This chapter aims to offer the reader an introduction to setting up a lumped parameter model. It is often the engineer’s task to set up a model that enables the representation of a given system. An abstraction effort is therefore required, and the representation of the model to be set up will have a level of detail that depends on the type of excitation and on the intended objective. This chapter draws on an example of an electric fan power drive. It presents deduction approaches that progressively increase model complexity until achieving the intended phenomenon, as well as model reduction approaches that enable the selection of the main elements from an initially complex model.
On completing this chapter, the reader is expected to:
This chapter aims to provide the reader with an introduction to setting up simulation models. Chapter 2 focused on the fundamental laws governing:
For the examples that have already been studied, the elementary effects and the values of the corresponding parameters were known. Here, the aim is to determine the elementary effects to be considered for the representation of the phenomenon to be studied. As will be seen, the model to be set up depends, in particular, not only on the system’s topology but also on the type of excitations it will undergo and on the objective of the study.
The approach taken here to set up an adapted model can be described as follows:
In order to illustrate these various concepts, a guideline example will be used throughout this chapter: the starting of a high-power electric fan. This type of electric fan is present in some cooling towers of electric power plants (Figure 3.1). The coolant is the endpoint of the cooling circuit in which heated water is cooled by an ascending flow of cool air. These induced flow cooling towers [HAM 18] tend to replace the classical atmospheric cooling towers of power plants, on the grounds of visual impact and control flexibility.
As shown in Figure 3.2, the electric fan located at the top of the tower includes an induction motor, a driveshaft, a reducer, and the fan blades. The motor is directly connected to the network through power contactors and protection elements. It has no variable speed drive and, therefore, runs in steady state at a fixed speed, except when starting. As the remainder of this chapter highlights, a poor model choice may lead to undersizing during the selection of components and explain, for example, the possible short service life of the reducers employed in such applications.
Simulation models can be more or less precise, depending on the type of excitation:
The electrical example in Figure 3.3 illustrates the possibility to use more or less detailed representations depending on the frequency and type of excitation. Here the objective is to simulate the current absorbed by the load depending on the applied voltage. It is worth noting that for low- or high-frequency voltages, the diagram can be simplified while the absorbed current is accurately represented. The response of the simplified diagrams is always compared in the graphics (Figure 3.3.d and f, superposed red and blue curves) with that of the complete diagram.
As a first step in the modeling process, a table may be used in the systematic search for effects to consider in the overall representation of the system. Table 3.1, represented below, has three columns: the first one for components or subsets to be represented, the second one indicating the domain (mechanics/electricity/…) to which these components belong, and the last one to indicate the source/transformer, storage or dissipative effects that may be identified. The choice of the latter effects requires analytical skills that the reader may acquire by solving the small exercises suggested at the end of the chapter.
Table 3.1. Systematic analysis of effects
Main and parasitic effects | ||||
System component or subset | Domain | Source or transformer | Energy storage | Dissipation |
Electric network | Electricity | Voltage source | ||
Electric motor | Electricity and mechanics (rotation) | Electromechanical transformer | Winding inductance Rotor inertia |
Winding resistance Bearing friction |
Driveshaft | Mechanics (rotation) | Inertia, shaft stiffness | Internal damping | |
Reducer | Mechanics (rotation) | Reduction ratio | Pinion inertia, tooth stiffness | Reducer efficiency |
Fan | Mechanics (rotation) | Source of aerodynamic forces (function of rotational speed) | Blades inertia |
As noted earlier, the simplest model often includes only the device transformer and dissipative effects. The latter may have nonlinearities that are beyond the scope of this chapter. Chapter 6 will show how the nonlinearities of certain transformer effects in mechanics (nonlinear kinematics) or in electrical engineering (electromagnet) can be modeled. A more detailed model should integrate energy storage elements. The analysis of the geometric and material configuration of the device may help in finding the dominant effects. A mechanical system such as the electrical fan requires the identification of the main inertias and elasticities of the device.
