High-precision NVH simulation analysis method for permanent magnet synchronous motor

Abstract

The invention discloses a high-precision NVH (Noise Vibration and Harshness) simulation analysis method for a permanent magnet synchronous motor, which relates to the field of motor simulation and comprises a motor manufacturing process based on a finite element method, combining a modal test result and a rack vibration test result and integrating a motor winding end part pouring sealant and a motor end cover joint surface sealant. Performing high-precision NVH simulation analysis on the permanent magnet synchronous motor; wherein the stator assembly needs to be preheated to the working temperature before testing, and it is ensured that the internal temperature of the stator assembly is at the working temperature at the moment when testing is started; the method further comprises the following steps: establishing a structural finite element model of the stator assembly before testing; in the structural finite element model of the stator assembly, a grid model specifically comprises a silicon steel sheet of a stator, wherein the silicon steel sheet is stretched into a hexahedral grid by adopting a two-dimensional plane grid; the winding layer is formed by stretching a two-dimensional plane grid into a hexahedral grid, and one layer of grid at the two ends of the winding grid is taken as an end winding.

Description

Technical Field

[0001] This application relates to the field of motor simulation, and in particular to high-precision NVH simulation analysis methods for permanent magnet synchronous motors, electronic devices, storage media, and motor simulation platforms. Background Technology

[0002] Against the backdrop of electrification, the market share of pure electric vehicles is increasing year by year. Compared with traditional fuel vehicles, electric vehicles do not have engines and intake and exhaust systems, resulting in significantly reduced in-vehicle noise. However, the drive motor is prone to generating high-frequency vibration noise, which is particularly prominent due to the absence of the masking effect of engine noise and its frequency falling within the sensitive range of the human ear, severely affecting driving comfort. Whether in the early NVH development stage of the motor or the later NVH optimization stage, the most economical approach is to conduct motor NVH simulation. However, this requires high precision in the motor NVH simulation to accurately predict motor noise.

[0003] Patent document 1 (CN 108920761 A) discloses a simulation calculation method for electromagnetic vibration and noise of a switched reluctance motor. By obtaining electromagnetic force, obtaining modal parameters, and applying the modal superposition method and boundary element method, the electromagnetic vibration and electromagnetic noise of the motor are obtained. However, it is only applicable to switched reluctance motors and not to permanent magnet synchronous motors.

[0004] Patent document 2 (CN 109214125 B) discloses a method for calculating the electromagnetic vibration noise of a motor. Through electromagnetic finite element and structural finite element simulations, it analytically calculates the electromagnetic resultant force on the stator teeth, the transfer function of the motor's mechanical structure, and the frequency response functions corresponding to each mode of the structure. Further analytical calculations yield the motor's vibration velocity and acceleration. Combined with the modal acoustic radiation efficiency of the motor housing, the radiated sound power level and sound pressure level of the motor are finally calculated analytically. However, the simulation model was not compared and calibrated with test results, resulting in uncertainty in its accuracy.

[0005] Patent document 3 (CN 112560302 A) discloses a simulation calculation method for electromagnetic noise of a permanent magnet synchronous motor under acceleration conditions. It calculates the electromagnetic noise of the motor at steady-state speed through simulation and finally obtains a color map of the permanent magnet synchronous motor under acceleration conditions through data processing. However, the simulation model was not compared and calibrated with test results during the process, resulting in uncertainty in the accuracy of the simulation model.

[0006] Patent document 4 (CN 113343540 B) discloses a method for calculating electromagnetic noise during acceleration and deceleration of a permanent magnet synchronous motor. It calculates the resultant radial and tangential electromagnetic forces on the stator teeth at different speed points, performs a Fourier transform on the resultant forces, extracts the corresponding order forces, and synthesizes them to simulate electromagnetic noise during acceleration and deceleration. However, the simulation model was not compared and calibrated with test results during the process, resulting in uncertainty in the accuracy of the simulation model.

[0007] Patent document 5 (CN 116992709 A) discloses a simulation method for motor vibration and noise under rotor eccentricity conditions. Compared with the aforementioned patent, this invention incorporates the consideration that "under rotor eccentricity conditions, the electromagnetic force experienced by the rotor assembly is the main source of vibration and noise excitation," making the entire simulation process more consistent with reality. However, the simulation model was not compared and calibrated with test results during the process, resulting in uncertainty in the accuracy of the simulation model.

[0008] Patent document 6 (CN 112749499 B) discloses a simulation method for rapidly diagnosing the NVH performance of a motor structure. By setting a unit force excitation, the vibration response curve of the motor under a preset loading mode is obtained. However, since the excitation does not match reality, the actual vibration results of the motor cannot be simulated. Furthermore, the simulation model is not compared and calibrated with the test results, resulting in uncertainty in the accuracy of the simulation model.

[0009] Patent document 7 (CN 118780182 B) discloses a simulation method for noise of a multi-speed motor. For a sample dataset, noise simulation is performed using an acoustic transfer vector solution scheme and a fast solution scheme to obtain a classification model. The classification model outputs classification results, indicating the optimal solution scheme. Then, a simulation module is used to perform multi-speed noise simulation on the optimal solution scheme, improving computational efficiency. However, the simulation model is not compared and calibrated with test results during the process, resulting in uncertainty in the accuracy of the simulation model.

[0010] Based on this technical background, a high-precision NVH simulation analysis method for permanent magnet synchronous motors was developed. Specifically addressing the core requirement of uncertainty in the accuracy of simulation models, this method is based on the finite element method, combined with modal test results and bench vibration test results, and comprehensively considers the actual manufacturing processes of the motor, such as the potting compound at the motor winding ends and the sealant at the motor end cover joint surface, to achieve high-precision NVH simulation analysis of permanent magnet synchronous motors.

