Highlights of FluxMotor2022.2
1. Transient thermal computation for Reluctance Synchronous Machines
A new test is available for characterizing the transient thermal behavior of the Reluctance Synchronous machine while applying a power step.
The aim of “Characterization – Thermal – Motor & Generator – Transient” test is to evaluate the impact of electromagnetic performance on thermal behavior of the machine in a transient mode.
The thermal working point defined by the speed and a set of losses can be considered to compute the temperature charts and the main thermal parameters, like the heat capacities and the thermal time constants.
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2. Computation of AC losses in winding – Hybrid method
From now on, while running the test to characterize the behavior of machines, operating at a targeted “working point” by considering the “Accurate mode” of computation, there will be three options for computing or ignoring AC losses in winding:
None: AC losses are not computed. However, as the computation mode is “Accurate”, a transient computation is performed, but without representing the solid conductors (wires) inside the slots. Phases are modeled with coil regions. Thanks to that, the mesh density is lower with a lower number of nodes and a lower computation time.
FE-One phase: AC losses are computed on one phase. Only one phase is modeled with solid conductors. The two other ones are modeled with coil regions. One gets AC losses in winding, but with a lower computation time than if all the phases were modeled with solid conductors. However, this can have a little impact on the accuracy of results.
FE-All phase: AC losses are computed on all the phases. All the phases are modeled with solid conductors. This computation method gives the best results in terms of accuracy, but with a higher computation time
With the current version, a new method is available:
FE-Hybrid: AC losses in winding are computed without representing the wires (strands, solid conductors) inside the slots.
Since the location of each wire is accurately defined in the winding environment, sensors evaluate the evolution of the flux density close to each wire. Then, a postprocessing based on analytical approaches computes the resulting current density inside the conductors and the corresponding Joule losses.
The wire topology can be “Circular” or “Rectangular”.
There can be one or several wires in parallel (in hand) in a conductor (per turn).
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| Mode of computation “Accurate” with Hybrid method of computation for AC losses in winding |
This new method of computation is available for all the machines:
Synchronous Machines with Permanent magnets – Inner and outer rotor or Reluctance Synchronous Machines – Inner rotor, when running the test “Working point – Sine wave – Motor – I, Ψ, N” to characterize the behavior of the synchronous machines, operating at the targeted input values I, Ψ, N (Magnitude of current, Control angle, Speed).
Induction Machines with squirrel cage – Inner and Outer rotor, when running the test “Working point – Sine wave – Motor – U, f, N” to characterize the behavior of the induction machines, operating at the targeted input values U, f, N (Line-Line voltage, Power supply frequency, Speed).
This method leads to more accurate results with lower computation time. This is a good trade off between accuracy and computation time.
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| Computation of AC losses in winding – Classical and Hybrid methods are embedded |
3. A new option for characterizing the equivalent scheme of induction machines
The characterization of the equivalent scheme for induction machines with squirrel cage has been improved with one additional option.
The frequency analysis to compute the operational inductance - L(p) – can be based on a working point defined with the Line-Line voltage U, the power supply frequency f and the speed N.
Indeed, the magnetic permeability mapping of a motor is done at the selected working point (U, f, N).
The resulting map of permeability is then applied to the model while performing the frequency analysis. This is what known as the frozen permeability method.
This must lead to even more accurate results.
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| Equivalent scheme of induction machines - An even more accurate approach |
4. A new application “Materials”
The application “Materials” has been entirely rebuilt. This leads to a streamlined and consistent usage with all the other applications of FluxMotor.
Note that this modification is due to an evolution of our software architecture to get even more reliability, robustness, and performance.
All the functions to create and manage the materials are implemented in the new user-oriented GUI.
A scrolling selection bar helps to choose the sections (1, 2, 3) in which one can define the material property settings.
The material properties can be defined step by step.
- “Desc.” to give the general information and memos
- “Mechanics” to set the mechanical properties
- “Magnetics” to define the B(H) curve parameters
- “Iron losses” to define the model iron loss parameters
- “Thermic” to define the thermal properties of the material
- “Operating” to adjust the environment parameters for evaluating the material
properties inside the application "Materials"
In this example, the operating conditions deal with the frequency to be considered for evaluating the iron losses inside the application “Materials”
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| New GUI of “Materials”Selection of sections in which one can define the material property settings – Example for laminations |
- “Desc.” to give the general information and memos
- “Mechanics” to set the mechanical properties
- “Electric” to define the resistivity parameters
- “Magnetics” to define the B(H) and J(H) curve parameters
- “Thermic” to define the thermal properties of the material
- “Operating” (1) to adjust the environment parameters for evaluating the material properties inside the application “Materials”.
- The temperature to be considered for evaluating the remanent flux density and the intrinsic coercivity field
- The load line permeance coefficient
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| Selection of sections in which one can define the material property settings – Example for magnets |
For all the materials, it is possible to export the datasheet of a material which is being displayed.
Material properties are classified in different categories depending on its family. It is possible to choose one or several of these categories to be exported.
Data can be exported either into *.txt or *.xls files. The results can be merged or not, which implies that these can be written in one single file or that a file can be provided for each category of result.
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| A dialog box for exporting material datasheet |
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| Material datasheet can be provided either into *.txt or *.xls files |
5. A new application “Script Factory” in standard mode
The application “Script Factory” has been entirely rebuilt. From now on, it will be available in standard mode with a new user-friendly editor for driving the FluxMotor via python script files.
Note that this modification is due to an evolution of our software architecture to get even more reliability, robustness, and performance.
