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ANSYS 2011 中国用户大会优秀论文

混合励磁爪极皮 BSG 电机多领域仿真分析 [李维亚黄苏融张琪]

[上海大学，200072]

[ 摘要 ] 摘要字数 300~500 字左右传统的爪极电机通过调节励磁电流控制气隙磁通用以满足变负载运

行时恒压向蓄电池供电，但由于漏磁大导致输出能力小、效率低等缺点满足不了目前混合动力

汽车供电要求，本文设计了一种 42V 供电系统混合动车用混合励磁爪极皮带式起动发电机

（BSG），通过在爪极间镶嵌磁钢的方法减小爪极间漏磁，提高电机功率密度和低速输出能

力。采用磁路法和三维有限元法分析 BSG 电机结构及其原理，基于机械、模态和热工多领域

综合仿真分析方法解决高密度电机极限能力分析与优化设计。仿真分析得出样机在电动模式下

可以获得起动转矩起动引擎，在发电模式下可以在宽速度变化范围内输出恒定的电压向蓄电池

供电。实验数据和三维有限元计算结果与理论分析一致，样机具有漏磁低，输出能力大，输出

特性硬等优点，该电机的设计在混合动力汽车中具有广泛的应用前景。

[ 关键词 ] 混合励磁; BSG; 混合动力汽车; 三维有限元; 多领域仿

Multi-domain Simulation Analysis of a Hybrid Excitation Claw-pole Belt-Starter-Generator

[Weiya Li, Surong Huang, Qi Zhang]

[Shanghai University,200072]

[ Abstract ] The traditional claw-pole machine control air-gap flux to transmit stable output voltage to

batteries by regulation excitation current, which has disadvantages such as lower output

capacity and inefficiency caused by leakage flux. It doesn’t meet the current requirements of

hybrid vehicle power supply. A hybrid excitation claw-pole Belt-Starter-Generator (BSG)

machine for 42V power supply system Hybrid Electric Vehicles (HEVs) has been created.

Through permanent magnets inserted among claws, this kind of generator can reduce the

leakage between the claw-poles, increase machine power density and output capacity under

low speed. This paper will use magnetic circuit and three-dimension finite element methods

to analyze the structure and principles of BSG. The multi-domain simulation methods include

mechanism, vibration modal and thermotics to solve the analysis of high-density machine

ultimate capacity and optimization. The simulation results have showed that with high

starting torque in starter mode, the machine can constantly provide output voltage at wide


speed range for batteries charging in generator mode. Experimental results of prototype

confirm the theoretical analysis and simulation conclusion. The prototype has advantages

such as low leakage, large output capacity and hard output characteristics, which has broad

application prospect for Hybrid Electrical Vehicles.

[ Keyword ] hybrid excitation; BSG; HEVs; three-dimension finite element; multi-domain simulation

基金项目：863 节能与新能源汽车重大项目（2008AA11A108, 2008AA11A109）资助；上海市高校机电驱动和功能部件

创新团队；上海大学博士创新基金项目（SHUCX101011）资助。

The energy and new energy vehicles of 863 program (2008AA11A108, 2008AA11A109)；University of Shanghai Mechanical & Electrical drive and feature innovation team ； Doctoral Innovation Fund of Shanghai University (SHUCX101011)

1 INTRODUCTION

Under the growing concern on environmental protection and energy conservation, the development of hybrid electric vehicles (HEVs) has taken on an accelerated pace [1]. As one of the core parts of HEVs, the generator is required to pursue perfect performance and high efficiency. Rather than the separated starter generator in the conventional automotive electrical system, the concept of the Belt-alternator Starter Generator (BSG), namely, the functions of both the starting engine and generating electric power are fulfilled by one electrical machine in an onboard vehicle system, which has been becoming more and more popular in modern auto industry [2-4]. Valeo has developed the first generation of “Stop-Start” system with 14V power supply system, which has 2.5kW output power [5].

With the wide application of ventilation, air-conditioning, anti-lock braking system, electronic ignition device, automobile safety fault diagnosis system, information systems, and entertainment products, etc., auto power consumption has rapidly increased to 1.5 ~ 3 kW. Due to high space usage, compact structure, low cost and excellent regulated performance, the traditional claw-pole generator has become the mainstream product within automotive generators. Nevertheless, its further development will confront with the following limitations: leakage flux, noise, inefficiency and poor output performance. How to move forward hybrid excitation claw-pole generator to high-density, high-speed and high-efficiency remains an important topic for researchers.

