high-power electronics design - ansys uk/staticassets/02... · high-power electronics design ......

© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

High-Power

Electronics Design

Leon Voss

ANSYS, Inc.

© 2010 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

Contents

• Simplorer System Simulator

• Electrothermal Inverter Simulation

• Ansys Workbench Coupling

– Thermal Stress Simulation

– Mechanical Stress simulation


• Complex System Modelling through hybrid

simulator approach

– Multi-domain analog circuit simulator

– Digital event-based simulator

– State-graph simulator

– Block Diagram Simulator

• Interactive and Intuitive

User Interface Simplorer

Kernel

ANSYS Simplorer

Simulator Kernel


+

-

B 11A 11 C11

A 12 A 2

B 12 B 2

C12 C2

ROT2ROT1

ASMS

3~M

J

STF

M(t)

GN

D

m

STF

F(t)

GN

D

Magnetics

JA

MMF

Mechanics

L

HQ

Hydraulics, Thermal,

...

Simplorer Simulation Data Bus / Simulator Coupling Technology

Block DiagramsState-space

Models

Digital/

VHDL

JK-Flip flop with Active-low Preset and Clear

CLK

INV

CLK

CLK

J Q

QB

CLR

PST

Flip flop

K

CLK

CLK

INV

0 0 0 0 1 1 1 1 1 1X-Axis

Curve Data

ffjkcpal1.clk:TR

ffjkcpal1.j:TR

ffjkcpal1.k:TR

ffjkcpal1.clr:TR

ffjkcpal1.pst:TR

ffjkcpal1.q:TR

ffjkcpal1.qb:TR

MX1: 0.1000

PROCESS (CLK,PST,CLR)

BEGIN

IF (PST = '0') THEN

state <= '1';

ELSIF (CLR = '0') THEN

state <= '0';

ENDIF;

statetransition

AUS

SET: TSV1:=0SET: TSV2:=1SET: TSV3:=1SET: TSV4:=0

(R_LAST.I <= I_UGR)

(R_LAST.I >= I_OGR)

EIN

SET: TSV1:=1SET: TSV2:=0SET: TSV3:=0SET: TSV4:=1

State Graphs

Cxy

BuAxx

Electrical circuits

ANSYS Simplorer

Solver technologies


Kernel

Spice/PSPICE

VHDL-AMS

C/C++

Characterization

Simulink®

Maxwell transient

Multi-Body Dynamics

ANSYS Mechanical

ANSYS CFD

Maxwell Static

Q3D, HFSS

RMxprt, Pexprt

Extraction

Cosimulation

Modelling

• Simplorer System Simulator

– Advanced modelling techniques

– Model extraction from CFD, FEM, Analytic

techniques

– Co-simulation techniques to ANSYS products

and 3rd party vendors

ANSYS Simplorer

Multi-domain system simulator


• Multi-domain simulation

– Electrical supply

– Digital Control

– Mechanical / fluid

behavioural models

• Coupling to EM FEM

– Equivalent Circuit Extraction)

– Transient co-simulation

• Current work:

Extension to Multidomain model

extraction and co-simulation

plunger

limit

spring

F

F

em_force

Battery

- +

bjt1 bjt2

accumulator

Digital Control

TRIG

CTRL2

CTRL1 BS=>Q

BS=>Q

DETECT

PLUNGERI

TRIG

Solenoidmp2

pp1

75

m := 0.0066 s0 := 0.0002

gravity

v alue := 0.0066*9.8

spacer

sul := 0.0002sll_ := 0.0

Digital Electrical

Mechanical Hydraulic

Solenoid

A

orifice

75

ctrl1

ctrl2

plunger_control

ANSYS Simplorer

Example System Model


Simplorer Modelling

SPICE/PSPICE Capabilities

• Full coverage of mainstream SPICE language

– Support SPICE 3f5 & PSPICE

• Direct usage of the original SPICE text

– SPICE model can be maintained /

modified within Simplorer


ANSYS Simplorer

Simulink®

Co-simulation

Co-simulation using

Simulink S-Function

and Simplorer kernel

Co-simulation using

RTW and C-Interface

1

2


ANSYS Simplorer

VHDL-Based Digital Simulator

• Integrated digital simulator with hybrid synchronisation

algorithm for mixed signal models

0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]