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| The Script Factory – A new workspace organization | |
| 1 | Buttons for actions on files currently edited (Edit, Store, Undo, Redo) |
| 2 | Actions for operating on available files |
| 3 | Buttons to Run or Stop the execution of a python file |
| 4 | Access to the files to be edited (Scripts workspace). Python files are well identified and visualized. |
| 5 | Editor area to display the selected python file |
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| The Script Factory – User help guide and glossary of commands for helping the users | |
| 1 | Actions available in a drop-down menu |
| 2 | Help link to reach the user help guide dedicated to the Script Factory |
| 3 | Buttons to open the glossary of FluxMotor commands |
| 3' | Html files in which are displayed all the available commands for each FluxMotor application |
6. A new Export / Document / Script file
A new function is now implemented in Motor Factory / Export / Document area. Next to the Report, the Script function gives the capability to export a script file in which all the needed command lines are written to rebuild the considered motor.
The script is generated with all the needed sections and sub-sections in Motor Factory, dedicated to the design, to the test, and the exports
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| The full script for building a project, just a click away | |
| 1 | Button “Script” in the Export / Document area to build and export a script file dedicated to the considered motor. |
| 2 | Export parameters allow defining the script name, the motor name, the motor catalog, and the folder in which it must be stored. |
| 3 | Buttons to export the resulting python file and/or to directly open it in Script Factory |
Concerning the process, either you get the script (python file) or you can get into “Script Factory” directly and instantaneously to work on it.
Here an example is shown below for the provided python script in which are described all the sections to define the design of the motor, the tests and the exports which can be performed.
This is a very powerful way for keeping all the information for rebuilding motors, whatever will be the used version of FluxMotor.
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| Example of python script in which are described all the sections to define the design of the motor, the tests and the exports which can be performed |
Functions are implemented for helping the management of python files like “Find and Replace”, Edit, Copy, Paste, Delete,...
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| Function “Find and Replace” is available |
7. Export to Flux 3D is available
The export of project from FluxMotor to Flux 3D is now available for both types of machines, Synchronous Machines with Permanent Magnets - Inner rotor and Reluctance Synchronous Machines – Inner rotor.
While exporting the project from FluxMotor to Flux 3D, after having defined the project name and the folder in which it must be stored, the user has two possible choices to make:
- Export a full geometry or not. If the answer is “No”, the resulting project in Flux 3D is a reduced one in terms of periodicity based on the number of poles and the number of slots.
- Consider half the topology along the axial direction or not. If the
answer is “Yes”, only half of the topology is represented. Note: This is possible only when all the dimensions are equal on both sides of the machine (Connection Side and Opposite Connection Side), especially regarding the end winding dimensions.
If the answer is “No” the whole machine is represented along the axial direction. This allows to consider the differences there can be on both sides of the machines especially regarding the end winding dimensions.
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| Export project to Flux 3D environment – Export information |
A dialog box is provided for defining the lengths of the stator, the rotor, and the magnets. These three lengths can be different.
The illustration here below shows the resulting topology in Flux 3D environment where the three lengths are different. This is automatically managed and built from the export area of FluxMotor.
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| Export project to Flux 3D environment – Stator, rotor, and magnets with different lengths |
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| Export project to Flux 3D environment available for Reluctance Synchronous Machines |
When a motor with a skewed topology is considered, on rotor side or stator side, the export to Flux 3D is not possible. In that case, only the export to Flux Skew is accessible.
When the machine topology is not symmetric, especially, with the end winding lengths, the whole the machine must be modelled in Flux 3D. The choice Symmetry “Yes” is not available
In that case, end-windings can be represented with different dimensions on the “Connection Side” and the “Opposite Connection Side” like what is represented in the picture below.
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| Different end-winding dimensions in Flux 3D on both machine sides: Connection Side and Opposite Connection Side |
8. A new Export / SYSTEM environment for providing LUT
In the current version, and in near future, one big target is to develop and export more and more machine models, like lookup table (LUT), from FluxMotor to Activate and PSIM.
A new area is now dedicated to export LUT using both FMU or MAT format files to be used in Activate, PSIM or other system software.
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| A new area is now dedicated to export LUT |
In the EXPORT / ADVANCED TOOLS environment, “FORMAT/ FMU” has been removed and replaced by the new one: “SYSTEM / LUT”.
Like in the previous version, the users can export FMU format files dedicated for Activate® by selecting the input “FMU – Activate” or compatible with other system simulation tools with the input “FMU – Generic”.
But now these can also export MAT format files dedicated to Activate as well as PSIM by selecting the input “MAT – PSIM – Activate”
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| Export formats which are available for exporting LUT |
The data which can be exported are mainly based on what is computed in the test Characterization / Model / Maps.
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| D-Axis and Q-Axis cross dynamic inductances are computed and displayed in the test Characterization / Model / Maps |
9. Further new functions
- Special script function for filling the slots
From the drop-down menu available from the left top part of Motor Factory, it is possible to open a “Debug” dialog box, in which script commands can be written and executed.
A new command dedicated to the slot filling has been implemented. It allows to define and apply a geometric slot filling (height filling factor).
Here is the definition of the geometric fill factor = Height filling factor
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| Definition of the geometric fill factor = Height filling factor |
The script command is:
setDiameterBasedOnGeometricalFillFactor(geoFF=0.65,noTurnsPerCoil=12,noWiresInHand=4)
In this example, the goal is to find the wire diameter, which allows to define a geometric fill factor equal to 0.65 by considering a coil built with 12 turns and 4 wires in hand (in parallel).
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| Debug dialog box to execute script commands |
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Result one gets while applying the command below: setDiameterBasedOnGeometricalFillFactor(geoFF=0.65,noTurnsPerCoil=12,noWiresInHand=4 |
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| Definition of the geometric fill factor for the tooth winding = Height filling factor |
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| Result one gets while applying the command below: setDiameterBasedOnGeometricalFillFactor(geoFF=0.55,noTurnsPerCoil=12,noWiresInHand=4) |