一个BLDC仿真结果与实际电机数据不符，求助各位大神。问题出在哪里可以帮我看看。

青鸟飞鱼

以下是基于RMxprt我自己做的一个BLDC的仿真，电机的原始数据为48V 、60W、8P、12槽、4000RPM 、0.145NM、1.6A、反电动势系数6.35Vrms/kRPM、电阻1.8Ω、电感1.9mH，
但我的仿真结果如下，效率很低，铜耗较高，问题出在哪里，而且额定转速也不正确，有哪位大神可以帮我看看。谢谢。   



      BRUSHLESS PERMANENT MAGNET DC MOTOR DESIGN

                      File: Setup1.res


     GENERAL DATA

Rated Output Power (kW):        0.06
Rated Voltage (V):        48
Number of Poles:        8
Given Rated Speed (rpm):        4000
Frictional Loss (W):        7
Windage Loss (W):        0
Rotor Position:        Inner
Type of Load:        Constant Power
Type of Circuit:        L3
Lead Angle of Trigger in Elec. Degrees:        0
Trigger Pulse Width in Elec. Degrees:        120
One-Transistor Voltage Drop (V):        0
One-Diode Voltage Drop (V):        0
Operating Temperature (C):        75
Maximum Current for CCC (A):        0
Minimum Current for CCC (A):        0


     STATOR DATA

Number of Stator Slots:        12
Outer Diameter of Stator (mm):          56
Inner Diameter of Stator (mm):          30

Type of Stator Slot:        3
Stator Slot       
            hs0 (mm):          1
            hs1 (mm):          2.15
            hs2 (mm):          6.4
            bs0 (mm):          2.52
            bs1 (mm):          6.22
            bs2 (mm):          9.72
            rs (mm):          0.65

Top Tooth Width (mm):          3.35963
Bottom Tooth Width (mm):          3.29177
Skew Width (Number of Slots)        0

Length of Stator Core (mm):          28
Stacking Factor of Stator Core:        0.95
Type of Steel:        D23_50
Designed Wedge Thickness (mm):          2.15
Slot Insulation Thickness (mm):          0
Layer Insulation Thickness (mm):          0
End Length Adjustment (mm):          0
Number of Parallel Branches:        4
Number of Conductors per Slot:        454
Type of Coils:        21
Average Coil Pitch:        1
Number of Wires per Conductor:        1
Wire Diameter (mm):          0.19
Wire Wrap Thickness (mm):          0.04
Slot Area (mm^2):        69.0602
Net Slot Area (mm^2):        57.1447
Limited Slot Fill Factor (%):        75
Stator Slot Fill Factor (%):        42.0277
Coil Half-Turn Length (mm):          41.0961


     ROTOR DATA

Minimum Air Gap (mm):          0.5
Inner Diameter (mm):          8
Length of Rotor (mm):          28
Stacking Factor of Iron Core:        0.95
Type of Steel:        D23_50
Polar Arc Radius (mm):          14.5
Mechanical Pole Embrace:        0.9
Electrical Pole Embrace:        0.856917
Max. Thickness of Magnet (mm):          2.75
Width of Magnet (mm):          9.27752
Type of Magnet:        NdFe35
Type of Rotor:        1
Magnetic Shaft:        No


     PERMANENT MAGNET DATA

Residual Flux Density (Tesla):        1.23
Coercive Force (kA/m):        890
Maximum Energy Density (kJ/m^3):        273.675
Relative Recoil Permeability:        1.09981
Demagnetized Flux Density (Tesla):        0.88624
Recoil Residual Flux Density (Tesla):        1.23
Recoil Coercive Force (kA/m):        890

     MATERIAL CONSUMPTION

Armature Copper Density (kg/m^3):          8900
Permanent Magnet Density (kg/m^3):          7400
Armature Core Steel Density (kg/m^3):          7820
Rotor Core Steel Density (kg/m^3):          7820

Armature Copper Weight (kg):          0.0564969
Permanent Magnet Weight (kg):          0.0422906
Armature Core Steel Weight (kg):          0.192916
Rotor Core Steel Weight (kg):          0.0797665
Total Net Weight (kg):          0.37147

Armature Core Steel Consumption (kg):          0.609362
Rotor Core Steel Consumption (kg):          0.114728


     STEADY STATE PARAMETERS

Stator Winding Factor:        0.866025
D-Axis Reactive Inductance Lad (H):        0.000636432
Q-Axis Reactive Inductance Laq (H):        0.000636432
D-Axis Inductance L1+Lad(H):        0.00288636
Q-Axis Inductance L1+Laq(H):        0.00288636
Armature Leakage Inductance L1 (H):        0.00224993
Zero-Sequence Inductance L0 (H):        0.000258732
Armature Phase Resistance R1 (ohm):        3.56992
Armature Phase Resistance at 20C (ohm):        2.93655
D-Axis Time Constant (s):        0.000178276
Q-Axis Time Constant (s):        0.000178276

