PExprt

7.1

Design Software for Magnetic Components

Users Guide

Page 01-1

PExprt v7.1 Users Guide

Agenda
9:00am Introduction to PExprt (01,02,03,03a) Example Problem #1 Inductor design with fixed gap Example Problem #2 Winding Loss Recalculation (Eq,1D,2D) BREAK Example Problem #3 Core Loss Modeling Example Problem #4 PExprt to Maxwell 2D Coupling (flux,J,E,C) Example Problem #5 Influence of core gap on the winding losses Lunch 12 noon 1pm 1:00 pm PExprt Additional Features (04,05) Example Problem #6 Influence of the interleaving on the winding losses Example Problem #7 Integrated Magnetics BREAK Example Problem #8 Buck Converter with Simplorer Example Problem #9 Forward Converter with Simplorer Example Problem #10 3ph to 6ph transformer with Simplorer 4:00 pm adjourn

Page 01-2

PExprt v7.1 Users Guide

PExprt
Design Software for Magnetic Components

7.1

Users Guide

PExprt Introduction

Page 01-3

PExprt v7.1 Users Guide

Quick Overview of PExprt

Design Software for transformers and inductors Includes standard libraries for cores, wires, bobbins, insulators, and material Creates potential designs automatically that can be analyzed and Modeled

Types Inductors Multi-winding transformers Coupled inductors Flyback components

Page 01-4

PExprt v7.1 Users Guide

Magnetic Design, Modeling & Analysis

C1 R2 C2 C3 R3 R1 vs
vref vref

vctrl

ctr

FEA

PID_Cont1

ET1

Inductor_2

SMPS Library
ctr a c

BUCK_Converter
p

MEAN VALUE

42

Inductor_LossesC2 50u Diode_Characteristic

Load
240m

Page 01-5

PExprt v7.1 Users Guide

Power System Design Suite

ANSYS offers the most complete solution for power systems design in the industry through its Power System Design Suite of tools What is the Power System Design Suite of tools? Four combinable tools which assist engineers in designing and analyzing power systems, power supplies, and drives Integrates electromagnetic, circuit, and system engineering using a common desktop environment The Power System Design Suite includes: PExprt for transformer and inductor design Simplorer for complete system/circuit analysis Maxwell 2D/3D for finite element analysis Q3D Extractor for parasitic extraction of interconnects, busbars, and cables

Page 01-6

PExprt v7.1 Users Guide

Power System Design Suite

System

Circuit / Subsystem Simplorer XPrt Tools Component FEA Field Solvers ANSYS: Multiphysics Solvers
Thermal Fluidic Mechanical

Electromagnetic

Page 01-7

PExprt v7.1 Users Guide

HF/SI
HFSS, Q3D, SIWave

ANSYS Simplorer
System Design
IA
A

SCADE Suite
Control Systems

RLCG Parasitics

PMSYNC IB
A ICA:

Torque
A
D2D

IC
A

PP := 6

GAIN

ANSYS CFD
Thermal

PExprt Optimetrics
LS-DSO

RMxprt
Machine Design

Magnetics

ANSYS Mechanical
Thermal/Stress

ANSYS Maxwell
2D/3D FEA Analysis

Embedded Design Model order Reduction Co-simulation Field Solution FE Model Generation Push Back Excitations

Page 01-8

PExprt v7.1 Users Guide

FEA Model Extraction

Machines RMxprt - Broad library of machine topologies (Generators, Motors) Fully Parameterizable
Mechanical Source Generator

RMxprt

Evaluate Machine Performance Export to Maxwell 3D Export Circuit Model Simplorer

engine_ss
Engine
ROT1

FML_INIT1
ICA:

PWR_Probe1
PWR Probe

DigViewSel1 Name PWR_Probe1.VE [V] Total_Power Value 114.18 5.43k

RLoad:=7.2
FML1
EQU

RMxprtLink11

Total_Power := PWR_Probe1.S[0] *3

Ra R := RLoad Ohm
A

n := 3000*1.0 rpm Rb R := RLoad Ohm

ROT2 B

R1
F1

Rc R := RLoad Ohm
C

66.5

E1

2.0

RMX
F2

+ VMphaseA
V

+ VMphaseB
V

+ VMphaseC
2DGraphSel1 179.07 V

100.00 2DGraphSel2 VMp... VMp... VMp... 4.10

-100.00

Maxwell
145.00m 146.00m 148.00m 150.00m

2.00

E1.I [A]

