AC Machines and Drives Simulation Platform

C. M. Apostoaia, Member, IEEE

AbstractThis paper presents the development of a cosimulation platform of ac drives control systems. Two studies are
performed, one for an induction motor (IM) and the second one
for a permanent magnet synchronous motor (PMSM) drive. The
studies provide advanced modeling and simulation tools for ac
machines designers and the developers of electric drives control
systems allowing them to model the individual components using
the appropriate software and finally integrate all into one
common simulation platform environment. In this work, the
electric machine model is developed using JMAG software based
on finite element analysis (FEA), whereas the power electronic
converter and drive control models are built in SimulinkMATLAB. The proposed simulation platform allows a coupled
analysis that links FEA machine model with the external drive
control system for a more realistic simulation, analysis and
validation.

Index TermsCo-simulation,
Simulink

electric

motors,

analyze different types of models with the highest possible

level of accuracy in the design process. The solution proposed
in this paper to respond to these needs is first utilizing the
simulation technology based on FEA for electric machine
models with JMAG software components [2], easier to use
and highly competitive alternative, [3], to other similar
software options such as Infolytica, Magsoft, or using ANSYS
Maxwell-RMxprt-Simplorer [4], [5]. Second, JMAG allows
co-simulation with circuit and control simulation external
software such as PSIM, PSpice and Simulink-MATLAB [6].
In this study, the development of the ac drives power
electronics and control algorithm models is performed in
Simulink. Finally, the FEA machine models are dynamically
linked with the electric drives control simulators for the final
overall system co- simulation and validation.
II. INDUCTION MOTOR DRIVE SIMULATOR DEVELOPMENT

JMAG,

I. INTRODUCTION

HIS paper presents the development of the design tools

needed to integrate the ac machines advanced models
based on finite element analysis (FEA) with the external
drives control simulators into a common co-simulation
platform. Two studies are performed: one for a three-phase
squirrel-cage induction motor (IM) drive and a second one for
a permanent magnet synchronous motor (PMSM) drive.
The motor designers and system circuit and control
developers cannot use in simulation simple linear models to
analyze control algorithms for high dynamic performances. It
is known that the machines behavior becomes more nonlinear
depending on the drive changing conditions, and the effects of
magnetic saturation and spatial harmonics should be taken into
account. The application of FEA appropriate for the ac
machines design is now relatively easy to use first because of
the capability to import geometry drawings from CAD
programs. The FEA has become automated to the point of
being useful in modern machine design offering flexibility in
the geometrical shape, material properties and boundary
conditions in different regions of the machine, [1].
The design advanced tools are needed to simultaneously
This work was supported in part by the 2012 Purdue University Calumet
Faculty Summer Research Grant. The use of the JMAG software was possible
during free trial licenses obtained by the author for two software components,
JMAG-Designer and JMAG-Express.
C. M. Apostoaia is with the Electrical and Computer Engineering
Department, Purdue University Calumet, Hammond, IN 46323 USA (e-mail:
apostoai@ purduecal.edu).

978-1-4673-4974-1/13/$31.00 2013 IEEE

A. FEA Model of the Three-Phase IM

The JMAG software, used in this paper, provides multiple
alternatives to create the geometry of the electric machine
models and to perform detailed finite element calculations.
JMAG can import geometry files from various CAD external
sources such as CATIA, Pro/ENGINEER, SolidWorks, and
NX (Unigraphics). Other ways to create machine models in
JMAG are the direct use of its own geometry editor, or the
simplest method that is chosen in this study is using the
provided template-based electric machine design tool. A brief
description of the motor design steps using JMAG is presented
next.
Several types of studies are available in JMAG such as
magnetic transient analysis, magnetic frequency analysis,
transformer analysis, or thermal analysis. To create a new
study, the magnetic frequency response is selected here, being
required later to create the JMAG-RT model that will be
linked with Simulink-MATLAB environment.
Based on the existent motor template, a modified geometry
of the three-phase squirrel-cage IM test model is created with
JMAG-Express and used for simulation in this paper as shown
in Fig. 1a.
In the next motor design step, the stator and rotor core
materials are selected from the category of electrical steel,
isotropic, soft magnetic materials. The B-H curve is specified
for the selected magnetic materials, including the steel
magnetic material for the rotor shaft. Nonmagnetic materials
are assigned for the coils, that is, copper for all three phase
coils, and aluminum for the rotor cage, end rings and bars. The
other defined electrical and mechanical material properties are
the electric conductivity and permittivity, materials density,

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Youngs modulus, thermal conductivity and specific heat.

