
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
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227
A red switch symbol is displayed in the upper left corner of the circuit sheet.
Ready to place first switch component
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228
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
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The following figure shows Switch 1 in position.
Switch 1 in place
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230
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
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231
Place the remaining 4 switches as shown (slightly enlarged) in the following figure.
6 switches in place
Program
Input click right click S1 click right click S3 to place switch S3 to the of S1 to place switch S4 below to place switch S5 to the of S3 to place switch S6 below
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232
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
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233
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
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234
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 rotates 90 clockwise click S5 symbol
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235
Program
Input
S2 rotates 90 clockwise
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236
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)
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237
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
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238
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
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239
Move the cursor and place the 5 other series voltages, as shown in the following figure:
Series voltages in position
Program
Input click click click click click to to to to to place place place place place V2 V3 V4 V5 V6 below below below below below S2 S3 S4 S5 S6
drag cursor off the sheet When you have placed the last series voltage, drag the cursor off the sheet to stop adding voltages for now.
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240
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
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241
Rotate each series voltage 90 clockwise. Program Input click V3 symbol click once
click V5 symbol click once
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242
The following figure shows the series voltages in the proper orientation.
Six series voltages rotated
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243
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.
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244
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 drag cursor off the sheet
To stop adding voltage components, drag your cursor off the sheet.
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245
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
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246
Add the 3 coils
Next, add 3 coils for the stator windings. Click Coil conductor in the Components library. Program Input
click Coil conductor
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247
A red coil symbol is displayed in the upper left corner of the sheet.
Ready to place the first coil component
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248
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
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249
Move the cursor to place the other 2 coils, as shown in the following figure.
Three coils placed on sheet
Program
Input click right click right to of to of place B2 below and V6 place B3 below and V2
drag cursor off the sheet To stop adding coil components, drag the cursor off the sheet.
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250
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
B3 turns red
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251
Program
Input click once
B3 rotates 90 clockwise With the three coils properly oriented, your sheet should resemble the following figure:
Coils oriented (after rotation)
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252
Add the inductors
Now add inductors to model the stator winding end turn inductances. Click Inductor in the Components library. Program Input click Inductor
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253
A red inductor symbol is displayed in the upper left corner of your sheet.
Ready to position inductors
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254
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 click to place L2 under coil B3 click to place L3 under coil B2 drag cursor off the sheet To stop adding inductors, drag the cursor off the sheet.
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255
With the inductors added, your display should resemble the following figure:
Inductors placed on circuit sheet
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256
Rotate the 3 inductors
Now rotate the 3 inductors for proper orientation. Proceed as follows: Program Input click L1 symbol
L3 rotates 90 clockwise
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257
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
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258
To add the resistor, click Resistor in the Components library. Program Input
click Resistor
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259
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
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260
click to place R1 between V3 and V5 drag cursor off the sheet
Drag the cursor off the sheet to stop adding resistors.
Save your circuit

Now is a good time to save your circuit. Click the Program icon or choose File, Save from the menu. Input
File
Save
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261
Saving the circuit file
Enter or verify the following: Program Save in File name Input Brushless_V9 [working directory] squarewave [or your name] Save
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262
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.
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263
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
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264
The coils and inductors are connected as shown below.
Connections for lower part of circuit
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265
The following figure shows the connections for the whole circuit:
Circuit connections completed
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266
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 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)
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267
If you wish, you can edit the name of the switch and add a description in the Comment field.
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 Switch Name Ron(ohm) Value Roff(ohm) Value S1 Input
1e-4
10000 Ok
When you choose Ok, the dialog closes.
The default Roff value is 10000 ; 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
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268
Program
Input Double click S3
1e-4 10000
Ok
Double click S4
1e-4 10000
Ok
Double click S5
1e-4 10000
Ok
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269
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)
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270
In the Inductor dialog, enter or verify the following: Program Name Characteristics Name Value L(henry) 3.1e-5 Ok Define the other inductors as follows: Program Input L1
Input Double click L2
3.1e-5
Ok
Double click L3
3.1e-5
Ok
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271
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 Name Comment Characteristics Name Value R(ohm) 1e5 Ok When you click Ok, the dialog closes. Input R1 voltmeter
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272
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
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273
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
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274
The following dialog opens with a report of the analysis.
Analysis of the circuit
Click Exit to close the dialog. Program The circuit is connexe. Input Exit
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275
Save and close the circuit file