[0011] This method can simulate and analyze the radiated noise of the optimized prototype before the prototype is manufactured and tested, predict the effect of motor noise optimization, reduce the number of test verifications, help designers optimize the motor, and solve the motor howling problem. Summary of the Invention

[0012] The purpose of this invention is to provide a high-precision NVH simulation analysis method, electronic equipment, storage medium, and motor simulation platform for permanent magnet synchronous motors, which at least solves one technical problem in the problems of stator assembly finite element model calibration, surface vibration response computer calibration, and determining process methods to improve NVH simulation analysis.

[0013] This invention provides the following solution:

[0014] According to a first aspect of the present invention, a high-precision NVH simulation analysis method for a permanent magnet synchronous motor is provided, comprising:

[0015] Based on the finite element method, combined with modal test results and bench vibration test results, and taking into account the motor manufacturing process of the motor winding end potting compound and the motor end cover joint surface sealant, a high-precision NVH simulation analysis of the permanent magnet synchronous motor is performed.

[0016] Before testing, the stator assembly must be preheated to the operating temperature to ensure that the internal temperature of the stator assembly is at the operating temperature at the moment the test begins.

[0017] This also includes establishing a structural finite element model of the stator assembly before testing;

[0018] The structural finite element model of the stator assembly specifically includes:

[0019] The silicon steel sheet core of the stator is made by stretching a two-dimensional planar grid into a hexahedral grid;

[0020] The winding layer is made by stretching a two-dimensional planar mesh into a hexahedral mesh, wherein one layer of mesh at both ends of the winding mesh is taken as the end winding;

[0021] The winding insulation paper mesh located between the winding and the stator slot is only one layer, wherein the insulation paper, the winding, and the stator silicon steel sheet core are treated as coplanar and common nodes;

[0022] Based on the potting compound at the end of the motor winding, the grid of the potting compound at the end of the winding is divided, using a tetrahedral grid;

[0023] Based on the grid of the end winding potting compound, the contact surfaces between the potting compound and the stator core are treated to be coplanar and have common nodes.

[0024] The housing adopts a tetrahedral grid, and the contact surfaces with the stator core and end winding potting are treated with coplanar and common node treatment;

[0025] Except for the stator silicon steel sheets, the structural damping of other metal components of the motor adopts an empirical value of 0.05;

[0026] The density, Young's modulus, and structural damping parameters of each component of the motor were determined through an optimization process.

[0027] Electromagnetic force is not output to the intermediate nodes of higher-order structured meshes, but is only mapped to first-order structured meshes;

[0028] The joint surface of the motor end cover uses a tie connection, and the bolt connection diameter of the end cover is set to twice the bolt size.

[0029] Furthermore, based on the finite element method, combined with modal test results and bench vibration test results, and taking into account the motor manufacturing process of the motor winding end potting compound and the motor end cover joint surface sealant, a high-precision NVH simulation analysis of the permanent magnet synchronous motor is conducted, including:

[0030] The steps for modal testing and finite element model calibration, electromagnetic force calculation and mapping, shell surface vibration response calculation and calibration, and radiated noise calculation.

[0031] The steps of modal testing and finite element model calibration include preheating the stator assembly to the operating temperature, performing free modal testing, and obtaining the modal frequencies and corresponding mode shapes and modal damping of each order; it also includes obtaining the frequency response function and coherence.

[0032] Furthermore, the modal testing and finite element model calibration steps also include:

[0033] A finite element model of the stator assembly structure is pre-established, and the material, properties and modal solution parameters are set for each component;

[0034] Among them, the end potting compound of the motor winding includes, based on the density uncertainty of the end winding and the end winding potting compound, measuring the physical mass of the stator core + winding and the stator core + winding + end winding potting compound + shell respectively, adjusting the density of the end winding and the end winding potting compound so that the physical mass and the simulation model mass are close to the preset order of magnitude.

[0035] Furthermore, the modal testing and finite element model calibration steps also include:

[0036] The optimization process includes designing a DOE test scheme based on the uncertainty of Young's modulus of stator silicon steel core, winding, end winding potting and winding insulation paper, according to the range of Young's modulus values, and performing modal simulation calculations to obtain a set of modal simulation results.

[0037] Based on the modal simulation results set, with the goal of minimizing the deviation between the simulated and experimental values ​​of the modal frequencies of the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator, multi-objective optimization software was used to perform multi-objective optimization and find the Pareto front to find the optimal solution for each Young's modulus.

[0038] The optimization process also includes designing a DOE test scheme based on the uncertainty of the structural damping of the end winding potting compound, winding insulation paper, and stator silicon steel sheet core, according to the range of values ​​of the structural damping, and performing complex modal analysis to obtain a set of complex modal analysis results.

[0039] Based on the complex modal analysis results set, with the goal of minimizing the deviation between the simulated and experimental values ​​of the structural damping of the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator, multi-objective optimization software was used to perform multi-objective optimization and find the Pareto front to find the optimal solution for each structural damping.

[0040] After optimization, the finite element model is calibrated to obtain the optimal combination of material parameters, which is used to give the modal simulation model of the stator assembly the preset high-precision characteristics.

[0041] Further steps in the electromagnetic force calculation and mapping include:

[0042] A two-dimensional electromagnetic simulation model was established, and the electromagnetic forces under multiple steady-state conditions were calculated using the nodal force method.

[0043] Electromagnetic forces of various orders in the frequency domain are extracted from electromagnetic forces under steady-state conditions.

[0044] The direct mapping method is used to map the electromagnetic forces of each order on the fine electromagnetic grid of the stator to the coarse finite element grid of the stator.

[0045] Among them, the origin position is adjusted before electromagnetic force mapping so that the stator electromagnetic mesh model and the stator structural finite element mesh model are in the same position;

[0046] Electromagnetic force is not output to the intermediate nodes of higher-order structured meshes, but is only mapped to first-order structured meshes.

[0047] Further steps for calculating and calibrating the vibration response of the housing surface include:

[0048] First, the vibration velocity response of the finite element model of the motor assembly structure after loading an order electromagnetic force is calculated using the modal superposition method. Second, the measured values ​​of the order vibration velocity at the vibration measurement points on the surface of the motor housing under the same operating conditions on the test bench are compared with the obtained simulated values ​​of the order vibration, and the peak values ​​of each vibration are compared.

