CN107977518B - Multidisciplinary joint simulation method for servo motor design - Google Patents
Multidisciplinary joint simulation method for servo motor design Download PDFInfo
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- CN107977518B CN107977518B CN201711279443.9A CN201711279443A CN107977518B CN 107977518 B CN107977518 B CN 107977518B CN 201711279443 A CN201711279443 A CN 201711279443A CN 107977518 B CN107977518 B CN 107977518B
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- G06F30/00—Computer-aided design [CAD]
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Abstract
A multidisciplinary joint simulation method for servo motor design comprises the following steps: (1) parameters required by electromagnetic simulation, static simulation and thermal simulation analysis of the servo motor are given according to index requirements, use conditions and installation conditions; (2) updating the sizes of a shell, a stator, a rotor and a rotor shaft of the servo motor based on a parameterized model by using geometric configuration software; (3) through the recording function of the scripts of the electromagnetic simulation software, the thermal simulation software and the static simulation software, the automatic replacement of simulation parameters is realized according to the identification basis of keywords and the affiliated row numbers in the scripts, and then the automation of the electromagnetic, thermal and static simulation is completed, so that a torque and counter electromotive force of the motor at a rated rotating speed, a stress strain cloud chart of the shell and the rotor shaft and a temperature distribution cloud chart of the servo motor are obtained. The invention integrates multidisciplinary simulation flow of servo motor design, extracts parameters required by simulation analysis, realizes the automation of full digitalization performance estimation of the servo motor, effectively reduces the repetitive work in the design process of the servo motor and has strong engineering practicability.
Description
Technical Field
The invention belongs to the technical field of servo motor simulation, and relates to a rapid prediction method for the full-digital performance of a servo motor based on a multidisciplinary joint simulation technology.
Background
At present, the multidisciplinary joint simulation research on the servo motor at home and abroad has a certain foundation, and after Ansoft company is purchased by ANSYS company, the electromagnetic, thermal and static joint simulation of the servo motor is basically realized at home and abroad on the basis of a Workbench of ANSYS software by utilizing an electromagnetic simulation module Maxwell and a mechanical simulation module Mechanics. However, this method has significant disadvantages: on one hand, a servo motor model established by using an ANSYS/Maxwell module is only used for solving the problem of electromagnetic simulation of a servo motor, and the generated three-dimensional model only comprises three-dimensional geometric models of a stator and a rotor; in order to obtain an accurate thermal analysis result, thermal simulation analysis of the motor needs to analyze the heat dissipation condition of the whole servo motor, namely, geometric models of components such as a motor shell, a rotor shaft, a bearing, a copper wire winding and the like are needed besides geometric models of a stator and a rotor; on the other hand, when the stress deformation condition and the service life prediction of the servo motor are examined, the stator and the rotor of the motor are non-bearing parts, and in order to avoid the non-bearing parts occupying a large amount of computing resources during statics analysis, simplification processing is often needed, geometric models of the stator and the rotor generated by Maxwell cannot be directly utilized, and particularly, singular or divergence is easily caused when a groove body part in the stator is used for dividing grids to perform finite element simulation analysis, so that simulation failure is caused.
Disclosure of Invention
The technical problem solved by the invention is as follows: the invention provides a multidisciplinary joint simulation method for servo motor design, aiming at the situations that electromagnetic, thermal and static simulation required models and required model fineness are different, which relate to servo motor performance verification. The method aims to solve the problem that simulation analysis requirements of different disciplines are different in servo motor design, and realizes full-digital virtual experimental performance rapid prediction of various performance indexes of the servo motor.
The technical scheme of the invention is as follows: a multidisciplinary joint simulation method for servo motor design comprises the following steps:
(1) determining electromagnetic simulation analysis parameters of a stator and a rotor of the servo motor according to a torque and speed envelope curve and the size of an installation space of the servo motor;
(2) determining statics simulation analysis parameters of the servo motor according to stress conditions of the servo motor in storage, transportation and working processes and the electromagnetism simulation analysis parameters of the stator and the rotor of the servo motor determined in the step (1);
(3) determining thermal characteristic simulation parameters of the servo motor according to an attribute table of materials of a stator, a rotor, a shell and a rotor shaft component of the servo motor;
(4) performing electromagnetic finite element simulation on the servo motor according to the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor in the step (1) to obtain the torque and the counter electromotive force of the servo motor at the rated rotating speed;
(5) judging whether the torque and the counter electromotive force obtained in the step (4) both meet the requirements of the torque and the speed envelope curve in the step (1), if so, performing the step (6), otherwise, returning to the step (1) to reset the electromagnetic simulation parameters of the stator and the rotor of the motor;
(6) establishing a geometric configuration of the servo motor according to the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor in the step (1) and the static simulation analysis parameters of the shell and the rotor shaft of the servo motor in the step (2);
(7) establishing a geometric configuration of the servo motor according to the statics simulation analysis parameters of the servo motor shell and the rotor shaft determined in the step (2) and the step (6), and performing statics finite element simulation on the servo motor shell and the rotor shaft to obtain the statics force bearing characteristics of the servo motor, wherein the statics force bearing characteristics comprise stress strain cloud charts of the shell and the rotor shaft under the condition of being pulled and pressed by the maximum bearing force;
(8) judging whether the stress-strain cloud picture of the shell or the rotor shaft obtained in the step (7) exceeds the required limit stress condition, if so, returning to the step (2) to reset the static simulation parameters of the shell or the rotor shaft, and if not, performing the step (11);
(9) determining thermal characteristic simulation parameters of the servo motor and the geometric configuration established in the step (6) according to the step (3) while the step (7) is carried out, and carrying out servo motor thermal characteristic simulation finite element analysis to obtain thermal protection characteristics of the servo motor, wherein the thermal protection characteristics comprise a thermal distribution cloud chart of the servo motor;
(10) judging whether the maximum temperatures of the stator, the rotor, the shell and the rotor shaft of the servo motor in the servo motor heat distribution cloud picture obtained in the step (9) exceed the limit temperatures or not, if more than one of the maximum temperatures exceed the limit temperatures, returning to the step (3) to replace the materials of the parts exceeding the limit temperatures, and if the materials cannot be replaced, returning to the step (1) to re-determine the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor; if the limit temperature is not exceeded, performing step (11);
(11) electromagnetic simulation analysis parameters of a stator and a rotor of the servo motor, static simulation analysis parameters of a shell and a rotor shaft, and thermal characteristic simulation parameter records of the servo motor are determined to form a design scheme of the servo motor and stored in a database, wherein the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor, the static simulation analysis parameters of the shell and the rotor shaft meet electromagnetic output characteristics, thermal protection characteristics and static bearing characteristics of the servo motor.