The circuit and transmission files are now complete. Save the circuit by clicking the choosing File, Save from the menu. Program Input File icon or
Save
Close the circuit by choosing File, Close. Program Input File
Close
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276
Confirmation to close circuit
Click Yes to confirm the close of the circuit: Program Close circuit? Input Yes
Close ELECTRIFLUX
Finally, close ELECTRIFLUX by choosing File, Exit. Program Input File
Chapter
Assign the physical properties
277

Start Preflu 9.1

Starting the Preflu module
Chapter
278
Program
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. You can open an existing project either with the toolbar icon or the menu.
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279
Using the icon in the toolbar To open an existing Flux project, click the Program icon on the toolbar. Input click
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280
Opening the Back EMF project
Enter or verify the following: Program Look in File Name Input Brushless_V9 [your working directory] bemf.flu [your name] Open
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281
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. To save your project with a new name, choose Project, Save As from the menu:
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282
Program
Input
Project
Save As
Saving the bemf model as constspeed
Enter or verify the following: Program Save In: File Name: Input Brushless_V9[working directory] constspeed [your name] Save
Chapter
283
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 Delete electrical circuit?
Input OK
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284
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 Program
icon on the toolbar. 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
Chapter
285
in the dialog box.
The Import circuit dialog appears. Click on the browse file selector Program Input Click
The Open circuit dialog appears.
Selecting the squarewave circuit to import
Enter or verify the following: Program Look In: File Name: Input Brushless_V9 [your working directory] squarewave.ccs [your name] Open
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286
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
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287
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
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288
Enter or verify the following: Program Type of region Material of the region Input
Coil conductor region type <verify selection is blank> Positive orientation of the current
10 B_COILA All the symmetrical and periodical conductors are in series OK
Edit the MA region
Similarly, select the MA region for editing (right-click on MA in the data Tree, select Edit)
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289
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 Type of region Material of the region Input Coil conductor region type <verify selection is blank> Negative orientation of the current Number of turns of the conductor Coil conductor region component Symmetries and periodicities 10 B_COILA All the symmetrical and periodical conductors are in series OK
Edit the PB region
Now, select the PB region for editing (right-click on PB in the data Tree, select Edit).
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290
Enter or verify the following: Program Type of region Material of the region Input
Coil conductor region type <verify selection is blank> Positive orientation of the current
20 B_COILB All the symmetrical and periodical conductors are in series OK
Edit the MC region
Now, select the MC region for editing (right-click on MC in the data Tree, select Edit).
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291
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 Type of region Material of the region Input Coil conductor region type <verify selection is blank> Negative orientation of the current Number of turns of the conductor Coil conductor region component Symmetries and periodicities 20 B_COILC All the symmetrical and periodical conductors are in 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 0.141/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.
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292
Click B_COILA Click B_COILC + Shift Right click, Edit array
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 Modify all - Resistance formula Input 0.141 OK
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293
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.
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294
Proceed as follows: Program Value Input 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 Right click, Edit array
The Edit Voltage Source dialog appears. In the Modify All column, enter the voltage.
Setting all series voltages supplies
Chapter
295
Proceed as follows: Program Modify all - RMS_MODULUS Input 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: switchs 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
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296
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
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297
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 No. ON Angle OFF Angle Switch Cycle
1 2 3 4 5 6
15 45 75 105 135 165
75 105 135 165 15 45
180 180 180 180 180 180

Now that all physical attributes have been assigned to our model, we should have Flux check it before proceeding to solving. Select the Program icon from the toolbar to start the Physical Check. Input Click
Chapter
298
Close and save the model

Project
Exit
Chapter
Solve with user version
299

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
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300
You should see "Flux2D: brushlike_921" at the top of the Program manager, as shown in the following figure:
Flux2D custom version (brushlike_921)
Make sure the appropriate user version (brushlike_921) is selected before you start the solver.
Chapter
301
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
Chapter
302
In the Open dialog, select the problem to be solved and click Open:
Input Brushless_V9[working directory] CONSTSPEED.TRA Open
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303
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 Requested precision Thermal iterations Number of iterations Required precision 50 1.e-004 50 1.e-004
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304
Program Magnetic updatings to coupled problem Minimal number of updatings Maximal number of updatings Requested precision Progressive Newton Raphson algorithm
Input
1 5 1.e-002 Disabled
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 Accuracy definition Solver type Priority associated to the computation Input Automatic accuracy SuperLU (9.20) Priority normal Apply
Chapter
305
Start the computation