[0049] Based on the comparison results of each vibration peak value, the finite element model was calibrated, including adjusting the connection method and bolt connection diameter in the simulation model.

[0050] Further steps in calculating radiated noise include:

[0051] First, the vibration velocity results from the shell surface vibration response calculation and calibration steps need to be exported as a load file as the excitation input for acoustic calculations.

[0052] Next, the finite element mesh of the motor assembly structure is imported into the acoustic simulation software for acoustic mesh generation, and the sound field mesh is defined.

[0053] It also includes setting up calculation control and submitting the calculation to obtain the radiated noise results for each order.

[0054] According to a second aspect of the present invention, an electronic device is provided, comprising: a processor, a communication interface, a memory, and a communication bus, wherein the processor, the communication interface, and the memory communicate with each other via the communication bus;

[0055] The memory stores a computer program, which, when executed by the processor, causes the processor to perform the steps of a high-precision NVH simulation analysis method for permanent magnet synchronous motors.

[0056] According to a third aspect of the present invention, a computer-readable storage medium is provided, storing a computer program executable by an electronic device, which, when run on the electronic device, causes the electronic device to perform the steps of a high-precision NVH simulation analysis method for a permanent magnet synchronous motor.

[0057] According to a fourth aspect of the present invention, a motor simulation platform is provided, comprising:

[0058] Electronic equipment, steps for implementing a high-precision NVH simulation analysis method for permanent magnet synchronous motors;

[0059] The processor runs a program, and when the program runs, it executes the steps of a high-precision NVH simulation analysis method for permanent magnet synchronous motors based on data output from electronic devices.

[0060] Storage medium for storing programs that, when running, execute steps of a high-precision NVH simulation analysis method for permanent magnet synchronous motors based on data output from electronic devices.

[0061] The above solution achieves the following beneficial technical effects:

[0062] This application, through the actual NVH optimization effect of the optimization scheme, only requires modal test and bench vibration test data of a basic prototype to achieve accurate modeling of the motor NVH simulation model, quickly predict the NVH performance level of different optimization schemes of the motor, and eliminate the experimental verification work of intermediate optimization schemes.

[0063] This application achieves high-precision NVH simulation of permanent magnet synchronous motors through a process method for calibrating the motor assembly modal simulation model and a vibration response calibration method.

[0064] This application obtains the optimal combination of material parameters through a parameter optimization process of density, Young's modulus, and structural damping of each component, thereby enabling the stator assembly modal simulation model to have high accuracy.

[0065] This application uses sealant to seal the end cap mating surface. Some areas of the mating surface need to be connected by a tie. The bolt connection diameter of the end cap is set to twice the bolt size (the equivalent diameter of the bolt hole = 2 × the nominal diameter of the bolt) to reduce the difference in vibration peak value.

[0066] This application performs free modal testing on the stator assembly after heating at operating temperature, so that the solid simulation is close to the actual operating conditions, obtains the modal frequencies and corresponding mode shapes and modal damping of each order, and obtains the frequency response function and coherence, thereby reducing simulation deviation. Attached Figure Description

[0067] Figure 1 This is a flowchart of a high-precision NVH simulation analysis method for permanent magnet synchronous motors provided by one or more embodiments of the present invention.

[0068] Figure 2 This is a schematic diagram of a simulation analysis process provided in a specific embodiment of the present invention.

[0069] Figure 3 This is a schematic diagram of a motor assembly model provided in a specific embodiment of the present invention.

[0070] Figure 4 This is a block diagram of an electronic device structure for a high-precision NVH simulation analysis method for permanent magnet synchronous motors provided by one or more embodiments of the present invention. Detailed Implementation

[0071] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0072] Figure 1 This is a flowchart of a high-precision NVH simulation analysis method for permanent magnet synchronous motors provided by one or more embodiments of the present invention.

[0073] like Figure 1 The high-precision NVH simulation analysis method for permanent magnet synchronous motors shown includes:

[0074] Step A1: Based on the finite element method, combined with modal test results and bench vibration test results, and taking into account the motor manufacturing process of the motor winding end potting compound and the motor end cover joint surface sealant, a high-precision NVH simulation analysis is performed on the permanent magnet synchronous motor.

[0075] Step A2: Before testing, the stator assembly must be preheated to the operating temperature to ensure that the internal temperature of the stator assembly is at the operating temperature at the moment the test begins.

[0076] Step A3: Establish a structural finite element model of the stator assembly before testing;

[0077] Step A4, the finite element model of the stator assembly specifically includes:

[0078] Step A40: The silicon steel sheet core of the stator is stretched into a hexahedral mesh using a two-dimensional planar mesh;

[0079] Step A41: The winding layer is stretched from a two-dimensional planar mesh into a hexahedral mesh, wherein one layer of mesh at each end of the winding mesh is taken as the end winding.

[0080] Step A42: The winding insulation paper mesh located between the winding and the stator slot is only one layer, wherein the insulation paper, the winding, and the stator silicon steel sheet core are treated as coplanar and common nodes;

[0081] Step A43: Based on the potting compound at the end of the motor winding, divide the grid of the potting compound at the end of the winding into tetrahedral grids.

[0082] Step A44: Based on the grid of the end winding potting compound, the contact surfaces between the potting compound and the stator core are treated to be coplanar and have common nodes.

[0083] Step A45: The housing adopts a tetrahedral mesh, and the contact surfaces with the stator core and end winding potting are treated with coplanar and common node treatment;

[0084] Step A46: Except for the stator silicon steel sheet core, the structural damping of other metal components of the motor adopts an empirical value of 0.05;

[0085] Step A47: The density, Young's modulus, and structural damping parameters of each component of the motor are determined through an optimization process.

[0086] In step A48, the electromagnetic force is not output to the intermediate nodes of the higher-order structure mesh, but is only mapped to the first-order structure mesh.