Installation space size includes: the length, the width and the height are represented in a three-dimensional orthogonal coordinate system O-XYZ, namely a rectangular space, the length and the width are both positioned on an XY plane, and the height is along the positive direction of a Z axis;
electromagnetic simulation analysis parameters of a stator and a rotor of a servo motor comprise: the geometric parameters of the geometric shapes of the stator and the rotor of the servo motor and the simulation setting parameters of the finite element simulation of electromagnetism are defined, and the geometric parameters of the stator comprise: the stator comprises a stator outer diameter, a stator inner diameter, a stator length, a stator groove depth, a stator groove bottom width, a stator groove flaring depth, a stator groove opening width, a stator groove opening depth and a stator groove chamfer radius; the geometrical parameters of the rotor include: rotor outer diameter, rotor inner diameter, rotor length and permanent magnet thickness; the simulation setting parameters of the electromagnetic finite element simulation comprise: the simulation method comprises the following steps of stator material, rotor material, servo motor rotating speed, three-phase current expression, simulation step length and simulation time.
The stator geometric parameter determining steps are as follows:
the Z-axis direction is defined as the axial direction of the servo motor, and the length L of the stator can be determined according to the height of the space sizeefInner diameter D of statorilObtained by the following formula:
in the formula, TeThe electromagnetic torque of the servo motor can be obtained from the torque and speed envelope curve with the unit of N.m, Bδ1The unit of the amplitude of the air gap flux density fundamental wave is T, and the value range is 0.95-1.05T; a is the effective value of the electrical load of the stator, the unit is A/cm, and the value range is 150-700A/cm;
the stator outer diameter can be determined according to the smaller of the length and the width of the space size, and the stator outer diameter can be determined in a servo motorIn the initial design of the machine, the width Bs of the groove bottom2The value of (a) can be determined by the following formula;
Bs2＝2π*Dil/S
in the formula, S is the number of grooves and takes the value of a positive integer larger than 4; groove flaring width Bs1The width Bs of the groove bottom can be set during initial assignment20.25 times of the stator, the groove depth is smaller than the difference value between the stator outer diameter and the stator inner diameter, and other parameters including the groove flaring depth, the groove opening width, the groove opening depth and the groove chamfer radius can be assigned at will on the premise of ensuring the manufacturability and the geometric topological relation.
The geometric parameter determination process of the rotor requires that: the length of the rotor is equal to that of the stator, and the thickness of the permanent magnet cannot exceed the inner diameter of the stator.
The electromagnetic finite element simulation parameter determination method comprises the following steps:
the stator and rotor materials can be obtained from a material selection manual of a servo motor manufacturer;
the expression of the three-phase current comprises three variables of amplitude I, frequency f and phase angle phi;
in the formula, the subscript i represents A, B, C triphase;
according to a torque-speed envelope curve and an energy conservation law, under the condition of a given power supply voltage of the servo motor, the amplitude of the three-phase current can be obtained by the following formula:
I＝Tω/U
in the formula, U is voltage, T is torque, and omega is rotating speed;
the frequency of the three-phase current can be obtained by the following formula:
f＝np/60
in the formula, n is the rotating speed, the unit is revolution per minute, and p is the logarithm of the grade, namely half of the electromagnetic grade;
the phase angle difference between two three-phase currents is generally 120 °, and thus the expression of the three-phase currents can be expressed as
IA＝I sin(ft)
IB＝I sin(ft+π/3)
IC＝I sin(ft+2π/3)
The rotating speed of the servo motor is the speed of each working condition point of the torque and speed envelope curve, and the electromagnetic finite element simulation time generally takes the value
Electromagnetic finite element simulation step length
The expression of the three-phase current is as follows:
Ii＝I sin(ft+φ)
in the formula, subscript I represents A, B, C three phases, I is amplitude, f is frequency, and phi is phase angle;
the static simulation parameters of the servo motor are the geometric parameters and static simulation setting parameters of a shell and a rotor shaft of a main bearing part of the servo motor, and the geometric parameters of the shell and the rotor shaft comprise: the length, width, height and wall thickness of the motor shell, and the parameters of the rotor shaft comprise the diameter and length of the motor shaft; the statics simulation setting parameters include: the young's modulus and poisson's ratio of the housing material, the magnitude of the force and the fixing surface and the force application surface of the housing, the young's modulus and poisson's ratio of the rotor shaft, the magnitude of the force and the fixing surface and the force application surface of the rotor shaft.