Click the Solve button Program to begin the computation. Input click
The Definition of time data dialog opens, as shown in the following figure:
Definition of time data
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306
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 Restarting mode Input New computation initialised by static computation Time values Initial value of the time step Study time limit Limit number of time steps Storage of time steps one step on 1 OK Click OK to close the dialog. Before the computation begins, the following dialog opens: 0.00125 100 49
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.
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307
Program Initial position of the rotor 0. degrees
Input OK
When the computation is finished, the following dialog opens:
End of computation
Click OK to close the dialog. Program Stop the solving process Input OK
Close the solver

Then close the solver by selecting File, Exit from the menu:
Chapter
308
Program
Input File
Exit
Chapter
Results: Constant speed computation
309

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
Chapter
310
In the Open dialog, choose the problem to be analyzed and click open:
Choosing the problem to analyze
Input Brushless_V9[working directory] CONSTSPEED.TRA Open
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311
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
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312
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 menu: Program
icon or by choosing Results, Properties from the
Input Results
Properties
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313
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 Isovalues Analyzed quantity Support Computing parameters Quality Number Scaling Equi flux Graphic selection Input
Normal 21 Uniform
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314
Program Display characteristics Write numbers
Input
[check to enable, if desired] OK
When you click OK, the properties dialog closes.

To display the plot, click the Isovalues button from the menu. Program
in the toolbar, or choose Results, Isovalues
Input Results Isovalues
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315
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:
Chapter
316
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.
Chapter
317
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.
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318
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 Filter Objects available Input Region ROTOR MAGNET STATOR
Chapter
319
Program
Input Add ->
Current group:
ROTOR MAGNET STATOR Big3 [or your name] Create
Group name
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
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320
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 click Color Shade tab Analyzed quantity Support Computing parameters Quality Scaling |Flux density| Big3 [group name]
Normal Uniform OK
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321
When you click OK, the Display properties dialog closes.