-180.23

0 0 100.00m 250.00m

Simplorer
Page 01-9 PExprt v7.1 Users Guide

FEA Model Extraction

Magnetics PExprt - (Inductors/Transformers) Design Cores, Materials, Wires Modeling Toroid, Planar, Integrated,winding Nonlinear core, Skin and proximity effects, interwinding capacitance, leakage L Analysis Gap energy, leakage Inductance, flux paths, current density, temperature Circuit Extraction Simplorer
Page 01-10 PExprt v7.1 Users Guide

FEA Model Extraction

Parasitics Q3D - 2D / 3D Geometry Circuit Boards, Busbar, Cables, connectors Package Parasitics Creates Z matrix with coupling Circuit Extraction Simplorer EMI/EMC analysis CM, DM noise

Page 01-11

PExprt v7.1 Users Guide

Modeling with Maxwell 2D, 3D

2D and 3D Finite Element Analysis of Electrical Machines Sensors Actuators Transformers RFID Systems Wireless Power Transfer
and other electromagnetic and electromechanical components

Page 01-12

PExprt v7.1 Users Guide

FEA Model Extraction Into Simplorer

Electo-Mechanical Motors, Generators Actuators Power Magnetics Inductors, Transformers Electrical Parasitics PCB, Cables, bus bars Thermal IGBT package, CFD Mechanical Example Motor shafts
Page 01-13 PExprt v7.1 Users Guide

High Power Inverter System

MappingSimplorer Power Loss

Mapping Electromagnetic Force ANSYS Icepak Model Simplorer

Current profile
Thermal-Structural

Battery5 Battery4 Battery3

Battery2 Battery1

Simplorer

Battery0

Maxwell coupled with ANSYS Mechanical

ANSYS Thermal Model - CFD Maxwell /RMxprt Model
Page 01-14 PExprt v7.1 Users Guide

Fluid Flow Region

Temperature profile

ANSYS Mechanical Model

Co-Simulation Maxwell
Ansoft Corporation
500.00
TR

Torque

Basic_Inverter1
Curve Info FEA1.TORQUE

400.00

300.00 FEA1.TORQUE

200.00

100.00

0.00

-100.00

-200.00 0.00 2.50 5.00 7.50 10.00 Time [ms] 12.50 15.00 17.50 20.00

Ansoft Corporation
100.00 75.00 50.00

BackEMF

Basic_Inverter1
Curve Info FEA1.EIT1 TR FEA1.EIT2 TR FEA1.EIT3 TR

25.00 0.00 -25.00 -50.00 -75.00 -100.00 -125.00 0.00 2.50 5.00 7.50 10.00 Time [ms ] 12.50 15.00 17.50 20.00

Page 01-15

Y1 [V]

PExprt v7.1 Users Guide

Co-Simulation (3rd parties)

M otor C urrent
22.60 20.00

AM.I ... 10.00

0 0 50.00m 100.00m

Matlab/Simulink Mathcad ModelSim and QuestaSim - This also allows Simplorer and its VHDL-AMS capability to now include Verilog digital modeling.
Page 01-16 PExprt v7.1 Users Guide

Simplorers Integrated Environment

INREG

Equation Modeling Block

EQU

+
EQUBL

VBUS>=VSET VBUS<VSET OUTREG vset GAIN2

GAIN

vbus VM1

I_main

D1

EQU

vbus := VM1.V NL1

NL

a:= (t^(1.0/x)*rating)/(726.3^(1.0/x)) x:= -4.7306 rating:= 10

tY

sp

XY1 engine2generator VSET

CONST XY

I1 GAIN1
GAIN

GAIN3
GAIN

VBUS
CONST

GAIN4
GAIN

ERR

INTG1
I

SUM1

LIMIT1
LIM IT

DATAPAIRS1 RTH1 RTH2

Magnetics
therm

Circuit, Block, State

T1

R2 CTH1

G(s)

GS1

VHDLAMS FEA C code

1k 10*node.V*t*f*L.I

(S1.AC_Sim)? 1k: (S1.DC_Sim)? 1k: rload2_ctrl

rload21

TR Probe

TR_Probe1
#

pin

i=f(v)

Co-Sim (ie Simulink) Spice Import

Page 01-17

PExprt v7.1 Users Guide

Power of VHDL-AMS (Compatibility, Capability)

Standard Format Allows Model Portability (IEEE standard) Different engineering groups within same company With Sub-Contractors Between different simulators Multi-level Modeling Different levels of abstraction of model behavior Multi-domain Modeling Electrical, Thermal, Magnetic, Mechanical, etc Mixed-signal Modeling Supports analog and digital modeling
Page 01-18 PExprt v7.1 Users Guide

Motor Drive Example

DSP Program Model
vf_full

FPGA Program Model

VHDL-AMS
mu mv st1 st2 st3 st4

TMS320C6701

u_phase.i

w_phase.i

C code

mw

DC_link.v

PWM signal

st5 st6

dead time
ctrl_1 ctrl_2 ctrl_3 ctrl_4 ctrl_5 ctrl_6 u_phase
p u

ICA:

c_freq:=650 c_rpm:=60*c_freq

DC_link
p a a

+
b b

Conv.
n m V

PWM Inv.