The geometrical parameters of the housing and the rotor shaft are determined as follows: the sum of the length, the width, the height and the wall thickness of the motor shell is smaller than the size of the installation space and larger than the size of the servo motor stator; the diameter of the rotor shaft of the motor is smaller than the inner diameter of the rotor, the length of the rotor shaft is equal to the sum of the length of the stator and the length of the connecting piece, and the length of the connecting piece is obtained from a product manual of a manufacturer for consulting the connecting piece according to the maximum bearing capacity.
The static simulation setting parameter determination process is as follows: young modulus and Poisson ratio of materials of the shell and the rotor shaft can be obtained from a product manual of a manufacturer, a fixing surface of the shell is the bottom of the shell, a stress surface is a bolt connection part, and force application is maximum bearing force required by motor design; the fixed surface of the rotor shaft is a contact surface with the rotor, the stress surface of the rotor shaft is a contact surface with the connecting piece, and the force application size is the maximum moment of the moment and speed envelope curve.
The servo motor thermal simulation parameters comprise: the thermal conductivity and surface emissivity of the shell, the stator, the rotor and the rotor shaft of the servo motor, the initial environment temperature and the simulation time; the initial environment temperature is-40-60 ℃, the simulation time is the working time of the servo motor, and the thermal conductivity and the surface emissivity can be obtained from a product material manual of a motor manufacturer.
Compared with the prior art, the invention has the advantages that:
(1) the servo motor simulation method provided by the invention covers the full-digital simulation prediction of the conventional performance indexes required by the design of the servo motor;
(2) the multidisciplinary joint simulation method provided by the invention realizes the sharing of electromagnetic, thermal and static simulation parameters of the servo motor;
(3) the specific implementation steps of the servo motor joint simulation method provided by the invention realize the minimum rework of motor design simulation analysis;
(4) the servo motor joint simulation method provided by the invention realizes the parallel operation of thermal simulation and static simulation of motor design, and improves the simulation efficiency;
(5) the method for realizing the automation of the electromagnetic, thermal and static simulation of the servo motor through the script file is suitable for all professional simulation software with script recording function.
Drawings
FIG. 1 is a flow chart of a multidisciplinary joint simulation method of a servo motor according to the present invention;
FIG. 2 is a schematic cross-sectional view of a servo motor according to the present invention;
FIG. 3 is a schematic diagram of an envelope curve of torque and rotational speed according to the present invention;
FIG. 4 is a schematic view of stator slot parameter settings according to the present invention;
Detailed Description
The invention is described in further detail below with reference to the figures and specific embodiments.
As shown in fig. 1, the multidisciplinary joint simulation method for servo motor design of the present invention specifically comprises the following steps: firstly, designing parameters of a servo motor according to design indexes including torque and speed envelope curves, stress and temperature conditions in storage, transportation and working processes, wherein the parameters comprise servo motor electromagnetic simulation parameters, servo motor statics simulation parameters and servo motor thermal simulation parameters; secondly, performing electromagnetic finite element simulation analysis according to the servo motor electromagnetic simulation analysis parameters to obtain a torque and back electromotive force curve comparing a torque and speed curve, analyzing whether the output of the motor meets the requirements under various rotating speed conditions, if not, returning to modify the servo motor electromagnetic simulation parameters, and if so, performing the next step; thirdly, extracting a reference geometric model of the servo motor shell, the stator, the rotor and the rotor shaft from the database, wherein the configuration size of the reference geometric model is completely established according to geometric parameters contained in servo motor electromagnetism simulation parameters and servo motor statics simulation parameters, and the geometric model reconstruction of the servo motor shell, the stator, the rotor and the rotor shaft based on the servo motor electromagnetism simulation parameters and the servo motor statics simulation parameters can be realized by opening geometric configuration software and calling through scripts; fourthly, performing thermal characteristic simulation analysis according to thermal simulation parameters of the servo motor and the established motor shell, stator, rotor and rotor shaft models, and simultaneously performing statics simulation analysis according to geometric models of the shell and the rotor shaft of the servo motor and statics simulation parameters of the servo motor; and fifthly, judging whether the maximum temperature of the shell, the stator, the rotor and the rotor shaft of the servo motor in the temperature distribution cloud picture obtained by the thermal characteristic simulation analysis exceeds the limit temperature, judging whether the stress strain cloud picture obtained by the static simulation analysis exceeds the load bearing limit, if so, returning to modify the geometric parameters of the stator and the rotor in the electromagnetic simulation parameters of the servo motor, the static simulation parameters and the thermal simulation parameters again, if so, determining a set of motor scheme meeting the index requirements according to the electromagnetic, static and thermal simulation parameters of the servo motor, storing the motor scheme into a model library, and providing simulation model reference and performance verification support for subsequent prototype design of the servo motor.
The preferred embodiment 1 is:
taking the design of a three-phase permanent magnet synchronous motor as an example, wherein the three-phase permanent magnet synchronous motor is of an inner rotor structure, the power supply voltage is 96V, and the permanent magnet synchronous motor is of an 8-stage 9-slot structure. The components and the connection mode are shown in fig. 2, the shell of the servo motor is a rectangular shell structure at the outermost side, and the protection to the external acting force is provided for the whole servo motor; the inside of the shell is provided with a stator of a servo motor, the stator is an annular columnar body, a groove is formed in the annular columnar body, and copper wire windings connected with a three-phase power supply can be arranged in the groove to provide electric energy for the servo motor; the inside of the stator is provided with a rotor of the servo motor, the rotor is also an annular cylindrical body, and the rotor comprises a permanent magnet to provide a constant magnetic field for the servo motor; the rotor shaft is arranged in the rotor and fixedly connected with the rotor, and the motor is used for outputting mechanical energy converted from electric energy.