Display the color shade plot
To display the plot, click the color shade button shade from the menu. Program
in the toolbar or choose Results, Colour
Input Results Colour shade
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322
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 convergenceat an accuracy level of 1e-4.
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323
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 Program or choose Supports, Path manager from the menu: Input Supports Path manager
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324
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 figure above). (when Arc is selected, as shown in the
Chapter
325
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 Name Discretization [default color] Graphic section Numerical section Input CenterGap [or your choice] 200 [new color if desired] Arc New section
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326
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 Section type Center point X Y Origin point X Y Length Input Arc start angle
0 0
25.4 0 180 OK
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327
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 manager at the same time. Program
button to create the path and open the 2D Curves
Input click
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328
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 Curve description Name [default color] FDNorm [new color, if desired] Path First axis X axis Second axis CenterGap [path name] Input
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329
Program Quantity Components Third axis Parameter Parameter values Selection step
Input Flux density Normal component
Time 0.00125 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 Curve description Name [default color] FDTang [new color, if desired] Path First axis X axis CenterGap [path name] Input
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330
Program Second axis Quantity Components Third axis Parameter Parameter values Selection step
Input
Flux density Tangent component
Time 0.00125 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 Program icon to open a blank curves sheet. Input click
Then right click anywhere on the blank curve sheet, and open the properties dialog. Program Input click Right click on the sheet
Properties
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331
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 Curves filter Curves available Input Computation FDNorm FDTang Add --> Displayed curves FDNorm FDTang
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332
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 Gradations X Axis Range Scale Y Axis Range Automatic Automatic linear Superimposed ON
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333
Program Scale
Input 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
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334
Spectrum analysis
Next, use the Spectrum manager to display the harmonics of the normal component of the flux density. Proceed as follows: Click the Program button or choose Computation, 2D Spectrum manager from the menu. Input Computation
2D spectrum manager
The Spectrum manager opens.
Spectrum manager
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335
Enter or verify the following for the spectrum analysis: Program Analyzed curve Between and Part of cycle described Create this original curve Spectrum Harmonics number Spectrum scale Display the DC component line Name [default color] 30 Linear [check to enable if desired] SpectFDNorm [or other name] [new color, if desired] click Clicking the button creates and displays the spectrum with the curve on a new sheet. Input FDNorm 0 79.79644 Full cycle [check box to enable display of normal component curve]
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336
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
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337
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.
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338
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 manager from the menu. Program button or choose Computation, 2D curves
Input
Computation
2D curves manager
The 2D Curves manager opens.
Settings for AxisTorque curve
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339
Enter or verify the following information: Program Curve description Name [default color] AxisTorque [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Components Third data click Clicking the button creates and displays the curve. Mechanics Axis torque Time 0.00125 - 0.06125 1 Input
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340
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.
Chapter
341
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.
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342
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
2D curves manager
Settings for curve of voltage in the main voltage source (V7)
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343
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 Curve description Name [default color] V7Voltage [new color, if desired] Parameter First axis X axis Parameter values Second axis Quantity Components 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. Enter or verify the following: Program Curve description Name [default color] V7Current [new color, if desired] Parameter First axis Input Circuit Voltage Time 0.00125 - 0.06125 Input
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344
Program X axis Parameter values Second axis Quantity Components Third data Support
Input Time 0.00125 - 0.06125
Circuit Current
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 Program 2d curves manager button. Input click
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345
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 Program button to open the 2D curves manager. Input click
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346
Enter or verify the following: Program Curve description Name [default color] CurrSW1 Input
[new color, if desired] Parameter
First axis X axis Parameter values Second axis Quantity Components Third data Support S1 click Circuit Current Time 0.00125 - 0.06125
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347
The curve of the current for Switch 1 is shown below.
Current in Switch 1
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348
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
Enter or verify the following: Program Curve description Name [default color] CurrB1(PA) [new color, if desired] Parameter First axis X axis Parameter values Second axis Quantity Components Third data Support B_COILA click Circuit Current Time 0.00125 - 0.06125 Input
Chapter
349
The curve of the current in the B_COILA coil component is shown below:
Current in coil component B_COILA (PA, positive phase A)
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350
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
Enter or verify the following information: Program Curve description Name [default color] CurrB2(PB) [new color, if desired] Parameter First axis X axis Parameter values Second axis Quantity Components Third data Support B_COILB click Circuit Current Time 0.00125 - 0.06125 Input
Chapter
351
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)
Chapter
352
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
Enter or verify the following information: Program Curve description Name [default color] CurrB3(MC) [new color, if desired] Parameter First axis X axis Parameter values Second axis Quantity Components Third data Support B_COILC click Circuit Current Time 0.00125 - 0.06125 Input
Chapter
353
The curve of the current in B_COILC (MC) is shown below:
Current in coil component B_COILC (MC, negative phase C)
Chapter
354
This concludes our analysis of the motor at constant speed.
To save the analysis supports and the curves you have created, click the Save from the menu. Program Input File Save
icon or choose File,
Chapter
355
Then close PostPro_2D by choosing File, Exit. Program Input File
Chapter
356
Chapter
Chapter 5
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 Study time limit Limit number of time steps Store 1 on Initial position of the rotor
5e-4 s 100 s 100 1 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 Waveforms of electric quantities Voltage and current in voltage source 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
With the constant speed problem already defined, you can easily modify the physical properties to simulate the no load startup.
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
Start Preflu 9.1
Program
Chapter
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. You can open an existing project either with the toolbar icon or the menu. Using the icon in the toolbar To open an existing Flux project, click the Program icon on the toolbar. Input click
Chapter
362
Project Open Project
Opening the Constant Speed project
Chapter
363
Program Look in File Name
Input Brushless_V9 [your working directory] 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. To save your project with a new name, choose Project, Save As from the menu:
Chapter
364
Program
Input
Project
Save As
Saving the constspeed project as noload
Enter or verify the following: Program Save In: File Name: Input Brushless_V9[working directory] noload [your name] Save
Chapter
365
Define the no load characteristics

The no load model is identical to the constant speed model except for the definition of the MOVING_ROTOR mechanical set.
Edit the MOVING_ROTOR mechanical set
Expand the Mechanical Set in the Data tree. Select the MOVING_ROTOR mechanical set and right-click the mouse to select Edit. Proceed as follows: Program Input
Click MOVING_ROTOR Right-click, Edit
Chapter
366
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
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367
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 Type of kinematics Velocity at time t=0s (rpm) Position at time t=0s (deg) Input Coupled load 0 0 Click Internal characteristics
Chapter
368
Now enter the characteristics needed to do the No Load analysis.
Entering the No Load Internal Kinematic characteristics
Enter or verify the following: Program Type of load Moment of inertia Constant friction coefficient Viscous friction coefficient Friction coefficient proport Input Inertia, friction coefficients and spring 3.8675e-5 0 0.005 0 Click External characteristics
Note: Since only of the motor is being modeled, the value you enter for the moment of inertia is of the inertia of the entire motor.
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369
Enter the external kinematic characteristics.
Entering the No Load External Kinematic characteristics
Enter or verify the following: Program Type of load Moment of inertia Constant friction coefficient Viscous friction coefficient Friction coefficient proport Input Inertia, friction coefficients and spring 0 0 0 0 OK