The circuit editor tool is then used to create an external
circuit for setting the wye windings connection, the threephase power source supplying the stator windings, the number
of turns, layers and the resistance for each phase coil.

(a)

(b)

B. Simulation Results of the Induction Motor FEA Model

Once the analysis is completed, the mesh information and
the calculation folder are available and various graphs are
displayed, such as the magnetic flux produced by the coils,
rotational velocity, torque, and electric power. The magnetic
flux density distribution and the field lines are displayed in
Fig. 2a, for the induction motor under normal operating
conditions. The magnetic field lines plot is used to better
understand the machine magnetic field paths and flux
leakages. For comparison, Fig. 2b displays the magnetic flux
density and flux lines of the same induction motor under
faulty conditions, that is, a short between two of the stator
phases, in this study.
The current density contour plot returned by the FEA plays
a crucial role in any electric machine design and analysis. The
current density distribution is shown for the induction motor
operating under normal conditions in Fig. 3a, and with a fault
short occurred between two stator phases in Fig. 3b.

Fig. 1. Three-phase squirrel-cage induction test motor: (a) Modified template

created for the JMAG simulator design; (b) Winding pattern.

Before to generate the mesh, a list of conditions is selected

as follows: the rotation motion condition is set for all rotor's
elements such as the shaft, rotor magnetic core and the rotor
cage bars; the rotation periodic boundary condition is used
with a 180 degrees periodic angle; a nodal force condition and
the axis of rotation are specified for the torque exerted on the
rotor core. For the machine stator windings the FEA coil
condition setting ensures that the coil models of all three
phases in the external circuit, created in the previous step, are
linked to the coil models in the geometry graphics window
similar to Fig.1b and indicating the phase and the current
directions. Then, the FEA conductor condition (actually this
condition's name is FEM in JMAG software, but to avoid any
confusion only the FEA abbreviation will be used in this
paper) is created for the rotor bars, specifying the bars number
arranged 180 degrees around the rotor (group condition). The
group of bars requires setting the cage component which is
placed using the external circuit editor.
Finally, the study properties conditions are specified which
include: FEA calculation method and number of steps,
nonlinear calculation and maximum iterations, slip frequency
for the frequency analysis, and stack length. Once the
geometry and the settings of materials, windings and drive
conditions are specified, a simplified simulation is run with
JMAG-Express. The generated results include phase
resistance, inductance, torque, efficiency, copper and iron
losses, and torque constant providing the basic motor
characteristics for an initial evaluation. Then, the machine
model generated with JMAG-Express is sent to JMAGDesigner for the FEA model creation and analysis.
For the mesh generation, the following actions are required
using JMAG: setting the element size for parts, faces and skin
depth, mesh type (slide mesh for motion), radial and
circumferential divisions, air region scale, and symmetry
boundary conditions.

(a)

(b)
Fig. 2. Magnetic flux density distribution and flux lines- induction motor
model: (a) normal operating conditions; (b) fault short between two phases.

C. Induction Motor Drive Co-Simulation with JMAGSimulink

The link realization and co-simulation of the created JMAG
FEA advanced machine model to the circuit/control simulator
built in Simulink is the main objective of this study and is
presented in this section.
In this design step, a look-up table is created in an .rtt file,
representing the RT machine model that is exported, here, to
Simulink for the overall electric drive control system cosimulation. The JMAG-RT model can be considered a
behavior model generated from the FEA model with two

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possible levels of complexity: (1) basic system design, based

on the same principles as the ac machines d-q models and (2)
advanced motor control design, based on RT model with
enhanced accuracy accounting for the nonlinear characteristics
of the motor and also the spatial harmonics effects.

Simulink blocks as shown in Fig. 4. The Simulink block

diagram realization of the closed-loop speed control by slip
regulation for JMAG-Simulink co-simulation validation is
shown in Fig. 5. The RT model was previously created using
the FEA motor model and then linked to Simulink.