In the rotational domain, under the action of a torque, inertia limits acceleration and elasticity causes angular deformation. It is therefore important to identify the elements with significant inertia and those with low stiffness. Unlike the software tools for distributed parameter modeling, which rely, for example, on finite elements, and make it possible to directly represent a geometry close to reality, lumped parameter modeling requires additional abstraction. For a shaft composed of cylinder elements, inertia and stiffness can be approximated by the following formulae:
Hence, a driveshaft with a small diameter and a significant length has low inertia and low stiffness; therefore, only stiffness is retained for its modeling. The motor rotor with the most significant diameter will be represented by inertia.
Figure 3.4 shows a simplified 3D geometric representation of the fan/rotor/driveshaft set and its equivalent in 0D/1D modeling. This lumped parameter representation assumes that reducer inertia and elasticity are negligible (particularly with respect to motor inertia and driveshaft elasticity).
Table 3.2 presents a summary over various domains of the expressions of parameters associated with elementary geometries. The reader can use it to refine the analytical skills required to recognize these effects.
As described in the Introduction, these effects will be added in ascending order of complexity. The objective is to determine the mechanical actions through the shaft upon the start to validate the choice of components, particularly that of the reducer. The aim is to determine the model that meets the basic requirements for understanding the dominant interactions.
The deductive approach progressively refines the model until reaching the appropriate level: the components are first represented by their ideal operational behavior, and imperfections are added to represent the phenomena with increasingly small time constants. For the case study considered here, the objective is to represent the torques through the reducer to explain the particularly small service lifetimes observed in practice. Figure 3.5 presents these increasingly complex modeling levels:
Figure 3.6 shows the simulation results for the torque and the speed on the high-speed axis of the reducer for a), b), and c) modeling levels in Figure 3.5. It can be noted that the results in steady state at constant speed are similar for all modeling levels. Nevertheless, during the start, the maximal torque depends significantly on the chosen model. Considering inertias facilitates the representation of a starting torque surge due to the torque–speed characteristic of the induction motor. The model that takes into account the driveshaft stiffness generates an even stronger transient torque. It, therefore, seems that the representation of the mechanical resonance mode is essential. This mode is excited by the sudden rise in motor torque upon direct connection to the electrical network, as well as by the negative damping characteristic of the first part of the torque/speed curve of the induction motor. Chapter 5 provides the mathematical tools for analyzing these phenomena. The last level d) in Figure 3.5 (not represented here) provides no additional information for this maximal torque. The model that is just sufficient here is, therefore, c) level in Figure 3.5.
The previous section has highlighted torques oscillating with high amplitudes during the start. They require very strong oversizing of the reducer with respect to the torque to be provided in the steady state. Even the use of a 4 or 5 safety factor cannot avoid rapid deterioration of the reducer if the designer uses only model a) in Figure 3.5 to select this component. These usage constraints can be limited if resonance mode excitation is avoided. This requires the use of a starting torque that has no sudden discontinuity. This progressive starting can be obtained by driving the induction motor at variable speed by means of a static converter. This costly electronics device offers the additional function of a speed that can be controlled in the steady state for accurate control of the electric power plant operation.
The high starting torque of an induction motor can be reduced if a sloped speed profile with no discontinuity is applied by a speed control unit. Figure 3.7 shows the corresponding model in which a speed control unit can be represented by a Proportional Integral (PI) controller or by inverse simulation. Figure 3.8 shows the simulation results for these models.
Inverse simulation avoids the need to design the controller with the expected performance by imposing a zero error directly between the set-point and the actual speed. The two models produce the same results. Figure 3.8 shows that the maximal torque applied to the reducer has a much lower value in this case compared to the previous architecture. Torque oscillations are also significantly reduced.