The model is ready for solving. Close the Preflu application. Select Project, Exit from the menu.
Chapter
370
Verify the user version: brushlike_921
Program
Input
Project
Exit

Because the motor has rotor position dependent switches, you must use the brushlike_921 custom version, as you did with the constant speed problem.
Chapter
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
Chapter
372
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)
Chapter
373
Program
In the Open dialog, select the problem to be solved and click Open:
Input Brushless_V9[working directory] NOLOAD.TRA Open
Chapter
374
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 Number of iterations 50
Chapter
375
Program Requested precision Thermal iterations Number of iterations Requested precision Magnetic updatings for coupled problem Minimal number of updatings Maximal number of updatings Requested precision Progressive Newton Raphson algorithm Accuracy definition Solver type Priority associated to the computation
Input 1.e-004
50 1.e-004
1 5 1.e-002 Disabled Automatic accuracy SuperLU (9.20) Priority normal Apply
Click Apply to confirm the options.
Chapter
376
Then click the Solve icon Program to begin the computation. Input click
Definition of time data for no load startup
Chapter
377
Enter or verify the following information: Program Restarting mode Input New computation initialised by static computation Time values Initial value of the time step Study time limit Limit number of time steps Storage of time steps one step on 1 OK Click OK to close the dialog. Before the computation begins, the following dialog opens: 5e-4 100 100
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 Initial position of the rotor 0. degrees Input OK
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378
When the computation is finished, the following dialog opens:
End of solving (time steps completed)
Click OK to close the dialog and stop the computation. Program Stop the solving process Input OK
Chapter
379
Close the solver by selecting File, Exit from the menu: Program Input File
Exit
Chapter
380
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
Chapter
381
In the Open dialog, choose the problem to be analyzed and click Open.
Choosing no load problem to analyze
Input Brushless_V9[working directory] NOLOAD.TRA Open
Chapter
382
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.
Chapter
383
Select the 100th time step (0.05 s)
To select the 100th time step, click the Parameters manager button Manager from the menu: Program Input Parameters Manager
or choose Parameters,
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 Parameters Values 0.05 click Input
Chapter
384
You should see the model geometry with the rotor at approximately 256 degrees:
Rotor position at time step 100 (0.05 s)
Chapter
385
Set the display properties
Set the display for 21 isovalue lines (the default is 11). Click the Results, Properties icon Program or choose Results, Properties from the menu. Input Results
Properties
Chapter
386
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 Isovalues Analyzed quantity Support Computing parameters Quality Number Scaling Equi flux Graphic selection Input
Normal 21 Uniform
Chapter
387
Program Display characteristics Write numbers
Input
[check to enable if desired] OK
Click OK to apply the settings and close the dialog.

To display the plot, click the Isovalues button Program
or choose Results, Isovalues from the menu. Input Results Isovalues
Chapter
388
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 Geometry, Full geometry from the menu. Program Input click
icon in the toolbar or choose
Chapter
389
The plot on the full geometry is shown below.
Isovalues plot on full geometry (t = 0.05 s)
Chapter
390
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 Curves manager from the menu. Program button or by choosing Computation, 2D
Input Computation
2D curves manager
Chapter
391
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 Curve description Name [default color] AxisTorque [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Time 0.0005 - 0.05 1 Input
Chapter
392
Program Quantity Components
Input Mechanics Axis torque click
Clicking the
icon creates and displays the curve.
The axis torque curve is shown below:
Axis torque
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.
Chapter
393
Angular velocity curve
Create a curve of the angular velocity next. Open the 2D curves manager again with the button. Program Input click
Enter or verify the following: Program Curve description Name [default color] AngVel [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Mechanics Angular velocity click Time 0.0005 - 0.05 1 Input
Chapter
394
The angular velocity curve is shown below:
Angular velocity curve
Chapter
395
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
Chapter
396
Rotor position curve
Look next at a curve of the rotor position. Open the 2D curves manager again with the button. Program Input click
Enter or verify the following: Program Curve description Name [default color] Position [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Components Mechanics Position click Time 0.0005 - 0.05 1 Input
Chapter
397
The curve of the rotor position is shown below:
Position curve
Chapter
398
Superimpose the position and angular velocity curves (with "Stretched" Y axis) for a display like the following:
Position and angular velocity curves superimposed
Chapter
399
Waveforms of electric quantities