10

V_s *

usu

Vu

is_uv w

usv

Vv

thetam

Vw

wm

Tm

Te

Vc*

Iu,v,w
Boost
volt

w_r *

num(s)

2*pi*freq
Speed
Ref

w_sl *

-K- Va / wsyn
w_e *

rad to deg
1
s

rpm to
-Krad/s

usc

3-phase PWM
Voltage Fed Inverter

-Krad/s
to rpm

TL

JMAG_RT_Ind Motor

n_rpm

Fig. 5. Co-Simulation JMAG-Simulink of a V/f closed-loop speed control

and slip regulation of the IM drive.

The simulation results of the coupled analysis are next

presented as follows: the stator voltages fed by the three-phase
PWM inverter in Fig. 6a, the motor stator currents in Fig. 6b
and the motor controlled speed in Fig. 6c, respectively.

(b)
Fig. 3. Current density distribution induction motor model:
(a) Normal operating conditions; (b) Fault short between two phases.

Before to export the JMAG-RT model to Simulink the

[Simulink voltage signal input] option is specified, in this
paper, for the .rtt file creation. This is a Simulink model and
there is no need the use the SimPowerSystems toolbox. Also,
this option inputs the control signal as voltage to each coil
whereas the outputs are the torque, electromagnetic force, and
the current flowing in each phase.

(a)

-KVd/2
1

usu

-K-

(b)

-K-

Vc*

sqrt(2) x Vc

3
3

-C-

-K-

3
3

sin

usv

em

-K-

3
usc

theta_e*
-K-

V_tri
-Vd/2

-K-

(c)

Fig. 4. Three-phase, two-level, PWM voltage-fed inverter, a subsystem of

the Simulink block diagram of the controlled IM drive in Fig.5.

The focus on this paper is to demonstrate the use of the

JMAG-Simulink coupled analysis applied to ac drives and not
the development of advanced motor controls. The IM drive
application chosen here is a closed-loop speed control by slip
regulation, an improvement of the open loop V/f control [7].
The power electronic converter of this drive is a three-phase,
two-level PWM voltage-fed inverter and is modeled with

Fig. 6. Simulation results of the JMAG-Simulink coupled analysis for the

controlled drive in Fig. 5.

III. PMSM DRIVE SIMULATOR DEVELOPMENT

A. FEA Model of the PMSM
The second developed simulator in this work is using an
interior permanent magnet synchronous machine. The design
procedure follows the same steps (section II.A) performed for

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n_rpm

Load
Torque

(a)

theta

theta_e*

P-I

w_r

-K-

Torques

the induction motor drive, so that in this section only specific

details involving this synchronous machine are reported.
By using the provided template-based electric machine
design tool a modified geometry of the PMSM test model is
created with JMAG-Express and used for simulation in this
paper as shown in Fig. 7a. The generated machine model is
then sent to JMAG-Designer for the FEA model creation and
analysis.
(a)

(a)

(b)

(b)

Fig. 7. Interior permanent magnet synchronous test machine : (left) Modified

template created for the JMAG simulator design; (right) Winding pattern.

Fig.8. Interior permanent magnet synchronous machine, 90 degrees model,

JMAG simulation: (a) Generated mesh; (b) Magnetic flux lines.

Regarding the setting of the materials, both stator and rotor

core materials are selected from the category of steel,
isotropic, soft magnetic materials. The rotor permanent
magnets, positioned at a 45 degrees angle, are made from a
sintered NdFeB rare earth category and having a parallel
magnetization pattern. The anti-periodic boundary condition
was selected, meaning that the flux is reversing each period in
this study case. For the most accurate torque calculation the
nodal force method is applied.
A fine mesh is provided in the critical region of the
machines air gap, and to the edges of the permanent magnets
to catch the eddy currents effect. Then the mesh is uniformly
spread into the stator and rotor regions, taking care of a good
aspect ratio by choosing the radial and circumferential
divisions.
The analysis study steps were set to 96 per 90 degrees, in
order to have enough steps for a complete electrical cycle.
There are 11520 divisions for a 1 s stop time: 96 stepsx4
periods (steps per revolution) and the rotor is rotating at
1800rpm/60s (rev/s), so that 384x30=11520 (steps/s).
B. Simulation Results of the PMSM FEA Model
Once the analysis is completed, the mesh information and the
calculation folder are available and various graphs can be
displayed for the new case of the simulated interior permanent
magnet synchronous machine. In this study, Fig. 8a displays
the generated mesh, and the flux lines are shown in Fig. 8b.
The magnetic flux density and the flux lines of the same
PMSM under normal operating conditions are shown in Fig.
9a, whereas the current density is presented in Fig. 9b.