The next question to be addressed is whether it is possible to reduce model complexity while preserving an acceptable prediction in view of the reducer choice. Generally speaking, the model reduction approach starts with a very detailed model and preserves only the elements with the strongest influence on the response of the model. Literature [ERS 08] classifies the reduction techniques into approaches based on the frequency behavior and analyses based on energy. Only energy-based methods are studied here, as they can be directly applied to the lumped parameter without needing to determine the frequency representation (transfer function) or the state space (matrix) of the models. Chapter 5 illustrates the use of these latter representations. Energy-based techniques assume that the components that weigh the most in the precise modeling of a system are characterized by the largest amplitudes of energy flow. This amplitude, which is also known as the activity of an element or component, results from the integration of the absolute value of the power flowing through it over a specific time window and for a specific input. Therefore, the activity of an element Ai is defined as follows:
where e and f are power variables (effort and flow) and characteristics of the element such as force/speed in mechanics and voltage/current in electricity.
This measure, proposed by L. S. Louca [LOU 98], is directly involved in certain environments such as AMESim. In Modelica environments, it can be implemented in the form of sensors as shown in Figure 3.9. These sensors have been used for measuring the activities of inertia and stiffness in Figures 3.5.c and 3.6. The various activities (all positive) are then compared in percentage with their total sum in Table 3.3. It is worth noting that the activity of the driveshaft stiffness decreases particularly starting with an electronic speed controller. It, therefore, seems possible to eliminate the stiffness element from the diagram. Figure 3.10 compares the simulations of torque and speed on the high-speed driveshaft by considering or neglecting this stiffness. Speed profiles are superimposed. In the absence of the shaft stiffness, the low-amplitude oscillations disappeared from the response of the direct starting. Since the model involves only inertias, it could be sufficient for the selection of the reducer or for making an HIL simulator of the physical system.
Table 3.3. Activity index of the models with and without a controller
Direct starting on the network by contactors | Controller-based starting (10 s of speed rise) | |
Fan inertia | 46.7% | 87.7% |
Driveshaft stiffness | 9% | 0.3% |
Motor inertia | 44.3% | 12% |
Although interesting, the activity index approach is not always implemented in a standard manner in multi-physics modeling software. Therefore, it may be quite difficult to implement, requiring specific additional sensors. Other analysis techniques are nevertheless available.
The first relies on Design of Experiments (DoE) [MON 17] and on the sensitivity analysis of simulation models. Many platforms propose parameter variation tools that can be used to estimate the effect of one or several parameters. The simple approach used here involves a disturbance applied according to a method referred to as One at a Time [ELM 05]. The model in Figure 3.7 is simulated for rated values of the motor inertia parameters, fan inertia, and driveshaft stiffness and their 10% variation. The torque on the high-speed axis of the reducer is then displayed, as shown in Figure 3.11, for various experiments. For this problem, the most influential parameter is fan inertia. It can also be noted that motor inertia has a small influence on the reducer torque. In fact, control imposes motor speed, and torque transients are functions only of the driveshaft stiffness and of the blade inertia. It can also be noted that stiffness variation has a very small effect on maximal torque.
The last approach presented here does not require any tool or simulation. It involves a direct comparison of the values of parameters to evaluate their importance in the problem at hand. This may require the determination of the equivalent parameters, as illustrated in Figure 3.12 for fan inertia. An equivalent parameter can be determined around a power transformer component as follows:
The introduction of speed and torque on the high-speed axis (index HS) gives:
which highlights the equivalent inertia on the high-speed axis:
Generally speaking, the equivalent parameter reveals the squared transformation ratio of the transformer. The transformer can connect different domains, as an electric motor connects electrical and mechanical domains, and reveals parameters of various natures, such as inductance or capacitance.