GM companies have proposed hybrid excitation claw-pole generator structure for vehicle [6], and some people comparative study on claw-pole electrical machine with different structure, which are CCPM, PMCPM[7] and outer rotor structure[8]. The permanent magnet claw-pole synchronous machine is used for direct-driven wind power applications [9]. 3D FEA method is used in [10] to analyze superconducting claw motor, and circuit coupled simulation method be used in [11] to research a temporary linearization claw-pole model. In order to reduce computing time, the improved equivalent magnetic circuit be used in analyzing claw-pole machine [12]. With the development of SMC (soft magnetic composite) material, claw-pole external rotor PMSM has been designed to reduce eddy current loss [13]. A magnetic circuit structure of series hybrid excitation claw-pole generator mentioned in [14] reduces the leakage flux to minimum when p=2, while the reducing number of pole-pairs increases the claws’ weight. On one hand, the


reducing number of pole-pairs makes claws enlarged, resulting in rotor-stator friction in high speed. [15] gives the inductance calculation methods of the hybrid excitation claw-pole motor.

The modern design concept of high-density motor is integrating electricity, magnetism, mechanics, thermal, structure, power electronics and control strategy [16]. This paper will lay emphasis on bypass magnetic path structure and discuss the principles of bypass magnetic path, computing three-dimension finite element and testing prototype which helps to verify the correctness of relevant theory. Other multi-domain simulation includes the accurate computation and design improvement in mechanical, vibration modal and thermodynamic characteristics to keep machine safety. This concept is newly extended to the BSG and a new type of vehicle bypass hybrid excitation claw-pole BSG from the engineering perspective is designed accordingly. It not only overcomes the drawbacks of machines mentioned above, but meets many rigorous requirements of the BSG system.

2 MECHANICAL STRUCTURE

(a) Flat Structure (b) Simulation of three-dimensional structure

Fig1. The structure of bypass hybrid excitation claw-pole BSG

It’s shown in Fig.1 that the structure of bypass hybrid excitation claw-pole generator includes stator, rotor, shaft, bearing, permanent magnets, carbon brushes and rectifier circuit. The stator consists of the armature coils (5) and stator core (6); the rotor is composed of rotor iron core (1), excitation coils (4), permanent magnet (3) and the magnets mounted between the claws; and chassis and cover are both made by non-magnetic materials. The design adopts water-cooled structure (12). In order to reduce product cost， the materials used like rotor in 08F low-carbon steel, stator in 50 silicon steel and shaft in 45# steel. The leakage flux hinders the improvement of claw-pole generator. Therefore, reduction in the leakage flux in a claw-pole magnetic generator is beneficial to output performance and efficiency improvement. As the claw-pole motor always operates under high temperature environment, N35SH permanent magnet is selected due to high temperature resistant. This permanent magnet owns many advantages: excellent magnetic properties, uniform magnetization, sufficient utilization ratio and anti-demagnetization. The bypass hybrid excitation claw-pole motor has similar manufacturing process as conventional claw-pole motor, but more practical.

3 BYPASS STRUCTURE CONCEPT AND ANALYSIS


(a) permanent magnet path (b) electrical excitation magnetic path

Fig2. The claw-pole magnetic paths analysis magnetic-paths consist of permanent magnetic-paths and excitation magnetic-paths forming

hybrid excitations bypass structure.

Hybrid excitation claw-pole motor voltage equation can be described as follows (Appendix 1):

u 0 0u 0 0u 0 0

a a a a

b b b b

c c c c

r idr idt

r i

ψψψ

⎡ ⎤ ⎡ ⎤ ⎡ ⎤ ⎡ ⎤⎢ ⎥ ⎢ ⎥ ⎢ ⎥ ⎢ ⎥= ⋅ +⎢ ⎥ ⎢ ⎥ ⎢ ⎥ ⎢ ⎥⎢ ⎥ ⎢ ⎥ ⎢ ⎥ ⎢ ⎥⎣ ⎦ ⎣ ⎦ ⎣ ⎦ ⎣ ⎦

（1）

Hybrid excitation flux linkage can be expressed as:

⎥⎥⎥

⎦

⎤

⎢⎢⎢

⎣

⎡+

⎥⎥⎥

⎦

⎤

⎢⎢⎢

⎣

⎡⋅⎥⎥⎥

⎦

⎤

⎢⎢⎢

⎣

⎡=

⎥⎥⎥

⎦

⎤

⎢⎢⎢

⎣

⎡

mc

mb

ma

c

b

a

cccbca

bcbbba

acabaa

c

b

a

iii

LLLLLLLLL

ψψψ

ψψψ （2）

No-load hybrid excitation flux linkage is:

⎥⎥⎥

⎦

⎤

⎢⎢⎢

⎣

⎡

⋅+⋅+⋅+

=⎥⎥⎥

⎦

⎤

⎢⎢⎢

⎣

⎡

cffpmc

bffpmb

affpma

mc

mb

ma

LiLiLi

ψψψ

ψψψ

（3）

No-load back EMF in Phase A is:

magtA

de KN bdψ ω= = （4）

In terms of the situation of single-phase power and steady state for hybrid excitation claw-pole machine, the terminal voltage U meets 1U AK e= . Therefore, when the supply

voltage is constant, there is a limit for speed maxω in machine.