(a)

(b)
Fig. 9. Interior permanent magnet synchronous machine, JMAG simulation
for normal operating conditions: (a) Magnetic flux density and flux lines (b)
Current density.

C. PMSM Drive Co-Simulation with JMAG-Simulink

The JMAG-RT model of the PMSM machine is created
based on the previously developed FEA model and then is
exported to Simulink. The PMSM drive application chosen
here for simplicity is a standard open loop volts/hertz speed
control.
The Simulink model of the three-phase PWM voltage-fed
inverter used in this drive is similar to the one sown in Fig. 4.

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The drive's control system block diagram realization in

Simulink is shown in Fig. 10.
10
Boost
voltage

Va

V_s *

is_abc
Vs*

2*pi*fc
Speed
Command

w_e *

theta_e*

1
s

teta_e *

v a*
v b*

-K- Va/wsyn

Iabc

Vb

v c*
wm_rpm

Command signals
generation

Vc

n(rpm)
3-phase PWM
Voltage Fed Inverter

Tm
Te

Torque

coilTemp

293
T emp

LdLq

magTemp

L_dq
IPM_SynMot_JMAG_RT

Fig. 10. Co-Simulation JMAG-Simulink of the V/f control of the PMSM test
drive.

The simulation results of the coupled analysis are next

presented as follows: the motor stator currents in Fig. 11a, the
torque in Fig. 11b and the motor calculated inductances, Ld
and Lq are shown in Fig. 11c.

where the developed simulation platform is allowing the cosimulation of the electric machine advanced model based on
finite elements analysis using ANSYS Maxwell [4], with the
power electronics and the drive's electromechanical parts
modeled using ANSYS Simplorer and the ac drive control
system built in Simulink/MATLAB. By comparing this study
with the work performed in [5], I found that the JMAG user
interface is the best with a flexible JMAG-Designer
environment by solving different cases from the same base
model. Maxwell users have to have other ANSYS (Ansoft)
products such as RMxprt and Simplorer [4] which I found not
so easy to use for co-simulation.
The future extended work will be the use of the data
generated by the developed co-simulation platforms for their
post processing using the advanced virtual reality visualization
and simulation technologies installed at Purdue University
Calumet in the Center for Innovation through Visualization
and Simulation, thereby providing an intuitive understanding
of simulation results to help the design optimization of the ac
machines and drives as well as for education and training
purposes.
REFERENCES
[1]

(a)

[2]
[3]
[4]
[5]
(b)
[6]
[7]

(c)
Fig. 11. Simulation results of the control system in Fig. 10:
(a) Stator currents; (b) Torque; (c) Inductances Ld and Lq.

IV. CONCLUSION
The FEA machine models exported to Simulink for more
realistic tests of the control algorithms offer the obvious
advantage of low cost simulations compared with costly and
unsafe physical system prototype testing. Tests have a degree
of danger increasing the costs that are incurred, like the motor
operated under abnormal conditions (i.e., short circuits), or the
drive forced to the maximum rotation speed. The biggest
disadvantage is the time required for the co-simulation and
this is caused by performing the FEA model calculations using
the time step for the control system simulation.
An alternative approach to this study was presented in [5],
1299

Thomas A. Lipo, Introduction To AC Machine Design. WPERC,

University of Wisconsin-Madison, 2007, ch. 10.
JMAG-Designer , JMAG-Express, software components of JSOL Corp
(Japan). Powersys Inc. is the JMAG's Distributor in North America,
Middleton, WI
C.R. Frontczak, Evaluation of Finite Element Software Packages,
TEMPEL Engineering Report, Chicago, IL, March 28, 2011
ANSYS-Maxwell, ANSYS-Simplorer, ANSYS-RMxprt, components of
ANSYS (Ansoft) software (USA).
C.M. Apostoaia, "Co-Simulation Platform for AC Drives Control
Systems", WASET 2012- ICEMDS International Conference on Electric
Machines and Drive Systems, November 28-29, 2012 Paris, France,
Issue 71 November 2012, pp.1879-1886
Simulink, registered trademark of the Mathworks, Inc.
Bimal K. Bose, Modern Power Electronics and AC Drives, Prentice
Hall, 2002, ch.8.