The equivalent fan inertia calculated here on the high-speed axis of the reducer is 11.72 kg.m2, which is more than that of the motor, 1.72 kg.m2. But model simplification requires, first of all, the evaluation of the importance of the presence of stiffness K of the driveshaft and particularly its possible interaction before the equivalent inertia. It can be quantified by the resonance frequency calculated here assuming that the potential effect of motor inertia is neutralized by speed control:
which here is 1.4 Hz. Depending on the spectral diversity of the speed profile, which can be controlled by the second-order filter located upstream of the speed set point, this resonance mode can be excited. Figure 3.13 illustrates two different cases, below and above 1.4 Hz, and shows the advantage of using a filtered speed set point to avoid resonance mode excitation. In this latter case, the effect of the driveshaft elasticity can be neglected when sizing the reducer.
The exercises in this section are designed as an introduction to setting up models with lumped parameters. Multi-physics modeling requires the formulation of modeling hypotheses that may sometimes be quite strong, but enable capturing the main effects to be represented. In contrast to the previous chapter, the effects and parameters are not given: they must be determined based on the textual or geometric description of the devices.
Lumped parameter modeling involves abstraction and choice of the main effects to be represented. Therefore, it requires knowledge of the considered domains. Table 3.2 summarizes, for elementary geometries, the storage and dissipative effects and the expressions of the associated parameters.
Table 3.4. Multiple-choice table corresponding to question 1
Domain | Effect | |||||||
Electricity | Mechanics T | Mechanics R | Hydraulics | Heat transfer | C a) | I b) | R c) | |
a | b | c | d | e | f | g | h | |
1. Conductive elements separated by a dielectric. | ||||||||
2. Surfaces in contact and in relative motion. | ||||||||
3. Massive rigid body. | ||||||||
4. Long wire of small cross-sectional area. | ||||||||
5. Poor heat conductor volume of low density. | ||||||||
6. Set of many conductive turns in a small volume. | ||||||||
7. Pipe blocked at one end and subjected to increasing pressure at the other end. | ||||||||
8. Heavy mass of uniform temperature. | ||||||||
9. Light body with a temperature gradient. | ||||||||
10. Large diameter rotating part. | ||||||||
11. Deformable blade. | ||||||||
12. Long pipe of small cross-sectional area. | ||||||||
13. Large volume of compressible fluid. |
The objective is to help the reader develop his or her analytical skills required to identify these effects.
NOTE.– C, I, or R are notations used for the elementary effects, as employed in the bond-graph approach that will be presented in Chapter 4. C and I effects or elements store the energy. With the exception of heat transfer, the R element dissipates energy in the form of heat. An I element stores energy in a state variable representing motion or speed (mechanical speed, electric current, hydraulic flow rate, etc.) while a C element stores energy in a static state variable (force, voltage, pressure, etc.).
The ideal behavior of many power transmission components is assimilated to a transformer effect that does not store nor degrade the transferred energy. They are characterized by a set of two equations connecting the power variables.
An ideal direct current motor is modeled by a set of equations:
with:
Table 3.5. Table to be filled corresponding to question 4
DC Elec | |||||
AC Elec | |||||
Mecha T | |||||
Mecha R | |||||
Hydro | |||||
DC Elec | AC Elec | Mecha T | Mecha R | Hydro |
Figure 3.17 describes the implementation and the general and detailed architecture of a Renault Twingo electric power steering.
Figure 3.18 shows the Modelica diagram modeling this power steering.
Direct injection systems by common rail use piezoelectric or electromagnetic injectors to enable the very precise control of the quantity and chronology of fuel injection in each cylinder of an internal combustion engine. This type of injector is electrically controlled, therefore software can be embedded in this technology. A direct injection system with common rail, represented in Figure 3.20, is composed of a low-pressure fuel boosting pump followed by a high-pressure pump, driven by the motor, which fuels the common rail; a pressure relief valve, which controls the common rail pressure; a hydraulic accumulator, known as common rail, which constitutes a high-pressure fuel reserve for the injectors; and an injector per cylinder, playing the role of electro-hydraulically controlled valves.