(1) Determining electromagnetic simulation analysis parameters of a stator and a rotor of the servo motor according to a torque and speed envelope curve and the size of an installation space of the servo motor;
as shown in fig. 3, the curve is an envelope curve of torque and rotation speed according to the present invention, the abscissa of the curve is the torque of the servo motor, the ordinate of the curve is the rotation speed of the servo motor, each solid point in the curve represents a working point that needs to be satisfied, that is, the output of the servo motor at the rotation speed is greater than or equal to the torque of the abscissa corresponding to the point, the limit working condition has two cases, i.e., no-load and locked-rotor, the output of the motor at no-load is the maximum rotation speed, and the maximum output of the motor at locked-rotor tends to zero.
Installation space size includes: the length, width and height, i.e. a rectangular space, are represented in a three-dimensional coordinate system 0XYZ, the length and width both lying in the OXY plane and the height in the positive direction of the Z axis.
Electromagnetic simulation analysis parameters of a stator and a rotor of a servo motor comprise: and defining geometric parameters of geometric shapes of a stator and a rotor of the servo motor and simulation setting parameters of finite element simulation of electromagnetism. The stator geometric parameters include: the stator comprises a stator outer diameter, a stator inner diameter, a stator length, a stator groove depth, a stator groove bottom width, a stator groove flaring depth, a stator groove opening width, a stator groove opening depth and a stator groove chamfer radius; the geometrical parameters of the rotor include: rotor outer diameter, rotor inner diameter, rotor length, and permanent magnet thickness. The simulation setting parameters of the electromagnetic finite element simulation comprise: the simulation method comprises the following steps of stator material, rotor material, servo motor rotating speed, three-phase current expression, simulation step length and simulation time.
As shown in fig. 4, the slot is located on the stator, and its geometric configuration size includes the slot depth of the stator, the slot bottom width of the stator, the slot flaring depth of the stator, the slot opening width of the stator, the slot opening depth of the stator, the slot chamfer radius of the stator, and other parameters.
The specific process for determining the geometric parameters of the stator comprises the following steps:
1) the Z-axis direction is defined as the axial direction of the servo motor, and the length L of the stator can be determined according to the height of the space sizeefInner diameter D of statorilCan be obtained by the following formula:
in the formula, TeThe electromagnetic torque of the servo motor can be obtained from the torque and speed envelope curve with the unit of N.m, Bδ1The unit of the amplitude of the air gap flux density fundamental wave is T, and the value range is 0.95-1.05T; a is the effective value of the electrical load of the stator, the unit is A/cm, and the value range is 150-700A/cm.
2) The stator outer diameter can be determined according to the smaller of the length and the width of the space size, and the groove bottom width Bs is determined during the primary design of the servo motor2Can be determined by
Bs2＝2π*Dil/S
3) Groove flaring width Bs1The width Bs of the groove bottom can be set during initial assignment20.25 times of the stator, the groove depth is smaller than the difference value between the stator outer diameter and the stator inner diameter, and other parameters including the groove flaring depth, the groove opening width, the groove opening depth and the groove chamfer radius can be assigned at will on the premise of ensuring the manufacturability and the geometric topological relation.
The determination process of the geometrical parameters of the rotor comprises the following steps:
the length of the rotor is equal to that of the stator, and the thickness of the permanent magnet cannot exceed the inner diameter of the stator.
The parameters for setting the finite element simulation of the servo motor electromagnetism are determined as follows:
the rotor material and the stator material can be screened from a material selection manual of a servo motor manufacturer, the rotating speed, namely the ordinate of a solid point in a torque and speed envelope curve, and the expression of three-phase current, including three variables of an amplitude I, a frequency f and a phase angle phi, can be represented by the following formula:
Ii＝I sin(ft+φ)
in the formula, the subscript i represents A, B, C three phases.
According to a torque-speed envelope curve and an energy conservation law, under the condition of a given power supply voltage of the servo motor, the amplitude of the three-phase current can be obtained by the following formula:
I＝Tω/U
in the formula, U is voltage, T is torque, and omega is rotation speed.
The frequency of the three-phase current can be obtained by the following formula:
f＝np/60
in the formula, n is the rotating speed, the unit is revolution per minute, and p is the logarithm of the grade, namely half of the electromagnetic grade.
The phase angle difference between two three-phase currents is generally 120 °, and thus the expression of the three-phase currents can be expressed as
IA＝I sin(ft)
IB＝I sin(ft+π/3)
IC＝I sin(ft+2π/3)
The final electromagnetic finite element simulation time generally takes the value of
Electromagnetic finite element simulation step length
(2) Determining statics simulation analysis parameters of the servo motor according to stress conditions of the servo motor in storage, transportation and working processes and the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor determined in the step (1);
the static simulation parameters of the servo motor are the geometric parameters and static simulation setting parameters of a shell and a rotor shaft of a main bearing part of the servo motor, and the geometric parameters of the shell and the rotor shaft comprise: the length, width, height and wall thickness of the motor housing, and the parameters of the rotor shaft include the diameter and length of the motor shaft. The statics simulation setting parameters include: the young's modulus and poisson's ratio of the housing material, the magnitude of the force and the fixing surface and the force application surface of the housing, the young's modulus and poisson's ratio of the rotor shaft, the magnitude of the force and the fixing surface and the force application surface of the rotor shaft.