Ideal Back-EMF Constant KE (Vs/rad):        0.151202
Start Torque Constant KT (Nm/A):        0.149694
Rated Torque Constant KT (Nm/A):        0.129209


     NO-LOAD MAGNETIC DATA

Stator-Teeth Flux Density (Tesla):        2.01548
Stator-Yoke Flux Density (Tesla):        1.42623
Rotor-Yoke Flux Density (Tesla):        0.555156
Air-Gap Flux Density (Tesla):        0.781827
Magnet Flux Density (Tesla):        0.925428

Stator-Teeth By-Pass Factor:        0.036558
Stator-Yoke By-Pass Factor:        6.87595e-005
Rotor-Yoke By-Pass Factor:        2.0285e-005

Stator-Teeth Ampere Turns (A.T):        204.274
Stator-Yoke Ampere Turns (A.T):        5.14705
Rotor-Yoke Ampere Turns (A.T):        0.413689
Air-Gap Ampere Turns (A.T):        396.433
Magnet Ampere Turns (A.T):        -606.049

Armature Reactive Ampere Turns
  at Start Operation (A.T):        146.115
Leakage-Flux Factor:        1
Correction Factor for Magnetic
  Circuit Length of Stator Yoke:        0.350499
Correction Factor for Magnetic
  Circuit Length of Rotor Yoke:        0.785806

No-Load Speed (rpm):        3056.65
Cogging Torque (N.m):        0.213669


     FULL-LOAD DATA

Average Input Current (A):        1.78035
Root-Mean-Square Armature Current (A):        0.719412
Armature Thermal Load (A^2/mm^3):        65.9484
Specific Electric Loading (A/mm):        10.3964
Armature Current Density (A/mm^2):        6.34338
Frictional and Windage Loss (W):        4.70456
Iron-Core Loss (W):        15.1538
Armature Copper Loss (W):        5.54288
Transistor Loss (W):        0
Diode Loss (W):        0
Total Loss (W):        25.4012
Output Power (W):        60.0558
Input Power (W):        85.457
Efficiency (%):        70.276

Rated Speed (rpm):        2688.32
Rated Torque (N.m):        0.213327

Locked-Rotor Torque (N.m):        2.99678
Locked-Rotor Current (A):        20.1311


     WINDING ARRANGEMENT

The 3-phase, 2-layer winding can be arranged in 3 slots as below:

ABC


Angle per slot (elec. degrees):        120
Phase-A axis (elec. degrees):        60
First slot center (elec. degrees):        0



     TRANSIENT FEA INPUT DATA

For Armature Winding:
  Number of Turns:        908
  Parallel Branches:        4
  Terminal Resistance (ohm):        3.56992
  End Leakage Inductance (H):        2.83884e-005
2D Equivalent Value:
  Equivalent Model Depth (mm):        28
  Equivalent Stator Stacking Factor:        0.95
  Equivalent Rotor Stacking Factor:        0.95
  Equivalent Br (Tesla):        1.23
  Equivalent Hc (kA/m):        890
Estimated Rotor Moment of Inertia (kg m^2):        1.51651e-005

土豆烧洋芋

这就是个错误  转速就一半多一点  磁密高低不均匀

mfkfnaps

供参考，
线圈匝数减小近1半，线径加大近3个线号，计算下试试，如果方向是对的，你可以反复多次调整直到达到你自己满意的效果;
空载转速低于负载转速不正常，提高转速可以减叠片或减线圈匝数。

mfkfnaps

没注意楼主的是实际电机与模拟不符，还以为楼主要调整设计呢，以下供参考。
可以从以下几个方面着手,以下是你设定的参数
Type of Load:        Constant Power
改为Liner,便于查看整体曲线及电流,效率等，易于调整
Operating Temperature (C):        75
操作温度，你实际电机一般不会在这个温度去进行测试，应该是室温，你可以改为25试试
Frictional Loss (W):        7
损失你的设定都11.7%，是否合理，也可以再考虑
二极管压降
没看到该参数，你是设定成0.3还是0.7
三极管压降
没看到该参数，你是设定成0.3还是0.2
48V是电你实际产品的电源电压还是加到线圈后的电压，这个对转速也是有影响的
另外，RM没那么准确，为了快速计算的，结果参考下，要想计算的相对准确，最好还是用2D来算。

青鸟飞鱼

mfkfnaps 发表于 2017-8-10 08:58
供参考，
线圈匝数减小近1半，线径加大近3个线号，计算下试试，如果方向是对的，你可以反复多次调整直到达 ...