[0087] Step A49: The joint surface area of ​​the motor end cover is connected by a Tie connection, and the bolt connection diameter of the end cover is set to twice the bolt size.

[0088] Specifically, in one particular embodiment, such as Figure 2 The simulation analysis process shown includes:

[0089] First, a free modal test of the stator assembly is required. Before the test, the stator assembly must be heated to the operating temperature to ensure that the internal temperature of the stator assembly is also at the operating temperature. Then, the free modal test is performed to obtain the frequency of each mode, the corresponding mode shape, and the modal damping. At the same time, the frequency response function and coherence are obtained. Simultaneously, the physical mass of the stator core + winding and the stator core + winding + end winding potting compound + housing are measured.

[0090] Then, a structural finite element model of the stator assembly is established, where the requirements for the mesh model are as follows:

[0091] 1. The stator silicon steel sheet is stretched into a hexahedral mesh using a 2D planar (two-dimensional) mesh.

[0092] 2. The number of winding layers is determined according to the actual situation, using a 2D planar mesh stretched into a hexahedral mesh. One layer from each end of the winding mesh is taken as the end winding.

[0093] 3. The winding insulation paper mesh has only one layer, located between the winding and the stator slots. The insulation paper, winding, and stator core are treated as coplanar and share nodes.

[0094] 4. Based on the actual potting method, divide the end winding potting compound into a grid using a tetrahedral grid. The contact surfaces between the potting compound and the stator core are treated to be coplanar and have common nodes.

[0095] 5. The housing adopts a tetrahedral mesh, and the contact surfaces with the stator core and end winding potting are treated with coplanar and common node treatment.

[0096] By setting the material parameters of each component and adjusting the density of the end winding and the potting compound, the actual mass is made equal to the mass of the simulation model.

[0097] Empirical ranges for the Young's modulus of the stator silicon steel sheets, windings, end winding potting, and winding insulation paper were determined, with the stator silicon steel sheets considered as isotropic materials. Based on these empirical ranges, DOE (Design of Experiments) test schemes were designed, and modal simulation calculations of the stator assembly were performed for each scheme. Based on the modal simulation result set, the optimization objective was to minimize the deviation between the simulated and experimental values ​​of the modal frequencies of the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator. Multi-objective optimization software was used to perform multi-objective optimization to find the Pareto front and the optimal solution for each Young's modulus (the Pareto front exists in multi-objective optimization problems, and these objectives are "mutually conflicting").

[0098] The empirical range of structural damping values ​​for the end winding potting compound, winding insulation paper, and stator silicon steel sheets was determined, while the empirical value of 0.05 was adopted for the structural damping of other metal components. Based on the above range of structural damping values, a DOE test scheme was designed, and complex modal analysis was performed. Based on the complex modal analysis result set, the optimization objective was to minimize the deviation between the simulated and experimental values ​​of the structural damping for the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator. Multi-objective optimization software was used to perform multi-objective optimization, find the Pareto front, and locate the optimal solution for each structural damping.

[0099] Then, a mesh model of the motor end cover is created, using a tetrahedral mesh, which is assembled with the previously created stator assembly mesh. Bolt connections use RBE2 connection elements. (RBE2 (Rigid Body Element 2) is a commonly used rigid connection element in finite element software (such as Nastran, ABAQUS, etc.). Essentially, it defines a "master node" and several "slave nodes," forcing the slave nodes to follow the master node's movement (displacement and rotation are completely consistent), with no relative deformation between them, equivalent to a "rigid connection." The master node is the "control node" of the rigid element; the movement of the slave nodes is entirely determined by the master node, and forces and torques are transmitted through the master node.)

[0100] A two-dimensional electromagnetic simulation model was then established in electromagnetic simulation software. The nodal force method was used to calculate the electromagnetic forces under multiple steady-state conditions, with a steady-state point taken at 500 rpm intervals. The electromagnetic forces of various orders in the frequency domain were extracted from the steady-state electromagnetic forces. A direct mapping method was used to map these orders from the fine electromagnetic mesh of the stator to the coarse finite element mesh of the stator structure. Before mapping the electromagnetic forces, the origin position must be adjusted so that the stator electromagnetic mesh model and the structural finite element mesh model are in the same position. Crucially, the electromagnetic forces cannot be output to the intermediate nodes of higher-order structural meshes; they can only be mapped to first-order structural meshes. Major orders, such as the 48th order, of electromagnetic forces were mapped to the stator structural mesh.

[0101] The vibration velocity response of the finite element model of the motor assembly structure after loading an order electromagnetic force is calculated using the modal superposition method. The measured values ​​of the order vibration velocity at vibration measurement points on the motor housing surface under the same operating conditions on a test bench are compared with the obtained simulated values ​​to compare the peak values. If there are significant differences in the peak vibration values, the mode shape corresponding to that peak frequency needs to be identified. Based on the actual manufacturing process, the connection method of the area with the largest displacement change in that mode shape needs to be adjusted. The end cover mating surfaces are sealed with sealant. In this case, some areas of the mating surfaces need to be connected using a tie connection. The bolt connection diameter of the end cover is set to twice the bolt size (bolt hole equivalent diameter = 2 × bolt nominal diameter) (e.g., Figure 3The motor assembly model shown is illustrated with brown for the end caps, green for the housing, and red for the connecting flanges.

[0102] The vibration velocity results of the node set on the surface of the motor assembly housing, calculated using the above vibration response, are exported as a load file and used as the excitation input for acoustic calculations. Using acoustic simulation software, the finite element mesh of the motor assembly structure is imported into the software for acoustic mesh generation. Then, the sound field mesh is defined, and the calculation control settings are configured and the calculation is submitted to obtain the radiated noise results for each order.

[0103] In this embodiment, based on the finite element method, combined with modal test results and bench vibration test results, and taking into account the motor manufacturing process of the motor winding end potting compound and the motor end cover joint surface sealant, a high-precision NVH simulation analysis of the permanent magnet synchronous motor is performed, including:

[0104] The steps for modal testing and finite element model calibration, electromagnetic force calculation and mapping, shell surface vibration response calculation and calibration, and radiated noise calculation.