Q 3 D
+
V

fan

rot1 rot1

w_phase
A
c

Motor
heatout thermalin

) ) V . v u V ( S B A ( G E T N I * m 0 . 0 2 / 0 . 1 * ) ) 0 . 2 ( t r q s * 0 . 2 ( / I P = : n m _ v u V ) ) V . w v V ( S B A ( G E T N I * m 0 . 0 2 / 0 . 1 * ) ) 0 . 2 ( t r q s * 0 . 2 ( / I P = : n m _ w v V

PWM inverter Model Simplorer

Page 01-19

EQU

PM Motor Model RMxprt/Maxwell

) ) V . u w V ( S B A ( G E T N I * m 0 . 0 2 / 0 . 1 * ) ) 0 . 2 ( t r q s * 0 . 2 ( / I P = : n m _ u w V 0 . 3 / ) n m _ u w V + n m _ w v V + n m _ v u V ( = : n m V

PExprt v7.1 Users Guide

Power of ANSYS
2DGraphSel7 200.00

VHDL-AMS
PExprtLink1
PEX

Probe2 13.00 10.00

DC/DC Converter
Probe1 28.00 20.00

dutym in 0.01 dutym ax 1.0

buck_vhdlams_dxn_ng

vout.V 5.00

v loadp v gp v gm v loadm

l 0.53m fs 200k
d1m

eoutp eoutm v m ode

-68.00u 0 200.00m

d1p

WM2
N025...

Maxwell
V Mph... V Mph... V Mph...

+
V

Simplorer
5m H

10.00

2.5u R1

C4

VM3 rload

0 0 200.00m

7.5 (1/2.5)*vopam p.V AC_MAG 0.0

Louttop

AC/DC Conversion
D1 D2 D3
+

1479p

50k 166k r2 r1
-

c2 E2 AC_MAG 0 EMF 2.0 V vopam p

7.45k r3

-200.00 158.41m 160.00m 162.00m 163.83m

OPV54

440p 87k r4 VOMAX 10 VOMIN -10 c1

A
engine_ss
Engine
ROT 1 A

VM1
M1

AC_MAG 1 E6

E5

RMxprtLink1

F_TR := 5m eg Hz R7 100m eg AD := 50k V/V 4 RO := 0 Ohm vref

Lina 50u H Rina10m Ohm Linb 50u H Rinb10m Ohm

B

B A C B
+ VMphaseA
V

D4

D5

D6

K := 0

n := 3000*1.0 rpm
ROT 2

PExprt
PWR_Probe1
PW R Probe

F1

Linc 50u H Rinc10m Ohm

C

E1

TFR3P21

28v Bus
Loutbot
5m H
2DGraphSel6 28.00 5.50k 4.00k

RMX
F2

C
+ VMphaseB
V

A
TFR3P11

2DGraphSel4

D7 B

D8

D9
+
V

+ VMphaseC

20.00

Generator

Cout VM2
3000u F
10.00 V Mou...

R_Load
1.4*100m

VMout
2.00k

PWR_...

RMxprt

Q3D
Probe5 16.00m 10.00m 0 0 100.00m 200.00m icoil1...

D10
TFR3P22

D11

D12

0 0 100.00m 200.00m

0 0 100.00m 200.00m

12v Bus
Probe6 0 -5.00 -14.00 0 100.00m 200.00m

Electrical Loads
f orce...

SSPC
R5
R := 365 Ohm

Vcc
EMF := 12 V

R4
R := 13.7E+006 Ohm

VHDL-AMS
TR Probe

RC
R := 1k Ohm

Winding current
CTRL := t>=0.15
A

Amature force
E3
force1
A

BJT1

C3

C1
C := 10n F C := 1u F FREQ := 1k Hz

VM4

R := 1500/1.8 Ohm

D2D2
D2D

MASS_TRB2

LIMIT_TRB2
Amplifier Input Voltage

R2
Amplifier Input, Output
R := 140 Ohm

TR_Probe1

TPERIO := Tend+1 s AMPL := 10m V

R3
R := 4k Ohm

S2
icoil1 R6 igrav1

RE

R := 375 Ohm

C2
C := 500u F

Mechanical Actuator
ECELink2
Probe4 1.00m 500.00u -5.00u 142.23m

N_1

N_3

IS := 0.00545*9.807 A
N_4

Amplif ier Input Voltage vs. Time 50.00m 25.00m 0 E3.V [V] -25.00m -50.00m 195.00m Time t 200.00m

Amplif ier Input, Output vs. Time 6.00 VM4.V [V]

N_2

ECE

E3.V [V]

5.00 VM4.... 4.00 195.00m 198.00m 200.00m Time t

E4
N034...