这是已经有产品的电机，采用0.19的线径，227匝，输出的额定数据为48V 、60W、8P、12槽、4000RPM 、0.145NM、1.6A、反电动势系数6.35Vrms/kRPM、电阻1.8Ω、电感1.9mH，我就是想仿真验证下，单输出结果跟额定数据相差很远，想找下问题原因。

青鸟飞鱼

mfkfnaps 发表于 2017-8-10 09:32
没注意楼主的是实际电机与模拟不符，还以为楼主要调整设计呢，以下供参考。
可以从以下几个方面着手,以下 ...

二极管和三极管我都没有设置，设置后也基本不变，温度也改到25℃了，至于7W损耗我这里有数据的，可见附件图片。为什么转速这么低呢，铜耗这么多，效率这么低，没找到原因，还有没有其他原因导致。下面是更改后的数据报告。

         BRUSHLESS PERMANENT MAGNET DC MOTOR DESIGN

                      File: Setup1.res


     GENERAL DATA

Rated Output Power (kW):        0.06
Rated Voltage (V):        48
Number of Poles:        8
Given Rated Speed (rpm):        4000
Frictional Loss (W):        6
Windage Loss (W):        0
Rotor Position:        Inner
Type of Load:        Constant Power
Type of Circuit:        L3
Lead Angle of Trigger in Elec. Degrees:        0
Trigger Pulse Width in Elec. Degrees:        120
One-Transistor Voltage Drop (V):        0.7
One-Diode Voltage Drop (V):        0.3
Operating Temperature (C):        75
Maximum Current for CCC (A):        0
Minimum Current for CCC (A):        0


     STATOR DATA

Number of Stator Slots:        12
Outer Diameter of Stator (mm):          56
Inner Diameter of Stator (mm):          30

Type of Stator Slot:        3
Stator Slot       
            hs0 (mm):          1
            hs1 (mm):          2.15
            hs2 (mm):          6.4
            bs0 (mm):          2.52
            bs1 (mm):          6.22
            bs2 (mm):          9.72
            rs (mm):          0.65

Top Tooth Width (mm):          3.35963
Bottom Tooth Width (mm):          3.29177
Skew Width (Number of Slots)        0

Length of Stator Core (mm):          28
Stacking Factor of Stator Core:        0.95
Type of Steel:        D23_50
Designed Wedge Thickness (mm):          2.15
Slot Insulation Thickness (mm):          0
Layer Insulation Thickness (mm):          0
End Length Adjustment (mm):          0
Number of Parallel Branches:        4
Number of Conductors per Slot:        454
Type of Coils:        21
Average Coil Pitch:        1
Number of Wires per Conductor:        1
Wire Diameter (mm):          0.19
Wire Wrap Thickness (mm):          0.04
Slot Area (mm^2):        69.0602
Net Slot Area (mm^2):        57.1447
Limited Slot Fill Factor (%):        75
Stator Slot Fill Factor (%):        42.0277
Coil Half-Turn Length (mm):          41.0961


     ROTOR DATA

Minimum Air Gap (mm):          0.5
Inner Diameter (mm):          8
Length of Rotor (mm):          28
Stacking Factor of Iron Core:        0.95
Type of Steel:        D23_50
Polar Arc Radius (mm):          14.5
Mechanical Pole Embrace:        0.9
Electrical Pole Embrace:        0.856917
Max. Thickness of Magnet (mm):          2.75
Width of Magnet (mm):          9.27752
Type of Magnet:        NdFe35
Type of Rotor:        1
Magnetic Shaft:        No


     PERMANENT MAGNET DATA

Residual Flux Density (Tesla):        1.23
Coercive Force (kA/m):        890
Maximum Energy Density (kJ/m^3):        273.675
Relative Recoil Permeability:        1.09981
Demagnetized Flux Density (Tesla):        0.887441
Recoil Residual Flux Density (Tesla):        1.23
Recoil Coercive Force (kA/m):        890

     MATERIAL CONSUMPTION

Armature Copper Density (kg/m^3):          8900
Permanent Magnet Density (kg/m^3):          7400
Armature Core Steel Density (kg/m^3):          7820
Rotor Core Steel Density (kg/m^3):          7820

Armature Copper Weight (kg):          0.0564969
Permanent Magnet Weight (kg):          0.0422906
Armature Core Steel Weight (kg):          0.192916
Rotor Core Steel Weight (kg):          0.0797665
Total Net Weight (kg):          0.37147