[0105] The steps of modal testing and finite element model calibration include preheating the stator assembly to the operating temperature, performing free modal testing, and obtaining the modal frequencies and corresponding mode shapes and modal damping of each order; it also includes obtaining the frequency response function and coherence.

[0106] In this embodiment, the modal testing and finite element model calibration steps further include:

[0107] A finite element model of the stator assembly structure is pre-established, and the material, properties and modal solution parameters are set for each component;

[0108] Among them, the end potting compound of the motor winding includes, based on the density uncertainty of the end winding and the end winding potting compound, measuring the physical mass of the stator core + winding and the stator core + winding + end winding potting compound + shell respectively, adjusting the density of the end winding and the end winding potting compound so that the physical mass and the simulation model mass are close to the preset order of magnitude.

[0109] In this embodiment, the modal testing and finite element model calibration steps further include:

[0110] The optimization process includes designing a DOE test scheme based on the uncertainty of Young's modulus of stator silicon steel core, winding, end winding potting and winding insulation paper, according to the range of Young's modulus values, and performing modal simulation calculations to obtain a set of modal simulation results.

[0111] Based on the modal simulation results set, with the goal of minimizing the deviation between the simulated and experimental values ​​of the modal frequencies of the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator, multi-objective optimization software was used to perform multi-objective optimization and find the Pareto front to find the optimal solution for each Young's modulus.

[0112] The optimization process also includes designing a DOE test scheme based on the uncertainty of the structural damping of the end winding potting compound, winding insulation paper, and stator silicon steel sheet core, according to the range of values ​​of the structural damping, and performing complex modal analysis to obtain a set of complex modal analysis results.

[0113] Based on the complex modal analysis results set, with the goal of minimizing the deviation between the simulated and experimental values ​​of the structural damping of the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator, multi-objective optimization software was used to perform multi-objective optimization and find the Pareto front to find the optimal solution for each structural damping.

[0114] After optimization, the finite element model is calibrated to obtain the optimal combination of material parameters, which is used to give the modal simulation model of the stator assembly the preset high-precision characteristics.

[0115] Specifically, in one embodiment, a high-precision NVH simulation analysis method for permanent magnet synchronous motors based on experimental benchmarking includes modal testing and finite element model calibration, electromagnetic force calculation and mapping, shell surface vibration response calculation and calibration, and radiated noise calculation.

[0116] Furthermore, modal testing and finite element model calibration refer to performing free modal testing on the stator assembly after heating at the operating temperature to obtain the modal frequencies and corresponding mode shapes and modal damping of each order, while also obtaining the frequency response function and coherence. A finite element model of the stator assembly structure is established in the pre-processing software, and the materials, properties, and modal solution parameters are set for each component.

[0117] To address the uncertainty in the density of the end windings and the end winding potting compound, the actual mass of the stator core + winding and the stator core + winding + end winding potting compound + housing were measured respectively. The density of the end windings and the end winding potting compound was adjusted to make the actual mass equal to the mass of the simulation model.

[0118] To address the uncertainty of Young's modulus in stator silicon steel sheets, windings, end winding potting, and winding insulation paper, a Design of the DOE (Design of Experiments) test scheme was designed based on the range of Young's modulus values, and modal simulation calculations were performed. Based on the modal simulation result set, the optimization objective was to minimize the deviation between the simulated and experimental values ​​of the modal frequencies of the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator. Multi-objective optimization software was used to perform multi-objective optimization, find the Pareto front, and locate the optimal solution for each Young's modulus.

[0119] To address the uncertainties in the structural damping of the end winding potting compound, winding insulation paper, and stator silicon steel sheets, a Design of Experimental (DOE) test scheme was designed based on the range of structural damping values, and complex modal analysis was performed. Based on the complex modal analysis results set, the optimization objective was to minimize the deviation between the simulated and experimental values ​​of the structural damping for the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator. Multi-objective optimization software was used to perform multi-objective optimization, searching for the Pareto front and finding the optimal solution for each structural damping.

[0120] By calibrating through the above steps, the optimal combination of material parameters can be obtained, enabling the stator assembly modal simulation model to have high accuracy.

[0121] In this embodiment, the steps for electromagnetic force calculation and mapping include:

[0122] A two-dimensional electromagnetic simulation model was established, and the electromagnetic forces under multiple steady-state conditions were calculated using the nodal force method.

[0123] Electromagnetic forces of various orders in the frequency domain are extracted from electromagnetic forces under steady-state conditions.

[0124] The direct mapping method is used to map the electromagnetic forces of each order on the fine electromagnetic grid of the stator to the coarse finite element grid of the stator.

[0125] Among them, the origin position is adjusted before electromagnetic force mapping so that the stator electromagnetic mesh model and the stator structural finite element mesh model are in the same position;

[0126] Electromagnetic force is not output to the intermediate nodes of higher-order structured meshes, but is only mapped to first-order structured meshes.

[0127] Specifically, in one embodiment, electromagnetic force calculation and mapping refers to establishing a two-dimensional electromagnetic simulation model in electromagnetic simulation software, calculating the electromagnetic forces under multiple steady-state conditions using the nodal force method, extracting the electromagnetic forces of various orders in the frequency domain from the steady-state electromagnetic forces, and mapping the electromagnetic forces of various orders on the stator's fine electromagnetic mesh to the stator's coarse structural finite element mesh using the direct mapping method. Before mapping the electromagnetic forces, the origin position must be adjusted so that the stator electromagnetic mesh model and the structural finite element mesh model are in the same position. Crucially, the electromagnetic forces cannot be output to the intermediate nodes of higher-order structural meshes; they can only be mapped to first-order structural meshes.