The sum of the length, the width, the height and the wall thickness of the motor shell is smaller than the size of the installation space and larger than the size of the servo motor stator; the diameter of the rotor shaft of the motor is smaller than the inner diameter of the rotor, the length of the rotor shaft is equal to the sum of the length of the stator and the length of the connecting piece, and the length of the connecting piece can be obtained by looking up a product manual of a connecting piece manufacturer through the maximum bearing capacity. Young modulus and Poisson ratio of materials of the shell and the rotor shaft can be obtained from a product manual of a manufacturer, a fixing surface of the shell is the bottom of the shell, a stress surface is a bolt connection part, and force application is maximum bearing force required by motor design; the fixed surface of the rotor shaft is a contact surface with the rotor, the stress surface of the rotor shaft is a contact surface with the connecting piece, and the force application size is the maximum moment of the moment and speed envelope curve.
(3) Determining thermal characteristic simulation parameters of the servo motor according to an attribute table (contents and obtained contents of the attribute table) of materials of parts such as a stator, a rotor, a shell and a rotor shaft of the servo motor;
the servo motor thermal simulation parameters comprise: the servo motor comprises a servo motor shell, a stator, a rotor and a rotor shaft, and is characterized by comprising a thermal conductivity coefficient, a surface emissivity, an initial environment temperature and simulation time of the servo motor shell, the stator, the rotor and the rotor shaft, wherein the initial environment temperature generally takes a value of-40-60 ℃, the simulation time is the working time of the servo motor, and the thermal conductivity coefficient and the surface emissivity can be obtained from a product material manual of a motor manufacturer.
(4) Performing electromagnetic finite element simulation on the servo motor according to the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor in the step (1) to obtain the torque and the counter electromotive force of the servo motor at the rated rotating speed;
firstly, professional servo motor electromagnetism finite element simulation analysis software is utilized, the example is preferably Maxwell software of ANSYS company, and besides the accuracy of a calculation result, the software has the advantage that the automation of the electromagnetism simulation can be realized through recording a script file, and the specific implementation process is as follows:
the script file is a file for recording the software operation process, the servo motor electromagnetic finite element simulation is a process of parameter setting, operation simulation and result viewing, except that the values of specific parameters are different in the process, the sentence grammars of each execution command are consistent, therefore, based on the recorded permanent magnet synchronous motor electromagnetic finite element simulation script, the specific numerical values of the simulation parameters can be replaced by the servo motor electromagnetic finite element simulation parameters in the step (1) through identifying keywords and the affiliated row and column numbers in the script file, the simulation result of each iteration of opening the permanent magnet synchronous motor design panel, inputting the servo motor electromagnetic finite element simulation parameters in the step (1), executing the electromagnetic finite element simulation, outputting the servo motor electromagnetic torque and the back electromotive force which are saved in the form of pictures and Excel tables and increasing along with the simulation step length is realized, until all electromagnetic finite element simulation operations of the software are shut down.
The servo motor joint simulation method provided by the invention carries out the electromagnetism simulation of the permanent magnet synchronous motor instead of the statics simulation and the thermal characteristic simulation, because the main function of the servo motor is to convert electric energy into mechanical energy, the electromagnetic output condition under the required rotating speed is considered firstly, so that the minimum rework in the motor design simulation analysis process is ensured.
(5) Judging whether the torque and the counter electromotive force obtained in the step (4) both meet the requirements of the torque and the speed envelope curve in the step (1), if so, performing the step (6), otherwise, returning to the step (1) to reset the electromagnetic simulation parameters of the stator and the rotor of the motor;
wherein the judgment conditions of the step (5) are as follows: judging whether the electromagnetic torque is more than or equal to the transverse of the corresponding working condition point of the torque and speed envelope curve under the rotating speed of all the working condition pointsAnd (4) taking the value of the coordinate. If the condition is met, the step (6) is continued, if the condition is not met, the step (1) is returned, the materials of the stator and the rotor are replaced according to a product manual provided by a manufacturer, and B is increasedδ1And (4) the amplitude of the air gap flux density fundamental wave or the value of the A stator electric load, and the geometric parameters of the stator and the rotor are recalculated.
(6) Establishing a geometric configuration of the servo motor according to the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor in the step (1) and the static simulation analysis parameters of the shell and the rotor shaft of the servo motor in the step (2);
the geometric parameters of the stator, the rotor, the shell and the rotor shaft of the servo motor determined in the step (1) and the step (2) are selected through years of engineering experience accumulation, and geometric models of the stator, the rotor, the shell and the rotor shaft of the servo motor can be established through the application of a parametric modeling technology by utilizing geometric configuration software through naming and assigning of each geometric parameter.
The example uses the preferred Pro/E geometry software to generate the magnitude of the geometric parameters and the geometric model. The Pro/E software has a strong API interface, utilizes the Update function of the API and takes the parameter name as an identifier, namely, the geometric parameters of the stator, the rotor, the shell and the rotor shaft of the permanent magnet synchronous motor obtained in the step (1) and the step (2) are assigned to the corresponding geometric models to realize the geometric dimension updating of the geometric models of the stator, the rotor, the shell and the rotor shaft, therefore, geometric models required by the static simulation and the thermal characteristic simulation of the permanent magnet synchronous motor are obtained, attention needs to be paid to the process that except the naming of geometric parameters, in order to facilitate the subsequent static simulation and the subsequent thermal characteristic simulation, the bottom surface of the shell and the contact surface of the rotor shaft and the rotor are named as a fixed surface, the bolt hole surface of the shell and the contact surface of the rotor shaft and the connecting piece are named as a stress surface, and the geometric bodies of the shell, the stator, the rotor and the rotor shaft of the motor are named by respective names.