196.50m

Gap vs. time

Simplorer PExprt v7.1 Users Guide

Maxwell Page 01-20

Flyback Example
Simplorer Q3D

PExprt

Simplorer Simplorer

Page 01-21

PExprt v7.1 Users Guide

PExprt - Introduction

PExprt is an interactive, performance based design tool that produces initial designs of magnetic components, such as transformers and inductors.
Designs can then be Modeled and Analyzed with the highest level of fidelity using FEA tools. Design Models can then be evaluated in the circuit using Simplorer

Standard libraries of magnetic cores, bobbins, insulators, and conductors allow you to define the model to your exact specifications. Using PExprt, you can design: inductors, multi-winding transformers, coupled inductors, and flyback components. Optimize constructive parameters, such as core size, core material, number of turns, air gap length, wire gauge, and winding stratagy.
Page 01-22 PExprt v7.1 Users Guide

PExprt - Introduction
Calculate performance parameters, such as winding losses, core losses, flux density, DC and AC resistance, Irms currents, magnetizing inductance, leakage inductance, and temperature rise. Consider complex effects, such as skin and proximity effects, fringing flux near the air-gap for energy calculations Calculate winding losses based on FEA field solution and core losses. PExprt also includes the PEmag modeling module, a powerful magnetic analysis module based on finite element analysis. This module conducts a detailed analysis of geometry, frequency, and material Generate model netlists for SIMPLORER, electrical simulator to perform a complete system simulation of the entire device.
Page 01-23 PExprt v7.1 Users Guide

Maxwell - Introduction
Solves 2D and 3D electromagnetic field problems using FEA Five Solution Types: Electrostatic, Magnetostatic, Eddy Current, Transient Electric, Transient Magnetic Determines R,L,C, forces, torques, losses, saturation, time-induced effects Parameter extraction for: Power Magnetics: Inductors, Transformers Machines: Motors, Generators, Actuators Electrical Parasitic: Cables, vias, bus bars
Page 01-24 PExprt v7.1 Users Guide

Q3D Extractor - Introduction

Electrical Parasitic Extraction
2D / 3D Geometry Circuit Boards, Busbars Cables, Connectors Interfaces with popular layout tools Cadence Mentor Circuit Extraction Numerical Analysis (MoM)

Page 01-25

PExprt v7.1 Users Guide

Simplorer - Introduction
Multi-domain, system simulator for designing high performance systems Three Basic Simulation Engines: Circuits, Block Diagrams, State Machines Mixed Signal Mixed Mode Modeling Digital / Analog Magnetic, Mechanical, Thermal Integrated analysis with electromagnetic simulation tools (Maxwell, PExprt, RMxprt, Q3D) Analysis Types: AC, DC, Transient Co-simulation with Maxwell and Simulink Statistical Analysis and Optimization VHDL-AMS Capability
Page 01-26 PExprt v7.1 Users Guide Circuits
R1
N0002

50 C1

R2

1k

R3

1k C2 3.3u

R4

50

12

3.3u V0 := 5

N0004 N0003

V0 := 0
N0005

Block Diagrams
I_PART_id
I CONST

UL := 9 LL := -9
LIMIT

P_PART_id
GAIN

id_ref id
G(s) GAIN

yd

KP := 0.76 SUM2_6

GS2

State Machines
SET: CS1:=-1 SET: CS2:=-1 SET: CS3:=-1 SET: CS4:=-1

IMP = 0 and RLine.I <= ILOW SET: CS1:=-1 SET: CS2:=1 SET: CS3:=-1 SET: CS4:=-1

IMP = 0 and RLine.I >= IUP

IMP = 1 IMP = 0 IMP = 1

IMP = 0

SET: CS1:=1 SET: CS2:=-1 SET: CS3:=-1 SET: CS4:=-1

IMP = 1 and RLine.I <= ILOW

SET: CS1:=-1 SET: CS2:=-1 SET: CS3:=-1 SET: CS4:=-1

IMP = 1 and RLine.I >= IUP