Look next at the waveforms of the electric quantities. Click again. Program Input click to open the 2D curves manager
To create a curve of the voltage in the main voltage source (V7)
Chapter
400
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 Curve description Name [default color] VoltV7 [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component 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. Circuit Voltage Time 0.0005 - 0.05 1 Input
Curves listed in 2D Curves manager
Chapter
401
For a curve of the current in the main voltage source, enter or verify the following: Program Curve description Name [default color] CurrV7 [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Third data Support V7 Create Click the Create button to create the current curve. Again, you will not see these curves displayed yet. Circuit Current Time 0.0005 - 0.05 1 Input
Chapter
402
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)
Chapter
403
Current in Switch1
Now create a curve of the current in Switch1 (S1). Click Program Input click
to open the 2D curves manager.
Enter or verify the following: Program Curve description Name [default color] CurrS1 [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Third data Support S1 click Circuit Current Time 0.0005 - 0.05 1 Input
Chapter
404
The curve of the current in SWITCH1 is shown below:
Current in Switch1
Chapter
405
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
Enter or verify the following: Program Curve description Name [default color] CurrB1-PA [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Third data Support B_COILA click Circuit Current Time 0.0005 - 0.05 1 Input
Chapter
406
The current curve for coil component B1 (PA) is shown below.
Current in B1 (PA) coil component
Chapter
407
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 Program button to open the 2D Curves manager and Input click
Enter or verify the following for a curve of the voltage in B2: Program Curve description Name [default color] VoltB2-PB [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component 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. Circuit Voltage Time 0.0005 - 0.05 1 Input
Chapter
408
Enter or verify the settings for the curve of the current in B2, as shown below. Program Curve description Name [default color] CurrB2-PB [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component 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.) Circuit Current Time 0.0005 - 0.05 1 Input
Chapter
409
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. Input click
Program
Chapter
410
Enter or verify the following for the voltage curve for coil component B3: Program Curve description Name [default color] VoltB3-MC [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component 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 Curve description Name [default color] CurrB3-MC [new color, if desired] Parameter First axis X axis Parameter values Selection step Time 0.0005 - 0.05 1 Input Circuit Voltage Time 0.0005 - 0.05 1 Input
Chapter
411
Program Second axis Quantity Component Third data Support
Input
Circuit Current
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.
Chapter
412
When you have finished your analysis, click the Save button and curves you have created. Program Input click
to save the analysis supports
Close PostPro_2D by choosing from File, Exit from the menu: Program Input File
Exit
Chapter
Chapter 6
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 Study time limit 100 s Limit number of time steps 65 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 Waveforms of electric quantities Voltage and current in voltage source Current in Switch1 Current in B1 coil component Voltage and current in B3 coil component
Save and close PostPro_2D Close Flux2D
414
Chapter 6
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.
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 Flux2Ds 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
Start Preflu 9.1
Program
Chapter
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. You can open an existing project either with the toolbar icon or the menu. Using the icon in the toolbar To open an existing Flux project, click the Program icon on the toolbar. Input click
Chapter
418
Project Open Project
The Open Project dialog opens.
Opening the No Load project
Chapter
419
Program Look in File Name
Input Brushless_V9 [your working directory] 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. To save your project with a new name, choose Project, Save As from the menu:
Chapter
420
Program
Input
Project
Save As
Saving the noload project as servo
Enter or verify the following: Program Save In: File Name: Input Brushless_V9[working directory] servo [your name] Save
Chapter
421
Define the servo model characteristics

The servo model is identical to the no load model except for the definition of the MOVING_ROTOR mechanical set.
Edit the MOVING_ROTOR mechanical set
Expand the Mechanical Set in the Data tree. Select the MOVING_ROTOR mechanical set and right-click the mouse to select Edit. Proceed as follows: Program Input
Click MOVING_ROTOR Right-click, Edit
Chapter
422
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
Chapter
423
Now go to define the Internal Characteristics of the kinematics.
Going to the Internal Characteristics tab
Proceed as follows: Program Input Click Internal characteristics
Chapter
424
Change the constant friction coefficient value.
Defining MOVING_ROTOR for servo model
Enter or verify the following: Program Type of load Moment of inertia Constant friction coefficient Viscous friction coefficient Friction coefficient proport Input Inertia, friction coefficients and spring 3.8675e-5 0.3 0.005 0 OK
Chapter
425

Project
Exit
Proceed as follows: Program Save current project before The Flux Supervisor is displayed. Now you can define the transient startup of the servo motor. Input Yes
Chapter
426
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
Chapter
427
Program
Input Double click Transient startup
The Transient starting (DEMEVO) module opens:
Transient startup (DEMEVO) screen
Prepare for the transient startup as follows:
Chapter
428
Solve the servo simulation with user version
Program Problem name Name of the problem containing 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 as initial value (default 100_0.1) Results are stored in the output file Memory size reached 184 k. words
Input servo NOLOAD
100
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.