The primary design process of the servo motor is a process of repeated iteration and repeated verification of parameters and performance. Geometric parameters of a stator, a rotor, a shell and a rotor shaft of the servo motor are extracted, and geometric model reconstruction is realized by using a parametric modeling technology, so that simple and repeated work of designers is saved by updating the size instead of redrawing, and electromagnetic, thermal and static simulation parameters of the servo motor are shared;
(7) establishing a geometric configuration of the servo motor according to the statics simulation analysis parameters of the servo motor shell and the rotor shaft determined in the step (2) and the step (6), and performing statics finite element simulation on the servo motor shell and the rotor shaft to obtain the statics force bearing characteristics of the servo motor, wherein the statics force bearing characteristics comprise stress strain cloud charts of the shell and the rotor shaft under the condition of being pulled and pressed by the maximum bearing force;
similar to the electromagnetic finite element simulation principle in the step (4), the static simulation of the shell and the rotor shaft is realized through script recording and parameter value replacement. The statics of the shell and the rotor shaft is preferably a Static Structural module of ANSYS, two statics simulation projects are respectively started by utilizing script file records, geometric models of the shell and the rotor shaft are respectively led in, grid division is completed, a fixed surface is changed into a shell bottom surface named as a fixed surface in the step (6) and a contact surface of the rotor shaft and the rotor, a force application surface is changed into a shell bolt hole surface named as a force application surface in the step (6) and a contact surface of the rotor shaft and a connecting piece, the numerical value of the force application magnitude is assigned as the magnitude of the ultimate force application, an equivalent stress and strain solver is configured, and stress strain cloud charts of the shell and the rotor shaft under the two kinds of ultimate force application conditions of tension and compression are respectively output in the form of pictures.
(8) Judging whether the stress-strain cloud picture of the shell or the rotor shaft obtained in the step (7) exceeds the required limit stress condition, if so, returning to the step (2) to reset the static simulation parameters of the shell or the rotor shaft, and if not, performing the step (11); the maximum force load that extreme atress and load-carrying part can receive among them deposit the transportation and in the course of working, the extreme atress of casing is the maximum force input of external effect, and the maximum torque under the rotor shaft's extreme atress promptly under the locked-rotor condition, if there is the dependent variable in the stress strain cloud picture to exceed the allowable requirement of material greatly, return to step (2) and change the material of casing or rotor shaft, or carry out the manufacturability to the meeting no requirement and handle, for example radius etc..
(9) Determining thermal characteristic simulation parameters of the servo motor and the geometric configuration established in the step (6) according to the step (3) while the step (7) is carried out, and carrying out servo motor thermal characteristic simulation finite element analysis to obtain thermal protection characteristics of the servo motor, wherein the thermal protection characteristics comprise a thermal distribution cloud chart of the servo motor;
and (4) sharing the geometric models of the motor shell and the rotor shaft which are subjected to static analysis, adding the geometric models of the stator and the rotor, and similar to the steps (4) and (7), and realizing the simulation finite element analysis of the thermal characteristics of the servo motor by using script recording and parameter value replacement. The Thermal analysis software of the permanent magnet synchronous motor preferably selects a Transient Thermal module of ANSYS, a script is used for leading in geometric models of a stator, a rotor, a shell and a rotor shaft of the motor, values are assigned to Thermal conductivity coefficients and surface emissivity of the stator, the rotor, the shell and the rotor shaft respectively, then grid division is completed, simulation time is set as working time of the permanent magnet synchronous motor, a temperature simulation solver is set, and finally a Thermal distribution cloud picture of the permanent magnet synchronous motor is output in a picture mode.
Through script recording and geometric model reconstruction technology, a designer does not need to design and analyze the servo motor in one step according to a serial structure in the design process, a computer can perform thermal characteristic finite element simulation analysis and statics simulation in parallel, and the design efficiency is effectively improved.
(10) Judging whether the maximum temperatures of the stator, the rotor, the shell and the rotor shaft of the servo motor in the servo motor heat distribution cloud picture obtained in the step (9) exceed the limit temperatures or not, if more than one of the maximum temperatures exceed the limit temperatures, returning to the step (3) to replace the materials of the parts exceeding the limit temperatures, and if the materials cannot be replaced, returning to the step (1) to re-determine the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor; if the limit temperature is not exceeded, performing step (11);
the maximum working temperature of the C-level insulation is 220 ℃ as the maximum temperature which can be borne by each component, such as a wire arranged in a stator slot, when the motor normally works. The main heating component of the permanent magnet synchronous motor is the stator in the working process, the copper loss of the winding in the stator slot and the iron core loss of the stator exist, and eddy current loss exists for the motor rotating at high speed, so that the situation that the exceeding of the limit temperature is mostly unreasonable in the setting of the geometric parameters of the stator in the step (1) exists, the phenomenon that the permanent magnet in the rotor is demagnetized due to high temperature exists, and the material of the rotor needs to be replaced at the moment.
(11) Electromagnetic simulation analysis parameters of a stator and a rotor of the servo motor, static simulation analysis parameters of a shell and a rotor shaft, and thermal characteristic simulation parameter records of the servo motor are determined to form a design scheme of the servo motor and stored in a database, wherein the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor, the static simulation analysis parameters of the shell and the rotor shaft meet electromagnetic output characteristics, thermal protection characteristics and static bearing characteristics of the servo motor.