In starter mode, maxω plays inverse ratio- to gb . When the applied reverse excitation, the motor air ga-p flux density decreases and the maximum speed increased, which is broadening the range of motor speed. In generation mode, output voltage is direct ratio to air gap flux density. Output voltage regulation is controlled by the air gap flux density.

To research the flux regulation capability of the hybrid excitation claw-pole machine, the flux regulation formula is defined as below:

pmpmft kΦ=Φ+Φ=Φ （6）

tΦ is the total excitation flux linkage in the armature windings; fΦ is the excitation flux

linkage generated by field windings, and pmΦ is the excitation--- flux linkage yielded by magnets. Considering insulation, temperature and leakage flux, the regulation factor is between 0~3.5 in average. When 0k = , it means that the air gap flux generated by magnets is totally offset by the field current. When 2k = , it means that the air gap flux is strengthened.

Due to longer and complicated magnetic path, the leakage flux between claws is comparatively more than other leakages, which can be reduced by optimizing the size of claw-pole machine.

Fig3.The simplify of claw-pole magnetic path

Fig.3 (Appendix 2) shows the claw-pole machine magnetic path. Bypass structure is used to block the leakage magnet flux Here G is called as bypass flux diverging point. When Fe≥FG (the Fig.3), the machine -stays at the state of increasing magnet. The main of the flux of permanent magnet which goes through G bypass path, and flows into stator, will convert to be effective magnet flux. That reduces the leakage flux along the rotor-yoke loop and promotes machine output. When Fe< FG, Fe is too weak to block the leakage from the rotor-yoke loop. Therefore, increasing leakage magnet flux flowing into rotor through G leads to decreasing Fe. When Fe <0, Fe accelerates the leakage flux through G to rotor-yoke loop. The machine is in demagnetizing state.

1 maxU gKK Nbω= （5）


Fig.4 Equivalent circuit of hybrid excitation claw-pole machine with armature

The Fig.4 (Appendix 3) shows the equivalent circuit of hybrid excitation claw-pole machine with armature. Thus, the air gap magnetic flux can be got:

( )e m m e ad e m m eg

e m e m g m g m e g

R R F R R F F R R R R R RR R R R R R R R R R R Rμ μ μ μ

μ μ

+ ± + +Φ =

+ + + （7）

Here the direct-axis armature MMF acts directly on the PM as the below formula:

' 1(1 )g adad ad ad

g g lm

G G FF F FG G G

μ

μ σ−= = + =

+ （8）

The direct-axis armature flux acting directly on the PM is reduced by bypass structure, which lower risk of PM demagnetization. The general expression for the coefficient of the PM leakage flux is

1 1lmg g

GG

μ μσΦ

= + = +Φ

（9）

4 ANALYSIS OF THREE-DIMENSIONAL FINITE ELEMENT ELECTROMAGNETIC SIMULATION

4.1 The Main Specifications and Structural Parameters Due to the following negative factors such as structural asymmetry, complexity of the

magnetic circuit (axial and radial flux) and increasing leakage flux, the traditional magnetic circuit method cannot meet the requirement of the precise calculation of prototype, while three-dimensional finite element simulation conquer the difficulty. The tab.1 displays the relevant specifications and structure parameters of hybrid excitation claw-pole.

Tab.1 Key design data

Rated power(4000rpm generator)

12V×190A

Rated power(6000rpm generator)

49.5V×90A

DC-link voltage 42V


Max stall torque 60Nm

Stator outside diameter 128mm

Stator length 33mm

Rotor outside diameter 96.7mm

PM dimensions 32×7×8mm3

PM remanence flux density 1.2T

4.2 Three-dimensional Finite Element Simulation

(a) Fe = -550A*N The Fig.5 (a) shows air gap magnetic density and rotor-stator magnetic density at Fe =

-550A*N. From the above picture, it is found that the average magnetic density value in air gap is Bav=0.07T, the maximum of rotor and stator yoke magnetic density value are Brc-max=1.20T and Bsc-max=1.20T respectively. Hence, through the bypass structure, the electrical excitation propels permanent magnet leakage flowing from division G to the rotor, which will add the leakage flux and lower the magnet density of stator and EMF. It makes demagnetization come into realization.