Curve Data

adc1.clk:TR

adc1.input:TR

adc1.val[0]:TR

adc1.val[1]:TR

adc1.val[2]:TR

adc1.val[3]:TR

dac1.val:TR

cntb41.q:TR

1

-2.2304

0

1

1

0

-2.5000

0000

Simplorer1Digital Plot5 ANSOFT

MX1: 3.4988

0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]

-4.00

-2.00

0.00

-1.60

-0.60

1.00

5.00

9.00

0.00 0.01 0.10 1.0010.00100.00

Curve Info

AM1.ITR

AM2.ITR

SIMPARAM1.IterationsTR

SIMPARAM1.StepsizeTR

Simplorer1XY Plot 4 ANSOFT


ANSYS Simplorer

FEM Co-simulation for HEV

270.00 275.00 280.00 285.00 290.00 295.00 300.00Time [ms]

-375.00

-175.00

25.00

225.00

375.00

Y1 [rp

m]

-40.00

-20.00

0.00

20.00

40.00

I_m

eas.I_B

Ansoft LLC 05_UMR_RMxprt_SMLMotor Currents

270.00 275.00 280.00 285.00 290.00 295.00 300.00Time [ms]

1400.00

1450.00

1500.00

1550.00

Y1 [rp

m]

-10.00

2.50

15.00

27.50

40.00

50.00

FM

_R

OT

1.T

OR

QU

E [N

ew

tonM

ete

r]

Ansoft LLC 05_UMR_RMxprt_SMLMotor Torque and Rotor Velocities

Study of Interaction of Power electronics and Electromechnical system


Electrothermal System Simulation

Available Technologies

• Necessary techologies available for efficient electrothermal

inverter simulation at the system level

• CFD for heat flow simulation

• Model Order Reduction

• Efficient state-space model in the system simulation

• Electrothermal model of power electronics

• Effective representation of remaining system components

Thermal Domain

Electrical Domain MechanicalDomain

0

R1 R2 R3

MASS_ROT1

DR1

SINE2

SINE1

A

A

A

IN_A

IN_B

IN_C

OUT_A

OUT_B

OUT_C

I_motSimplorer4

A

B

C

N

ROT1

ROT2

Induction_Motor_20kW

Q

Ambient

P1

P2

P3

P4

P5

P6

P7

P8 P

9

P1

0

P1

1

P1

2

P_

RE

F

z_um z_vm z_wm

z_wpz_vpz_up

+

V

VM311 R6 R5 R4

E1

RZM

DR1

RZM

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

-500.00

-250.00

0.00

250.00

500.00

Y1 [

V]

Curve Info rms

R1.VTR 230.9405

R4.VTR 313.3812

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

1475.00

1485.00

1495.00

1500.00

MA

SS

_R

OT

1.O

ME

GA

[rp

m]

0.00

50.00

100.00

150.00

180.00

MA

SS

_R

OT

1.P

HI

[deg]

Curve Info

MASS_ROT1.OMEGATR

MASS_ROT1.PHITR


Physics &

Geometry

Heat-Flow

Simulation

Reduced-order

State-spaceCFD MOR

Electrothermal Simulation with IGBTs:

From ANSYS Workbench to System Level in ANSYS Simplorer

Thermal Domain


0

R1 R2 R3

MASS_ROT1

DR1

SINE2

SINE1

A

A

A

IN_A

IN_B

IN_C

OUT_A

OUT_B

OUT_C

I_motSimplorer4

A

B

C

N

ROT1

ROT2


Q

Ambient

P1

P2

P3

P4

P5

P6

P7

P8 P

9

P1

0

P1

1

P1

2

P_

RE

F

z_um z_vm z_wm

z_wpz_vpz_up

+

V

VM311 R6 R5 R4

E1

RZM

DR1

RZM

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

-500.00

-250.00

0.00

250.00

500.00

Y1 [

V]

Curve Info rms

R1.VTR 230.9405

R4.VTR 313.3812

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

1475.00

1485.00

1495.00

1500.00

MA

SS

_R

OT

1.O

ME

GA

[rp

m]

0.00

50.00

100.00

150.00

180.00

MA

SS

_R

OT

1.P

HI

[deg]