Through the combined simulation of three subjects of electromagnetism, statics and heat of the permanent magnet synchronous motor, the obtained electromagnetic torque, back electromotive force, stress strain distribution cloud chart and heat distribution cloud chart can cover the full-digital simulation prediction of the conventional performance indexes required by the design of the servo motor, and can provide powerful support for the subsequent prototype design and performance verification of the permanent magnet servo motor.
The preferred embodiment 2 is:
and designing the direct-current brushless motor with the inner rotor structure, wherein the analysis process is the same as the above, and the design steps are the same. In addition, for the design of the servo motors with different geometric topological relations, the parameterized geometric models of the stator, the rotor shaft and the shell in the step (6) and the step (7) need to be changed according to the geometric structures of the servo motors for the input of thermal simulation and static simulation, and the rest steps are similar to the embodiment 1.
The servo motor simulation method provided by the invention covers the full-digital simulation prediction of the conventional performance indexes required by the design of the servo motor, the multidisciplinary joint simulation method realizes the sharing of the electromagnetic, thermal and static simulation parameters of the servo motor, the specific implementation steps of the servo motor joint simulation method realize the minimum rework of the simulation analysis of the motor design, and the method for realizing the automation of the electromagnetic, thermal and static simulation of the servo motor through the script file is suitable for all professional simulation software with script recording function, thereby realizing the parallel operation of the thermal simulation and the static simulation of the motor design and improving the simulation efficiency.
Claims (10)
1. A multidisciplinary joint simulation method aiming at servo motor design is characterized by comprising the following steps:
(1) determining electromagnetic simulation analysis parameters of a stator and a rotor of the servo motor according to a torque and speed envelope curve and the size of an installation space of the servo motor;
(2) determining statics simulation analysis parameters of the servo motor according to stress conditions of the servo motor in storage, transportation and working processes and the electromagnetism simulation analysis parameters of the stator and the rotor of the servo motor determined in the step (1);
(3) determining thermal characteristic simulation parameters of the servo motor according to an attribute table of materials of a stator, a rotor, a shell and a rotor shaft component of the servo motor;
(4) performing electromagnetic finite element simulation on the servo motor according to the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor in the step (1) to obtain the torque and the counter electromotive force of the servo motor at the rated rotating speed;
(5) judging whether the torque and the counter electromotive force obtained in the step (4) both meet the requirements of the torque and the speed envelope curve in the step (1), if so, performing the step (6), otherwise, returning to the step (1) to reset the electromagnetic simulation parameters of the stator and the rotor of the motor;
(6) establishing a geometric configuration of the servo motor according to the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor in the step (1) and the static simulation analysis parameters of the shell and the rotor shaft of the servo motor in the step (2);
(7) establishing a geometric configuration of the servo motor according to the statics simulation analysis parameters of the servo motor shell and the rotor shaft determined in the step (2) and the step (6), and performing statics finite element simulation on the servo motor shell and the rotor shaft to obtain the statics force bearing characteristics of the servo motor, wherein the statics force bearing characteristics comprise stress strain cloud charts of the shell and the rotor shaft under the condition of being pulled and pressed by the maximum bearing force;
(8) judging whether the stress-strain cloud picture of the shell or the rotor shaft obtained in the step (7) exceeds the required limit stress condition, if so, returning to the step (2) to reset the static simulation parameters of the shell or the rotor shaft, and if not, performing the step (11);
(9) determining thermal characteristic simulation parameters of the servo motor and the geometric configuration established in the step (6) according to the step (3) while the step (7) is carried out, and carrying out servo motor thermal characteristic simulation finite element analysis to obtain thermal protection characteristics of the servo motor, wherein the thermal protection characteristics comprise a thermal distribution cloud chart of the servo motor;
(10) judging whether the maximum temperatures of the stator, the rotor, the shell and the rotor shaft of the servo motor in the servo motor heat distribution cloud picture obtained in the step (9) exceed the limit temperatures or not, if more than one of the maximum temperatures exceed the limit temperatures, returning to the step (3) to replace the materials of the parts exceeding the limit temperatures, and if the materials cannot be replaced, returning to the step (1) to re-determine the electromagnetic simulation analysis parameters of the stator and the rotor of the servo motor; if the limit temperature is not exceeded, performing step (11);
(11) electromagnetic simulation analysis parameters of a stator and a rotor of the servo motor, static simulation analysis parameters of a shell and a rotor shaft, and thermal characteristic simulation parameter records of the servo motor, which meet electromagnetic output characteristics, thermal protection characteristics and static bearing characteristics of the servo motor, are recorded to form a design scheme of the servo motor and are stored in a database.
2. The multidisciplinary joint simulation method for servo motor design according to claim 1, characterized in that: installation space size includes: the length, the width and the height are represented in a three-dimensional orthogonal coordinate system O-XYZ, namely a rectangular space, the length and the width are both positioned on an XY plane, and the height is along the positive direction of a Z axis;
electromagnetic simulation analysis parameters of a stator and a rotor of a servo motor comprise: the geometric parameters of the geometric shapes of the stator and the rotor of the servo motor and the simulation setting parameters of the finite element simulation of electromagnetism are defined, and the geometric parameters of the stator comprise: the stator comprises a stator outer diameter, a stator inner diameter, a stator length, a stator groove depth, a stator groove bottom width, a stator groove flaring depth, a stator groove opening width, a stator groove opening depth and a stator groove chamfer radius; the geometrical parameters of the rotor include: rotor outer diameter, rotor inner diameter, rotor length and permanent magnet thickness; the simulation setting parameters of the electromagnetic finite element simulation comprise: the simulation method comprises the following steps of stator material, rotor material, servo motor rotating speed, three-phase current expression, simulation step length and simulation time.