[0128] In this embodiment, the steps for calculating and calibrating the vibration response of the housing surface include:

[0129] First, the vibration velocity response of the finite element model of the motor assembly structure after loading an order electromagnetic force is calculated using the modal superposition method. Second, the measured values ​​of the order vibration velocity at the vibration measurement points on the surface of the motor housing under the same operating conditions on the test bench are compared with the obtained simulated values ​​of the order vibration, and the peak values ​​of each vibration are compared.

[0130] Based on the comparison results of each vibration peak value, the finite element model was calibrated, including adjusting the connection method and bolt connection diameter in the simulation model.

[0131] Specifically, the vibration response calculation and calibration of the housing surface involves first calculating the vibration velocity response of the finite element model of the motor assembly structure after applying an order electromagnetic force using the modal superposition method. The measured values ​​of the order vibration velocities at vibration measurement points on the motor housing surface under the same operating conditions on a test bench are then compared with the obtained simulated values ​​to compare the peak values ​​of each vibration. For vibration measurement points on the surface of the motor cylindrical housing, after modal testing calibration, the simulation and experiment show good consistency. For vibration measurement points on the surface of the motor end cover, sealant is used between the mating surfaces of the resolver cover and the motor end cover, and between the motor end cover and the motor cylindrical housing, to meet sealing requirements. If the connection method between these mating surfaces is not handled properly, there will be a significant difference between the simulated and experimental vibration peak values ​​at the end cover surface vibration measurement points, which will seriously affect the accuracy of subsequent noise simulation results. For this type of connection method involving sealant, the connection method and bolt diameter in the simulation model can be adjusted according to the actual manufacturing process to ensure consistency between simulation and testing.

[0132] In this embodiment, the steps for calculating radiated noise include:

[0133] First, the vibration velocity results from the shell surface vibration response calculation and calibration steps need to be exported as a load file as the excitation input for acoustic calculations.

[0134] Next, the finite element mesh of the motor assembly structure is imported into the acoustic simulation software for acoustic mesh generation, and the sound field mesh is defined.

[0135] It also includes setting up calculation control and submitting the calculation to obtain the radiated noise results for each order.

[0136] Specifically, in one embodiment, the radiated noise calculation first requires exporting the vibration velocity results of the node set on the surface of the motor assembly housing from the vibration response calculation as a load file, which serves as the excitation input for the acoustic calculation. Using acoustic simulation software, the finite element mesh of the motor assembly structure is imported into the software for acoustic mesh generation. Then, the sound field mesh is defined, followed by calculation control settings and submission of the calculation to obtain the radiated noise results for each order.

[0137] In one specific embodiment, the steps of a high-precision NVH simulation analysis method for permanent magnet synchronous motors are disclosed:

[0138] Step S1: Obtain test data of the permanent magnet synchronous motor basic prototype, including modal test data and bench vibration test data of the basic prototype;

[0139] Step S2: Based on the structural parameters of the basic prototype, establish an initial modal simulation model of the motor assembly. Compare the simulated modal parameters of the initial modal simulation model with the measured modal parameters in the modal test data. Adjust the structural parameters of the initial modal simulation model until the error between the simulated modal parameters and the measured modal parameters meets the preset modal error threshold, and obtain the calibrated modal simulation model of the motor assembly.

[0140] Step S3: Based on the calibrated motor assembly modal simulation model, establish an initial vibration response simulation model. Compare the simulated vibration response data of the initial vibration response simulation model with the measured vibration response data in the bench vibration test data. Optimize the connection method of the initial vibration response simulation model until the error between the simulated vibration response data and the measured vibration response data meets the preset vibration error threshold, and obtain the calibrated vibration response simulation model.

[0141] Step S4: Based on the calibrated motor assembly modal simulation model and the calibrated vibration response simulation model, perform NVH simulation analysis on the target optimization scheme of the permanent magnet synchronous motor, and output the NVH performance prediction results of the target optimization scheme.

[0142] In step S2 of this embodiment, the modal test data includes the natural frequencies, mode shapes, and modal damping ratios of the basic prototype;

[0143] The simulation modal parameters include the natural frequencies, mode shapes, and modal damping ratios calculated from the initial modal simulation model;

[0144] Adjusting the structural parameters of the initial modal simulation model specifically involves adjusting the material elastic modulus, material density, or connection stiffness between motor components of the motor housing.

[0145] In step S3 of this embodiment, the bench vibration test data includes vibration velocity data and vibration acceleration data of the basic prototype at different steady-state speeds in the range of 500-12000 rpm;

[0146] The simulated vibration response data includes the vibration velocity simulation data and vibration acceleration simulation data of the initial vibration response simulation model at the corresponding steady-state rotational speed;

[0147] The connection method for optimizing the initial vibration response simulation model specifically includes the connection method of the motor adhesive joint surface and the diameter of the bolt connection.

[0148] In step S1 of this embodiment, the bench vibration test data is transmitted through the stator end cover of the basic prototype (e.g., Figure 3 (brown), casing (such as) Figure 3 The vibration data was collected by at least three vibration sensors installed on the green outer surface and the motor output shaft end.

[0149] Modal test data were collected using the impact test method.

[0150] In step S4 of this embodiment, the target optimization scheme includes optimization of motor stator slot shape, optimization of rotor magnetic pole auxiliary slot tangential offset, optimization of motor housing thickness, or optimization of stator winding method.

[0151] The NVH performance prediction results include the motor radiated sound power level, near-field sound pressure level, and vibration acceleration level at key measurement points.

[0152] In this embodiment, the preset modal error threshold in step S2 is that the relative error between the simulated modal parameters and the measured modal parameters does not exceed 5%.

[0153] In this embodiment, the preset vibration error threshold in step S3 is that the relative error between the simulated vibration response data and the measured vibration response data does not exceed 8%.

[0154] In this embodiment, finite element analysis software is used to establish the initial modal simulation model and the initial vibration response simulation model.

[0155] The finite element analysis software can be any one of ANSYS, ABAQUS, or COMSOL Multiphysics; and when establishing the initial modal simulation model, the mesh size of the motor housing and stator core should not exceed 2mm, and the mesh size of the rotor components should not exceed 3mm.