Curve Info

MASS_ROT1.OMEGATR

MASS_ROT1.PHITR

Electrothermal Simulation

Model Order Reduction - Thermal


• A thermal model is defined with 12 power “inputs” and 12

temperature “outputs”

• The convection model in ANSYS with 900.000 DoF is used

• The reduced model has 15 DoFs per input = 15*12 = 180 DoF

• The reduced model is formulated in the general state-space

form:

Cxy

BuAxx

Temperature

Power

(heat flow)

Electrothermal Simulation

Heat-Sink Model Reduction


Sub circuit of the Basic Dynamic IGBT modelIGBT Characterisation

Electrical Topologies

Average Model

=> Suitable for Electrothermal

(Basic) Dynamic Model

=> Suitable for Electrical Dynamics in System

i.e. EMC/EMI issues due to Parasitics


IGBT Characterisation

The IGBT Switching Transient

• Example: Turn-off (switching time e.g. 40ns)

– Electrical dynamic: Rise Time, Voltage Overshoot, …

– Switching Loss due to v(t) * i(t)


• Common Thermal Circuit

• Parameters can be extracted from

• R/C values from the data sheet

• Curve fitting of the thermal impedance Zth(t)

(measured or datasheet)

IGBT Characterisation

IGBT Thermal Circuit Topologies

cth1 cth2 cth3 cth4

rth1 rth2 rth3 rth4

H

h1cth_sinkrth_sinkTjunction

Tcase


Electrical System ElectrothermalSwitch Model

Thermal System

0

E1

R1

E2

0

Simplorer: Conservative

State-Space Formulation

Fully coupled conservative electrothermal (multidomain) solution

CxT

hBAxx

tuFi ,

tTuFi

tTiuFh

,,

,,,

h

T

i

u

Electrical System Electrothermal

TransformationThermal System


Thermal Domain


0

R1 R2 R3

MASS_ROT1

DR1

SINE2

SINE1

A

A

A

IN_A

IN_B

IN_C

OUT_A

OUT_B

OUT_C

I_motSimplorer4

A

B

C

N

ROT1

ROT2


Q

Ambient

P1

P2

P3

P4

P5

P6

P7

P8 P

9

P1

0

P1

1

P1

2

P_

RE

F

z_um z_vm z_wm

z_wpz_vpz_up

+

V

VM311 R6 R5 R4

E1

RZM

DR1

RZM

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

-500.00

-250.00

0.00

250.00

500.00

Y1 [

V]

Curve Info rms

R1.VTR 230.9405

R4.VTR 313.3812

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

1475.00

1485.00

1495.00

1500.00

MA

SS

_R

OT

1.O

ME

GA

[rp

m]

0.00

50.00

100.00

150.00

180.00

MA

SS

_R

OT

1.P

HI

[deg]

Curve Info

MASS_ROT1.OMEGATR

MASS_ROT1.PHITR

IcePak/MOR

Average IGBT Application

Cxy

BuAxx

Average IGBT Model


Thermal MOR Coupling

Simplorer Results


Ansys Workbench Couplings

Workflow

Simplorer V9Solve IGBT

Circuit

Terminal Current

(Manual Input)

Maxwell V14Solve for

Magnetostatics

Switching Losses

(Manual Input) ANSYS MechanicalSolve

Steady State Thermal

Temperature

Distribution

ANSYS MechanicalSolve

Static Structural

Stress and

Deformation

ANSYS

Workbench R13

Lorentz

Forces

Ohmic

Losses


ANSYS Workbench R13 Interface

Maxwell 2D and 3D ,

Simplorer and RMxprt all

available under ANSYS

Workbench R13


Steps

• Solving Simplorer Circuit

• Maxwell Solution for Forces and Ohmic Losses

• Thermal Solution using ANSYS Mechanical

• Structural Solution using ANSYS Mechanical


Steps






Create Simplorer Solution

• Launch ANSYS

Workbench R13

• Drag and Drop a

Simplorer Analysis

System onto the project

page

• Right click on Setup and

select Edit to launch

Simplorer V9


IGBT Circuit

• Input Pulse

• IGBT Unit

• Ammeter (Gives Terminal Current through IGBT)

• Multiplier (Gives Switching Losses across IGBT)