(b) Fe = 0 A* N

The Fig.5 (b) is air gap magnetic density and rotor-stator magnetic density at the Fe = 0A*N. In the picture, it is known that the average magnetic density value in air gap is Bav=0.14T, the maximum of rotor and stator yoke magnetic density value are Brc-max=1.10T and Bsc-max=0.30T respectively. If there is no electrical excitation, the leakage flux from rotor will form a loop. By means of three-dimensional magnet net, the 32% of magnetic flux generated by permanent magnets goes through the stator, 68% through the rotor form leakage flux.


(c) Fe =550A*N

Fig.5 The map of air gap and rotor-stator flux density under different excitation The Fig.5(c) indicates air gap magnetic density and rotor-stator magnetic density at the Fe

=550A*N. The average magnetic density value in air gap is Bav=0.46T, and the maximum of rotor and stator yoke magnetic density values are Brc-max=1.02T and Bsc-max=1.25T respectively. The electrical excitation drives the permanent magnet leakage flux to flow from G to the stator, which reduces the leakage flux, increases EMF and the magnetic density of stator and strengthens magnetization. In order to analyze regulating magnet field range and capability, regulating range coefficient of flux is defined as variation r:

0

0

100%av av

av

B BrB−

= × （10）

Bav is the average air gap magnet density value under hybrid excitation, while Bav0 is the average air gap magnet density value under no electrical excitation. When the electrical excitation changes from -550A*N to 550A*N, the machine flux regulation will accordingly ranges from -50% to 228.5%.

4.3 Simulation Results

(a) Complex fluxes


(b) Three-phase flux linkage

(c) three-phase back-EMF at 4000rpm

(d) Torque under 2000rpm and different electrical excitation

Fig.6. Electromagnetic simulation results

Fig.6 exhibits the electromagnetic simulation characteristics. Fig.6 (a) reveals hybrid excitation consisting of PM flux linkage and electrical excitation flux linkage, so the proportion of PM and electrical excitation can be reduced. Fig.6 (b) and Fig.6 (c) demonstrate three-phase fluxes and three-phase back-EMF under 4000rpm and no-load conditions. Thanks to structural


asymmetry, the waveform has fair property of sine. Fig.6 (d) displays the torque under 2000rpm and different electrical excitation.

5 SAFE MULTI-DOMAIN SIMULATION

5.1 Analysis of the Claw-pole Machine Mechanical Simulation in High Speed

(a) 20000rpm suffer stress (b) 20000rpm deformation

Fig.7 the diagrams of suffer stress distribution and deformation

Since the hybrid excitation claw-pole BSG machine is an important component of the automobile generators, mechanical strength and shape variables at the high speed 20000rpm are simulated to ensure electrical safety. Fig.7 provides the simulation results at 20000rpm: the maximum value of suffer-press in rotor-bottom is 398MPa, and deformation in rotor-top is 0.231mm. The 0.5mm length of air gap demonstrates it safe.

5.2 The Calculation of the Stator’s Natural Frequency

1

MN MX

X

Y

Z

.836501

.845518.854534

.86355.872567

.881583.890599

.899616.908632

.917648

JAN 19 201014:44:54

NODAL SOLUTION

STEP=1SUB =20FREQ=9868USUM (AVG)RSYS=0DMX =.917648SMN =.836501SMX =.917648

1

MN

MX

X

Y

Z

.420278

.49505.569821

.644592.719363

.794134.868905

.9436771.018

1.093

JAN 19 201014:43:17

NODAL SOLUTION

STEP=1SUB =7FREQ=1659USUM (AVG)RSYS=0DMX =1.093SMN =.420278SMX =1.093

0f = 9868Hz 2f = 1659 Hz


1

MN

MX

X

Y

Z

.167828

.278224.38862

.499015.609411

.719807.830203

.9405981.051

1.161

JAN 19 201014:45:14

NODAL SOLUTION


1

MN

MX

X

Y

Z

.012097

.143532.274966

.4064.537835

.669269.800703

.9321381.064

1.195

JAN 19 201014:46:55

NODAL SOLUTION


3f = 4417Hz 4f = 7922Hz

Fig.8 Stator and windings vibration modal analysis

According to Fig.8, when model order is 0, the machine noise is brought about by stator expansion vibration. As the zero-order vibration frequencies are relatively high, it involves the calculation of actual analysis of 2, 3 order the natural frequency of vibration mode. Both the finite element natural frequency and vibration of motor modal analysis reveal that the lowest second-order natural frequency is 1659Hz. The datum is far more than the range of machine speed, which is beneficial to avoid systematic resonance.