[0156] Figure 4 This is a block diagram of an electronic device structure for a high-precision NVH simulation analysis method for permanent magnet synchronous motors provided by one or more embodiments of the present invention.

[0157] like Figure 4 As shown, this application provides an electronic device, including: a processor, a communication interface, a memory, and a communication bus, wherein the processor, the communication interface, and the memory communicate with each other through the communication bus;

[0158] The memory stores a computer program, which, when executed by the processor, causes the processor to perform the steps of a high-precision NVH simulation analysis method for permanent magnet synchronous motors.

[0159] This application also provides a computer-readable storage medium storing a computer program executable by an electronic device, which, when run on the electronic device, causes the electronic device to perform the steps of a high-precision NVH simulation analysis method for permanent magnet synchronous motors.

[0160] This application also provides a motor simulation platform, including:

[0161] Electronic equipment, steps for implementing a high-precision NVH simulation analysis method for permanent magnet synchronous motors;

[0162] The processor runs a program, and when the program runs, it executes the steps of a high-precision NVH simulation analysis method for permanent magnet synchronous motors based on data output from electronic devices.

[0163] Storage medium for storing programs that, when running, execute steps of a high-precision NVH simulation analysis method for permanent magnet synchronous motors based on data output from electronic devices.

[0164] The communication bus mentioned in the above electronic devices can be a Peripheral Component Interconnect (PCI) bus or an Extended Industry Standard Architecture (EISA) bus, etc. This communication bus can be divided into address bus, data bus, control bus, etc. For ease of illustration, only one thick line is used to represent it in the diagram, but this does not mean that there is only one bus or one type of bus.

[0165] The electronic device comprises a hardware layer, an operating system layer running on top of the hardware layer, and an application layer running on the operating system. The hardware layer includes hardware such as a central processing unit (CPU), a memory management unit (MMU), and memory. The operating system can be any one or more computer operating systems that control the electronic device through processes, such as Linux, Unix, Android, iOS, or Windows. Furthermore, in this embodiment of the invention, the electronic device can be a smartphone, tablet computer, or other handheld device, or a desktop computer, portable computer, or other electronic device; there is no particular limitation in this embodiment.

[0166] In this embodiment of the invention, the executing entity for electronic device control can be an electronic device itself, or a functional module within an electronic device capable of calling and executing a program. The electronic device can obtain the firmware corresponding to the storage medium. This firmware is provided by the supplier, and different storage media may have the same or different firmware; no limitation is made here. After obtaining the firmware corresponding to the storage medium, the electronic device can write this firmware into the storage medium; specifically, it burns the firmware corresponding to the storage medium into the storage medium. The process of burning the firmware into the storage medium can be implemented using existing technology, and will not be elaborated upon in this embodiment of the invention.

[0167] Electronic devices can also obtain reset commands corresponding to the storage media. The reset commands corresponding to the storage media are provided by the supplier. The reset commands corresponding to different storage media can be the same or different, and no restrictions are imposed here.

[0168] At this time, the storage medium of the electronic device is a storage medium on which the corresponding firmware has been written. The electronic device can respond to the reset command corresponding to the storage medium on which the corresponding firmware has been written, thereby resetting the storage medium on which the corresponding firmware has been written according to the reset command. The process of resetting the storage medium according to the reset command can be implemented by existing technology and will not be described in detail in this embodiment of the invention.

[0169] For ease of description, the above devices are described separately by function as various units and modules. Of course, in implementing this application, the functions of each unit and module can be implemented in one or more software and / or hardware.

[0170] It will be understood by those skilled in the art that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have the meaning consistent with their meaning in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless specifically defined.

[0171] For the sake of simplicity, the method embodiments are described as a series of actions. However, those skilled in the art should understand that the embodiments of the present invention are not limited to the described order of actions, because according to the embodiments of the present invention, some steps can be performed in other orders or simultaneously. Furthermore, those skilled in the art should also understand that the embodiments described in the specification are preferred embodiments, and the actions involved are not necessarily essential to the embodiments of the present invention.

[0172] As can be seen from the above description of the embodiments, those skilled in the art can clearly understand that this application can be implemented by means of software plus necessary general-purpose hardware platforms. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in various embodiments or some parts of the embodiments of this application.

[0173] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A high-precision NVH simulation analysis method for permanent magnet synchronous motors, characterized in that, The high-precision NVH simulation analysis method for permanent magnet synchronous motors includes: Based on the finite element method, combined with modal test results and bench vibration test results, and taking into account the motor manufacturing process of the motor winding end potting compound and the motor end cover joint surface sealant, a high-precision NVH simulation analysis of the permanent magnet synchronous motor is performed. Before testing, the stator assembly must be preheated to the operating temperature to ensure that the internal temperature of the stator assembly is at the operating temperature at the moment the test begins. This also includes establishing a structural finite element model of the stator assembly before testing; The finite element model of the stator assembly structure specifically includes: The silicon steel sheet core of the stator is made by stretching a two-dimensional planar grid into a hexahedral grid; The winding layer is made by stretching a two-dimensional planar mesh into a hexahedral mesh, wherein one layer of mesh at both ends of the winding mesh is taken as the end winding; The winding insulation paper mesh located between the winding and the stator slot is only one layer, wherein the insulation paper, the winding, and the stator silicon steel sheet core are treated as coplanar and common nodes; Based on the potting compound at the end of the motor winding, the grid of the potting compound at the end of the winding is divided, using a tetrahedral grid; Based on the grid of the end winding potting compound, the contact surfaces between the potting compound and the stator core are treated to be coplanar and have common nodes. The housing adopts a tetrahedral grid, and the contact surfaces with the stator core and end winding potting are treated with coplanar and common node treatment; Except for the stator silicon steel sheets, the structural damping of other metal components of the motor adopts an empirical value of 0.05; The density, Young's modulus, and structural damping parameters of each component of the motor were determined through an optimization process. Electromagnetic force is not output to the intermediate nodes of higher-order structured meshes, but is only mapped to first-order structured meshes; The joint surface of the motor end cover uses a tie connection, and the bolt connection diameter of the end cover is set to twice the bolt size.