Transient Solution

• Transient Solution was run for time of 40 ms

with settings as shown in image

• Following results were obtained

– Max Current reported by

Ammeter = 20 A

– Average Losses reported by

multiplier = 49.5057 Watts


Steps






Create Maxwell System

• Select a Maxwell

Analysis System

• Drag and drop it on

Project Schematic

page as a Standalone

system

• Right click on

“Geometry” tab and

select Edit to Launch

Maxwell


Complete IGBT Module

12 IGBT’s

12 Diodes

The Current through

one phase is shared

equally between two

IGBT’s


Material Definition

• For simulation purposes,

consider only one IGBT

• Import the IGBT model

• Set Solution type to

“Magnetostatic”

• Set material properties of all

the objects

• Diodes and IGBT units

which are OFF mode are

applied with Vacuum

material


Set Current Excitations

• Maximum current

through IGBT was

calculated by Simplorer

which will be set as

terminal current

• Set Current excitations of

20A to positive terminals

• Set Current excitation of

40A as Phase current

– The value is set as

twice the terminal

current


Solve

• Add solution Setup and solve the case with

proper settings

• Plot J field to check the results

• Close Maxwell and return to Project Page


Steps






Create Steady State Thermal

System

• Select Steady State

Thermal Analysis

system

• Drag and drop it on

Solution tab of

Maxwell 3D

• This will enable

transfer of Ohmic

losses calculated in

Maxwell to ANSYS

Mechanical


Creating Material Data

• Right click on

Engineering Data and

select Edit to access

Material database

• Add needed required

material from database

to the project and return

to project page

• Right click on

“Geometry” tab and

select “Import

Geometry”


Steady State Thermal Setup

• Double click on “Model”

tab to launch ANSYS

Mechanical

• Specify appropriate

materials to all objects

– Diodes and IGBT units

which are under OFF

mode are also applied

with Silicon material

• Apply mesh sizes on

required objects and

Generate Mesh


Setup (Contd…)

• Ohmic Losses from Maxwell

are already link to Steady

State Thermal solver as Load

• Right Click on “Imported Load

(Maxwell3DSolution) tab and

select “Insert Heat

Generation”

• Under “Geometry”, select all

the volumes from the

geometry and select “Import

Load”

• Conduction losses will be

mapped from Maxwell to

ANSYS Mechanical


Setup (Contd…)

• In addition to conduction losses,

we also need to apply switching

• The switching losses which we

calculated using Simplorer was

49.5 Watts

• We need to divide the switching

losses by the volume of all

bodies which carry current as the

losses will be shared among

them

• The resulting value is around

0.01683 W/mm3

• We will apply this value through

command line as this value

should add with the conduction

losses to give actual thermal

load.


Solve

• Apply Convective boundary to all external faces of

geometry with Film Co-efficient of 1e-4 W/mm2 ̊C

• Run the solution

• Plot Temperature distribution on Objects

• Close ANSYS Mechanical and return to Project Page


Temperature Distribution


Steps






Create Static Structural System

• Select Static Structural

system from Analysis System

• Drag and drop it on the

“Solution” tab of Steady State

Thermal System

• This will enable data transfer

between two system

• Select “Solution” tab of

Maxwell 3D system, drag and

drop it on “Setup” tab of

Static Structural

• This will create a link between

Maxwell 3D and Static

structural enabling Force data

transfer from Maxwell


Setup

• Right click on “Setup” and

select “Edit” to launch ANSYS

Mechanical

• Right Click on “Imported Load

(Maxwell3DSolution) tab and

select “Insert Body Force

Density”

• Under “Geometry”, select

Bondwires to which we want

to apply Lorentz Forces

• The forces calculated by

Maxwell will be applied to the

Bondwires


Solve

• Specify Frictionless Support to the Bottom

faces of the plates

• Run the solution

• Plot Equivalent Stress and Deformation

images

• Compare Max. Stress values with material

properties to predict failure


Results

Equivalent Stress

Max Value: 211 MPa

Deformation

Max Value: 0.088 mm


Summary

• ANSYS Workbench is used to simulate

multiphysics problem of IGBT accurately

taking into account:

– Electric Circuits

– Electromagnetics

– Thermal

– Stress

• On the workbench platform, Simplorer,

Maxwell3D and ANSYS Mechanical were used

for various simulations and data transfer

high-power electronics design - ansys uk/staticassets/02... · high-power electronics design ......

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