5.3 The Thermal Simulation in the Rated Working Point The thermal simulation of the machine not only contributes to choose the insulation material

of machine winding and check the temperature of the working point， but supports the cooling system design of high-density machine vehicle. The rated working point of hybrid excitation claw-pole BSG is 4000rpm in long-term, 6000rpm in short-term. Heat value in 4000rpm long-term working point is comparatively more than the other, so it is selected to be rechecked and simulated by Ephics software.

(a) Machine temperatures distribution under rated working point


(b) heat calculation results under rated working point

Fig.9 Machine temperatures under rated working point

As shown in Fig.9, the temperatures of rated working points are less than 140℃. Since the machine insulation materials utilize H-grade insulation, the temperature remains within the permissible range. In brief, the problem of the temperature will not exist any more.

6 EXPERIMENT

Based on the above simulation, we have designed and manufactured the bypass hybrid excitation claw-pole BSG machine. The prototype and experiment platform in Fig.10 connect with rectifier followed by the pure resistive load.


Fig.10 Prototype pictures and experimental platform

In Fig.11, it is can be discovered that the measured no-load line voltage EMF at 4000rpm and different electrical excitations (-550A*N, permanent magnet, 550A*N), the value of line RMS is 2.6V、5.5V and 18.1V respectively.

Fig.11 Experimental no-load back-EMF voltage under -550 A* N、0 A* N and 550 A* N

Voltage regulation range coefficient of variation ε:

%1000

0 ×−

=rms

rmsrmse

eeε （11）

Here erms is the RMS value of voltage, and erms0 is the one of voltage under 0 A* N (no electrical excitation). When the electrical excitation changes from -550A*N to 550A*N, the machine voltage regulation correspondingly ranges from -52.7% to 229.0%. The measured voltage regulation characteristics are in good agreement with the finite element analysis results, demonstrating that the machine has a significant capability of flux regulation.

Fig.12 The curve of U-I characteristics under different excitation

Fig.12 depicts the measured U-I characteristic curves with the pure resistive load under different excitation current and speed (rated working point: 4000rpm and 6000rpm). The power under different rated working point is 2.62kw and 4.53kw. In starter mode, the torque meets the requirement of micro-hybrid vehicles. Compared with traditional excitation claw-pole machine, the power density of the proposed machine increased.


7 CONCLUSION

A hybrid excitation claw-pole BSG machine is designed by analyses and optimization of electromagnetic, mechanical, vibration modal and thermal energy comprehensive multi-domain simulation. The simulation and experimentation results both analyze and verify the machine design is reasonal and pratical. A hybrid excitation claw-pole BSG machine is recommended for a BSG for HEVs application, which has the 3 characteristics:

1) Compared with traditional electrical excitation claw-pole machine, series hybrid claw-pole machine, the bypass hybrid excitation claw-pole machine have high output, small leakage flux, high power density and hard output characteristic.

2) Not only bypass structure equips the air gap magnetic field with a bidirectional regulation function, but also reduces the risk of demagnetization caused by armature reaction.

3) At the starter stage, BSG can rapidly achieve a starting torque to start engine; while at the stage of generating voltage, the online regulation flux makes BSG remains a stable output voltage within a wide speed range for battery charging, which explores a wide application prospect for hybrid electric vehicles.

Appendix 1

Ψpma,b,c no-load three-phase permanent magnet flux linkage

if electrical excitation

Lfa,b,c mutual inductance between electrical excitation and three-phase winding

K1 terminal voltage and phase voltage proportional coefficient

K machine coefficient

bg average magnetic density in air gap

N winding turns

ω machine angular velocity

Appendix 2

Fe electrical excitation magnetic potential

Fmag permanent magnet magnetic potential

Rrr，Rrc，Rc reluctance associated with rotor-to-axial yoke, radial yoke and claw

Ra，Rmag，Rg reluctance associated with claw-to-claw, PM, air gap

Rst，Rsc reluctance associated with stator tooth and yoke

Rδ1，Rδ2，Rδ3 leakage reluctance associated with the claw, slots, rotor yoke

Φe，Φge，Φg flux associated with rotor yoke, stator tooth and air gap

Appendix 3

Fe electrical excitation magnetic potential

Fm permanent magnet magnetic potential


Re/ Ge rotor reluctance/permeance

Rm/ Gm permanent magnet reluctance/permeance

Rμ/ Gμ leakage reluctance/permeance in rotor

Rs / Gs leakage reluctance/permeance in stator

Fad the d-axis armature reaction MMF

Φμ leakage flux in rotor

Φg air gap flux

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