V150, a special TGV high-speed train, has set a speed record of 574.8 km/h on the railway on April 3, 2007, on East Paris–Strasbourg line. The previous record of 513.3 km/h had been achieved in 1990. The test train, schematically shown in Figure 3.21, included on that occasion TGV POS power cars (TGV Est lines, POS for Paris – Ostfrankreich – Süddeutschland), AGV (from the French Automotrice à Grande Vitesse, self-propelled carriages), and high-speed rail motor cars, and was expected to exceed 150 m/s (or 540 km/h).
AGV rail motor cars have bogies (Figure 3.22) powered by permanent magnet synchronous motors. Each motor has a nominal power of 700 kW and has been used during a short-term overload at 1 MW to break the speed record. An electric motor can significantly degrade if heat due to Joule losses induces very high temperatures in the winding insulation. A thermal model will be built to estimate the maximum overload time of these motors.
Nominal motor characteristics at 700 kW are as follows:
An electric power steering has a torque sensor located on the steering shaft between the steering wheel and the electric assistance motor drive. The electric motor torque is controlled depending on the torque provided by the driver and measured by this sensor. The objective of this problem is to analyze a sensor employing magnetic technology, which enables torque measurement without contacting a rotating shaft.
Figure 3.24 shows a cross-sectional view of the torque sensor of Twingo electric power steering. This sensor has three parts:
The electromagnetic part has two windings (A and B), each inducing a magnetic field in a magnetic circuit partially made of rings A and B connected to the steering shaft. Figure 3.25 shows an axisymmetric 2D finite element magnetic simulation of the winding/ring set A. The magnetic field lines represent the direction of the magnetic field . Their density expresses field intensity. In what follows, our modeling will ignore the magnetic field lines in the form of a quarter of a circle constituting the leakage flux of the magnetic circuit. The magnetic flux ? can be calculated by integration of the magnetic field over a surface:
Several laws can be used for magnetic circuit modeling:
It is possible to represent the behavior of a magnetic circuit using laws similar to Kirchhoff’s laws. The equivalent of the electric current is magnetic flux.
Figure 3.27 describes the global model of the torque sensor. It includes three domains: mechanical on the left part, magnetic for components A and B, and electronic/signal for the rest. Component A corresponds to Figure 3.26.
Diesel (non-nuclear) attack submarines often have a diesel-electric propelling system with generators driven by diesel motors and an electric motor that directly drives only one propeller. Battery recharge by diesel engines must be done just below the surface (periscope). Figure 3.28 shows some of these components such as alternators or the propulsion motor on the synthetic diagram in Figure 3.29.
The objective in the following is to implement the transient simulation enabling the calculation of the short-circuit torque of the electric motor. This situation is a sizing scenario for the driveshaft and makes it possible to verify that its integrity is preserved during an attack that may cause an electric failure.
The shaft line presented in Figure 3.30 transfers mechanical power from the electric motor to the propeller. Its main components are an electric motor, a hollow shaft, a seal, bearings, and end-stops enabling thrust transfer from the propeller to the submarine structure.
In what follows, the hypotheses used are:
Electric motor | |
Rated torque | 1.75.105 N.m |
Rated speed | 120 rpm |
Rated voltage | 700 V |
Resistance | 8 mΩ |
Inductance | 20 mH |
Rotor inertia | 3.103 kg.m2 |
Viscous friction | 10 N.m/(rad.s−1) |
Mass | 45 tonnes |
Propeller | |
Diameter | 6 m |
Mass | 41 tons |
Inertia | 150.103 kg.m2 |
Shaft | |
Diameter | 25 cm |
Length | 4.5 m |
Stiffness | 6.5.106 N.m/rad |
Inertia | 20 kg.m2 |
Viscous friction equivalent to internal damping | 25,000 N.m/(rad.s−1) |
Seal | |
Dry friction torque | 9000 N.m |
3. For a better understanding of the origin of this transient, the most important components to be preserved must be identified without significantly altering the simulation results. Suggest a model analysis and simplification approach for this purpose. After implementation, identify the nature of the components generating this transient torque.
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