Now you are ready to solve the servo problem.
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.
Chapter
429
Start the solver

Starting the solver for the servo problem (with customized release)
Program
Chapter
430
In the Open dialog, select the problem to be solved and click Open.
Choosing the servo problem to solve
Input Brushless_V9[working directory] SERVO.TRA Open
In the Solver window, click the Solve icon Program
to start the computation. Input click
Chapter
431
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 Do you want to continue ? Input Yes
Chapter
432
Defining the time data for the SERVO problem
Enter or verify the following: Program Restarting mode Input Restart at time step Step1: time = 5.e-002 s Keep the previous time steps Time values Value of the time step 1e-3
Chapter
433
Program Study time limit Number of additional time steps Storage of time steps one step on :
Input 100 65
1 OK
Click OK to close the dialog and watch as the solution proceeds. When the computation is finished, the following dialog opens:
End of SERVO computation
Chapter
434
Click OK to close the dialog and stop the computation. Program Stop the solving process Input OK
Close the solver by selecting File, Exit from the menu: Program Input File
Exit
Chapter
Results from servo motor
435

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
Chapter
436
In the Open dialog, choose the problem to be analyzed and click Open:
Choosing SERVO problem to be analyzed
Input Brushless_V9[working directory] SERVO.TRA Open
Chapter
437
PostPro_2D opens with a display of the model at the first time step (0.05 s).
Servo model open in PostPro_2D
Chapter
438
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 Manager from the menu: Program Input
button or choose Parameters,
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 Parameters Values 0.115 click Input
Chapter
439
You should see the geometry with the rotor at approximately 800 degrees:
Model at last time step, time 0.115 s
Chapter
440
Set properties for the isovalues display
Now set the display properties for 21 isovalue lines. Click the Results, Properties icon Program or choose Results, Properties from the menu. Input Results
Properties
Chapter
441
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 Isovalues Number 21 OK Input
Chapter
442
To display the plot, click the Isovalues icon Program
in the toolbar. Input click
The isovalues plot is shown below:
Equiflux (isovalues) lines at time 0.115 s
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.
Chapter
443
The isovalues plot over the full geometry is shown below:
Isovalues at t = 0.115 (full geometry)
Chapter
444
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 Group manager from the menu: Program Input Supports Group Manager
or choose Supports,
The Group manager dialog opens:
Settings to create display group for color shade plot
Chapter
445
Enter or verify the following: Program Filter Objects available Input Region ROTOR MAGNET STATOR Add --> Current group ROTOR MAGNET STATOR Big3 [or your name]
Group name
These regions are displayed on the model geometry:
Creating a regions group for color shade display
Chapter
446
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 Program
or choose Results, Properties from the menu. Input Results
Properties
Chapter
447
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 click Color Shade tab Support Big3 [your regions group] OK
Chapter
448
Display the color shade plot
To display the plot, click the Color shade icon Program
in the toolbar. Input click
The color shade plot is shown below:
Color shade plot of flux density on group of regions (rotor, magnet, and stator)
Chapter
449
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 manager from the menu. Program icon or by choosing Computation, 2D curves
Input Computation
2D curves manager
The 2D curves manager opens. Enter or verify the following: Program Curve description Name [default color] AxisTorque [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Components Mechanics Axis torque Create Click Create to create the axis torque curve (you will not see the curve yet). Time 0.05 - 0.115 1 Input
Chapter
450
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 Curve description Name [default color] AngVel [new color, if desired] Parameter First axis X axis Parameter values Time 0.05 - 0.115 Input
Chapter
451
Program Selection step Second axis Quantity Components
Input 1
Mechanics 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
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.
Chapter
452
Rotor position
Next, create a curve of the rotor position. Click Program
to open the 2D curves manager. Input click
Enter or verify the following: Program Curve description Name [default color] Position [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Mechanics Position click Click the button to create and display the position curve. Time 0.05 - 0.115 1 Input
Chapter
453
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.
Chapter
454
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. Input click
Program
Enter or verify the following: Program Curve description Name [default color] VoltV7 [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Third data Support V7 Create Click Create to create the curve. The 2D Curves manager should remain open. Circuit Voltage Time 0.05 - 0.115 1 Input
Chapter
455
For a curve of the current in the voltage source, enter or verify the following: Program Curve description Name [default color] CurrV7 [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Third data Support V7 click Click the button to create and display the V7 current curve. Circuit Current Time 0.05 - 0.115 1 Input
Chapter
456
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
Chapter
457
Current in Switch 1
Next, create a curve of the current in SWITCH1. Click Program Input click
to open the 2D Curves manager.
Enter or verify the following: Program Curve description Name [default color] CurrS1 [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Third data Support S1 click Click the button to create and display the curve. Circuit Current Time 0.05 - 0.115 1 Input
Chapter
458
The SWITCH1 current curve is shown below:
Current in Switch1
Chapter
459
Current in B1 (PA) coil component
Next look at a curve of the current in the B1 (PA) coil component. Click Curves manager. Program Input click
to open the 2D
Enter or verify the following: Program Curve description Name [default color] CurrB1-PA [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Third data Support Circuit Current Electrical component B_COILA click Click the button to create and display the curve. Time 0.05 - 0.115 1 Input
Chapter
460
The B1-PA current curve is shown below:
Current in the PA coil component (positive phase A)
Chapter
461
Voltage and current in B3 (MC) coil component
Finally, look at the voltage and current in the B3 (MC) coil component. Click 2D Curves manager. Program Input click
to open the
Enter or verify the following: Program Curve description Name [default color] VoltB3-MC [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Third data Support B_COILC Create Click Create to create the B3-MC voltage curve. Circuit Voltage Time 0.05 - 0.115 1 Input
Chapter
462
Then, still in the 2D Curves manager, enter the information for the B3-MC current curve: Program Curve description Name [default color] CurrB3-MC [new color, if desired] Parameter First axis X axis Parameter values Selection step Second axis Quantity Component Third data Support B_COILC click Click to create and display the B3-MC current curve. Circuit Current Time 0.05 - 0.115 [select all] 1 Input
Chapter
463
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.
Chapter
464
Close PostPro_2D
When you are ready, close PostPro2D by choosing File, Exit from the menu: Program Input File
Close PostPro_2D
Exit The following dialog opens.
Saving analysis file
Choose Yes to save your analysis. Program Do you want to save SERVO The Flux Supervisor is displayed. Input Yes
Chapter
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.
Chapter