Armature Core Steel Consumption (kg):          0.609362
Rotor Core Steel Consumption (kg):          0.114728


     STEADY STATE PARAMETERS

Stator Winding Factor:        0.866025
D-Axis Reactive Inductance Lad (H):        0.000636432
Q-Axis Reactive Inductance Laq (H):        0.000636432
D-Axis Inductance L1+Lad(H):        0.00288636
Q-Axis Inductance L1+Laq(H):        0.00288636
Armature Leakage Inductance L1 (H):        0.00224993
Zero-Sequence Inductance L0 (H):        0.000258732
Armature Phase Resistance R1 (ohm):        3.56992
Armature Phase Resistance at 20C (ohm):        2.93655
D-Axis Time Constant (s):        0.000178276
Q-Axis Time Constant (s):        0.000178276

Ideal Back-EMF Constant KE (Vs/rad):        0.151133
Start Torque Constant KT (Nm/A):        0.149669
Rated Torque Constant KT (Nm/A):        0.130675


     NO-LOAD MAGNETIC DATA

Stator-Teeth Flux Density (Tesla):        2.01548
Stator-Yoke Flux Density (Tesla):        1.42623
Rotor-Yoke Flux Density (Tesla):        0.555156
Air-Gap Flux Density (Tesla):        0.781827
Magnet Flux Density (Tesla):        0.925428

Stator-Teeth By-Pass Factor:        0.036558
Stator-Yoke By-Pass Factor:        6.87595e-005
Rotor-Yoke By-Pass Factor:        2.0285e-005

Stator-Teeth Ampere Turns (A.T):        204.274
Stator-Yoke Ampere Turns (A.T):        5.14705
Rotor-Yoke Ampere Turns (A.T):        0.413689
Air-Gap Ampere Turns (A.T):        396.433
Magnet Ampere Turns (A.T):        -606.049

Armature Reactive Ampere Turns
  at Start Operation (A.T):        141.853
Leakage-Flux Factor:        1
Correction Factor for Magnetic
  Circuit Length of Stator Yoke:        0.350499
Correction Factor for Magnetic
  Circuit Length of Rotor Yoke:        0.785806

No-Load Speed (rpm):        2967.5
Cogging Torque (N.m):        0.213669


     FULL-LOAD DATA

Average Input Current (A):        1.79913
Root-Mean-Square Armature Current (A):        0.735257
Armature Thermal Load (A^2/mm^3):        68.8854
Specific Electric Loading (A/mm):        10.6254
Armature Current Density (A/mm^2):        6.48309
Frictional and Windage Loss (W):        3.89524
Iron-Core Loss (W):        14.4868
Armature Copper Loss (W):        5.78973
Transistor Loss (W):        2.13247
Diode Loss (W):        0.0156924
Total Loss (W):        26.3199
Output Power (W):        60.0381
Input Power (W):        86.358
Efficiency (%):        69.5223

Rated Speed (rpm):        2596.83
Rated Torque (N.m):        0.220778

Locked-Rotor Torque (N.m):        2.91145
Locked-Rotor Current (A):        19.5482


     WINDING ARRANGEMENT

The 3-phase, 2-layer winding can be arranged in 3 slots as below:

ABC


Angle per slot (elec. degrees):        120
Phase-A axis (elec. degrees):        60
First slot center (elec. degrees):        0



     TRANSIENT FEA INPUT DATA

For Armature Winding:
  Number of Turns:        908
  Parallel Branches:        4
  Terminal Resistance (ohm):        3.56992
  End Leakage Inductance (H):        2.83884e-005
2D Equivalent Value:
  Equivalent Model Depth (mm):        28
  Equivalent Stator Stacking Factor:        0.95
  Equivalent Rotor Stacking Factor:        0.95
  Equivalent Br (Tesla):        1.23
  Equivalent Hc (kA/m):        890
Estimated Rotor Moment of Inertia (kg m^2):        1.51651e-005

lishiyou1990

                  云台电机？？

青鸟飞鱼

lishiyou1990 发表于 2017-8-10 19:52
云台电机？？

不是，云台电机是什么？

zy1986

很多原因会导致出现这样的结果，尺寸对不对？材料对不对？       你的定子齿磁密都有2t了。损耗大头在铁损，铜损基本上还算正常。   

青鸟飞鱼

zy1986 发表于 2017-8-11 19:00
很多原因会导致出现这样的结果，尺寸对不对？材料对不对？       你的定子齿磁密都有2t了。损耗大头在铁损 ...

额定转速才2500多也是这个原因吗？

lizhen2979371

应该从磁场入手吧~~~~齿磁密太高了，把齿改宽一些吧