2. The high-precision NVH simulation analysis method for permanent magnet synchronous motors according to claim 1, characterized in that, The high-precision NVH simulation analysis of the permanent magnet synchronous motor, based on the finite element method, combined with modal test results and bench vibration test results, and taking into account the motor manufacturing process of the motor winding end potting compound and the motor end cover joint surface sealant, includes: The steps for modal testing and finite element model calibration, electromagnetic force calculation and mapping, shell surface vibration response calculation and calibration, and radiated noise calculation. The modal testing and finite element model calibration steps include preheating the stator assembly to the operating temperature, performing free modal testing, and obtaining the modal frequencies and corresponding mode shapes and modal damping of each order; it also includes obtaining the frequency response function and coherence.

3. The high-precision NVH simulation analysis method for permanent magnet synchronous motors according to claim 2, characterized in that, The modal testing and finite element model calibration steps also include: A finite element model of the stator assembly structure is pre-established, and the material, properties and modal solution parameters are set for each component; Among them, the end potting compound of the motor winding includes, based on the density uncertainty of the end winding and the end winding potting compound, measuring the physical mass of the stator core + winding and the stator core + winding + end winding potting compound + shell respectively, adjusting the density of the end winding and the end winding potting compound so that the physical mass and the simulation model mass are close to the preset order of magnitude.

4. The high-precision NVH simulation analysis method for permanent magnet synchronous motors according to claim 3, characterized in that, The modal testing and finite element model calibration steps also include: The optimization process includes designing a DOE test scheme based on the uncertainty of Young's modulus of stator silicon steel core, winding, end winding potting and winding insulation paper, according to the range of Young's modulus values, and performing modal simulation calculations to obtain a set of modal simulation results. Based on the modal simulation results set, with the goal of minimizing the deviation between the simulated and experimental values ​​of the modal frequencies of the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator, multi-objective optimization software was used to perform multi-objective optimization and find the Pareto front to find the optimal solution for each Young's modulus. The optimization process also includes designing a DOE test scheme based on the uncertainty of the structural damping of the end winding potting compound, winding insulation paper, and stator silicon steel sheet core, according to the range of values ​​of the structural damping, and performing complex modal analysis to obtain a set of complex modal analysis results. Based on the complex modal analysis results set, with the goal of minimizing the deviation between the simulated and experimental values ​​of the structural damping of the 0th, 2nd, 3rd, and 4th order cylindrical modes of the stator, multi-objective optimization software was used to perform multi-objective optimization and find the Pareto front to find the optimal solution for each structural damping. After optimization, the finite element model is calibrated to obtain the optimal combination of material parameters, which is used to give the modal simulation model of the stator assembly the preset high-precision characteristics.

5. The high-precision NVH simulation analysis method for permanent magnet synchronous motors according to claim 1, characterized in that, The steps for electromagnetic force calculation and mapping include: A two-dimensional electromagnetic simulation model was established, and the electromagnetic forces under multiple steady-state conditions were calculated using the nodal force method. Electromagnetic forces of various orders in the frequency domain are extracted from electromagnetic forces under steady-state conditions. The direct mapping method is used to map the electromagnetic forces of each order on the fine electromagnetic grid of the stator to the coarse finite element grid of the stator. Among them, the origin position is adjusted before electromagnetic force mapping so that the stator electromagnetic mesh model and the stator structural finite element mesh model are in the same position; Electromagnetic force is not output to the intermediate nodes of higher-order structured meshes, but is only mapped to first-order structured meshes.

6. The high-precision NVH simulation analysis method for permanent magnet synchronous motors according to claim 1, characterized in that, The steps for calculating and calibrating the vibration response of the housing surface include: First, the vibration velocity response of the finite element model of the motor assembly structure after loading an order electromagnetic force is calculated using the modal superposition method. Second, the measured values ​​of the order vibration velocity at the vibration measurement points on the surface of the motor housing under the same operating conditions on the test bench are compared with the obtained simulated values ​​of the order vibration, and the peak values ​​of each vibration are compared. Based on the comparison results of each vibration peak value, the finite element model was calibrated, including adjusting the connection method and bolt connection diameter in the simulation model.

7. The high-precision NVH simulation analysis method for permanent magnet synchronous motors according to claim 1, characterized in that, The steps for calculating the radiated noise include: First, the vibration velocity results from the calculation and calibration of the vibration response of the shell surface need to be exported as a load file as the excitation input for acoustic calculation. Next, the finite element mesh of the motor assembly structure is imported into the acoustic simulation software for acoustic mesh generation, and the sound field mesh is defined. It also includes setting up calculation control and submitting the calculation to obtain the radiated noise results for each order.

8. An electronic device, characterized in that, include: The processor, communication interface, memory, and communication bus are connected, with the processor, communication interface, and memory communicating with each other via the communication bus. The memory stores a computer program, which, when executed by a processor, causes the processor to perform the steps of the high-precision NVH simulation analysis method for permanent magnet synchronous motors as described in any one of claims 1 to 7.

9. A computer-readable storage medium, characterized in that, The device stores a computer program executable by an electronic device, which, when run on the electronic device, causes the electronic device to perform the steps of the high-precision NVH simulation analysis method for permanent magnet synchronous motors as described in any one of claims 1 to 7.

10. A motor simulation platform, characterized in that, include: An electronic device for implementing the steps of the high-precision NVH simulation analysis method for permanent magnet synchronous motors as described in any one of claims 1 to 7; The processor runs a program that, when the program is running, executes the steps of the high-precision NVH simulation analysis method for permanent magnet synchronous motors as described in any one of claims 1 to 7 from the data output by the electronic device. A storage medium for storing a program that, when running, performs the steps of the high-precision NVH simulation analysis method for permanent magnet synchronous motors as described in any one of claims 1 to 7 on data output from an electronic device.

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