Tutorial Brushless DC Motor Calculations

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Brushless DC Motor

Enter the materials

Cogging torque computation

Special considerations for simulation 15 Enter the physical properties 17

Physics context toolbars 24

Creating and Assigning Mechanical Sets 38

Assigning Mechanical Sets 45

Boundary conditions (Periodicity) 49

Solve (batch mode) 54

Save your analyses 98 Close PostPro_2D 99

Back EMF computation

Create the back EMF external circuit model 102

ELECTRIFLUX toolbar 109 ELECTRIFLUX menus 110

Window menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 ? (Help) menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Add inductors 125

Add the open circuit loads 130

Add the voltmeter 135

Enter the physical properties 156

Save your project with a new name 159

Define as Transient Magnetic 161 Change to the Physics context 162

Creating and Assigning Mechanical Sets 181

Assigning Mechanical Sets 188

Boundary conditions (Periodicity) 193

Solve the back EMF problem 196

Results from the Back EMF computation 203

Square wave motor: Constant speed (torque ripples) 217

Add the 6 series voltages 236

Add the main voltage source 243

Add the 3 coils 246

Rotate the coil components . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Add the inductors 252

Assign the physical properties 277

Import the Squarewave Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 284

Assign face regions to the circuit 287

Solve with user version 299

Results: Constant speed computation 309

Color shade plot on a group of regions 318

Save and close PostPro_2D 354

No load startup with electromechanical coupling

Modify the physical properties 359

Close and save the model 369

Results from no load startup 380

Time variation analysis (2D Curves) 390

Waveforms of electric quantities 399

Save and close PostPro_2D 412

Servo action with electromechanical coupling

Modification of physical properties 415

Close and save the model 425

Results from servo motor 435

Display the isovalues plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442

Color shade plot for stator, rotor, and magnet 444

Time variation results (2D curves) 449

Close PostPro_2D 464 Close Flux2D 465

What this document contains

Chapters to complete for the different simulations

For experienced users

Add the nonlinear steel material

Enter the materials

Open the materials database

Open the materials database

Opening the materials database (CSLMAT)

Input Double click Materials database

Enter the materials

Add the magnetic material