3. The multidisciplinary joint simulation method for servo motor design according to claim 2, characterized in that: the stator geometric parameter determining steps are as follows:
the Z-axis direction is defined as the axial direction of the servo motor, and the length L of the stator can be determined according to the height of the space sizeefInner diameter D of statorilObtained by the following formula:
in the formula, TeThe electromagnetic torque of the servo motor can be obtained from the torque and speed envelope curve with the unit of N.m, Bδ1The unit of the amplitude of the air gap flux density fundamental wave is T, and the value range is 0.95-1.05T; a is the effective value of the electrical load of the stator, the unit is A/cm, and the value range is 150-700A/cm;
the stator outer diameter can be determined according to the smaller of the length and the width of the space size, and the groove bottom width Bs is determined during the primary design of the servo motor2The value of (a) can be determined by the following formula;
Bs2＝2π*Dil/S
in the formula, S is the number of grooves and takes the value of a positive integer larger than 4; groove flaring width Bs1The width Bs of the groove bottom can be set during initial assignment20.25 times of the stator, the groove depth is smaller than the difference value between the stator outer diameter and the stator inner diameter, and other parameters including the groove flaring depth, the groove opening width, the groove opening depth and the groove chamfer radius can be assigned at will on the premise of ensuring the manufacturability and the geometric topological relation.
4. The multidisciplinary joint simulation method for servo motor design according to claim 2, characterized in that: the geometric parameter determination process of the rotor requires that: the length of the rotor is equal to that of the stator, and the thickness of the permanent magnet cannot exceed the inner diameter of the stator.
5. The multidisciplinary joint simulation method for servo motor design according to claim 2, characterized in that: the electromagnetic finite element simulation parameter determination method comprises the following steps:
the stator and rotor materials can be obtained from a material selection manual of a servo motor manufacturer;
the expression of the three-phase current comprises three variables of amplitude I, frequency f and phase angle phi;
in the formula, the subscript i represents A, B, C triphase;
according to a torque-speed envelope curve and an energy conservation law, under the condition of a given power supply voltage of the servo motor, the amplitude of the three-phase current can be obtained by the following formula:
I＝Tω/U
in the formula, U is voltage, T is torque, and omega is rotating speed;
the frequency of the three-phase current can be obtained by the following formula:
f＝np/60
in the formula, n is the rotating speed, the unit is revolution per minute, and p is the logarithm of the grade, namely half of the electromagnetic grade;
the phase angle difference between two three-phase currents is generally 120 °, and thus the expression of the three-phase currents can be expressed as
IA＝Isin(ft)
IB＝Isin(ft+π/3)
IC＝Isin(ft+2π/3)
The rotating speed of the servo motor is the speed of each working condition point of the torque and speed envelope curve, and the electromagnetic finite element simulation time generally takes the value
Electromagnetic finite element simulation step length
6. The multidisciplinary joint simulation method for servo motor design according to claim 5, characterized in that: the expression of the three-phase current is as follows:
Ii＝Isin(ft+φ)
in the formula, the subscript I represents A, B, C three phases, I is amplitude, f is frequency, and φ is phase angle.
7. The multidisciplinary joint simulation method for servo motor design according to claim 1, characterized in that: the static simulation parameters of the servo motor are the geometric parameters and static simulation setting parameters of a shell and a rotor shaft of a main bearing part of the servo motor, and the geometric parameters of the shell and the rotor shaft comprise: the length, width, height and wall thickness of the motor shell, and the parameters of the rotor shaft comprise the diameter and length of the motor shaft; the statics simulation setting parameters include: the young's modulus and poisson's ratio of the housing material, the magnitude of the force and the fixing surface and the force application surface of the housing, the young's modulus and poisson's ratio of the rotor shaft, the magnitude of the force and the fixing surface and the force application surface of the rotor shaft.
8. The multidisciplinary joint simulation method for servo motor design according to claim 1, characterized in that: the geometric parameter determination process of the shell and the rotor shaft is as follows: the sum of the length, the width, the height and the wall thickness of the motor shell is smaller than the size of the installation space and larger than the size of the servo motor stator; the diameter of the rotor shaft of the motor is smaller than the inner diameter of the rotor, the length of the rotor shaft is equal to the sum of the length of the stator and the length of the connecting piece, and the length of the connecting piece is obtained from a product manual of a manufacturer for consulting the connecting piece according to the maximum bearing capacity.
9. The multidisciplinary joint simulation method for servo motor design according to claim 1, characterized in that: the static simulation setting parameter determining process is as follows: young modulus and Poisson ratio of materials of the shell and the rotor shaft can be obtained from a product manual of a manufacturer, a fixing surface of the shell is the bottom of the shell, a stress surface is a bolt connection part, and force application is maximum bearing force required by motor design; the fixed surface of the rotor shaft is a contact surface with the rotor, the stress surface of the rotor shaft is a contact surface with the connecting piece, and the force application size is the maximum moment of the moment and speed envelope curve.
10. The multidisciplinary joint simulation method for servo motor design according to claim 1, characterized in that: the servo motor thermal simulation parameters comprise: the thermal conductivity and surface emissivity of the shell, the stator, the rotor and the rotor shaft of the servo motor, the initial environment temperature and the simulation time; the initial environment temperature is-40-60 ℃, the simulation time is the working time of the servo motor, and the thermal conductivity and the surface emissivity can be obtained from a product material manual of a motor manufacturer.
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