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© 2011 ANSYS, Inc. June 24, 20131
Introduction to Low
Frequency ElectromagneticsSimulation
Olivier Roll
Application Engineer
ANSYS France
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© 2011 ANSYS, Inc. June 24, 20132
Electromechanical Design Flow
Simplorer
System Design
PP:=6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
JPMSYNCIA
IB
IC
Torque JPMSYNCIA
IB
IC
Torque
D2D
PExprtMagnetics
RMxprtMotor Design
Q3DParasitics
ANSYSMechanicalThermal/Stress
Model order Reduction
Co-simulation
Field Solution
Model Generation
Maxwell 2D/3DElectromagnetic Components
ANSYS CFD
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© 2011 ANSYS, Inc. June 24, 20133
Electromechanical (EM)
Applications
Definitions
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© 2011 ANSYS, Inc. June 24, 20134
EM Application Definitions Electrical Machine
Electromechanical devices converting- Electrical power to mechanical power as motor
- Mechanical power to electrical power as generator
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© 2011 ANSYS, Inc. June 24, 20136
EM Application Definitions Magnetic Sensors
Electromechanical devices that use magnetic field to sense motion
- Proximity sensors to determine the presence of conducting objects
- Microphones that sense air motion
- Linear variable-differential transformers to determine the object position
- Velocity sensors for antilock brakes and stability control
- Hall effect positions
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EM Application Definitions Transformers
Electromechanical device that transfers electrical energy from one circuitto another through inductively coupled conductors
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EM Application Definitions Semiconductors
Devices
A semiconductor is a material that has an electrical conductivity between that of a
conductor and an insulator. Devices made from semiconductor materials are the
foundation of modern electronics, including radio, computers, telephones, power
conversion devices (converters, inverters, etc.)
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Finite Element Solvers (3D/2D)• Transient with Motion
• Eddy Current
• DC Magnetic
• Electrostatic
Coupled Drive & Control Circuit
Equivalent Circuit Generation
Parametric/Optimization
Maxwell®
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Maxwell’s Approach
One type of elements
One formulation per solver
All solid objects are meshed
Adaptive Meshing to back-up
master
slave
Nodal
element
Edge
element
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© 2011 ANSYS, Inc. June 24, 201311
Maxwell – Auto-Adaptive Meshing
Geometry(no mesh data)
Create Initial Mesh
Calculate Field
Calculate
Field Accuracy
Error Acceptable?
Postprocess
No
Yes
Refine Mesh
Initial
Final
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© 2011 ANSYS, Inc. June 24, 201312
Example: Team Problem #20
Small Air Gaps
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© 2011 ANSYS, Inc. June 24, 201313
Automatic Adaptive Meshing
Measured
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© 2011 ANSYS, Inc. June 24, 201314
Comparison to Measurement
Measured
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© 2011 ANSYS, Inc. June 24, 201316
Modeling Capabilities
Equation-
based
surfaces
Equation-based
polylines
Fillet and Chamfer
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© 2011 ANSYS, Inc. June 24, 201317
Import / Export
Impor ts .sm2 .gds .sm3 .sat .step .iges .dwg .sld .geo.stl .dxf, CATpart, .NAS
Exports directly .sat, .dxf, .sm3, .sm2
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© 2011 ANSYS, Inc. June 24, 201318
Specific Capabilities
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© 2011 ANSYS, Inc. June 24, 201319
Induced eddy current
Zero order vector shape functions
Induced eddy current
First order vector shape functions
Coil
Mesh on the plate
Plate
3D Eddy Current High Order Elements
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© 2011 ANSYS, Inc. June 24, 201320
• Significant memory saving
• Allow to solve large problem
• Develop good pre-conditioners to get efficient speed performance
64 bit machine
(2.83 GHz,16.0 GB of RAM)
Example: Team Workshop Problem #8
Mesh (volume, adaptive) 00:19:26 00:19:26 2.9 G 3,665,594 tetrahedra
Iterative Solver 02:44:37 02:44:19 13.5 G 5,308,396 matrix
Adapt 01:43:22 01:43:19 13.5 G 3,665,594 tetrahedra
Residual tolerance 0.00001
Eddy-Current Problem
PCG Iterative Solver
Higher Capacity Solver Capabilities
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© 2011 ANSYS, Inc. June 24, 201321
• Expand the existing algorithm to the
3rd quadrant for demag computation
• Base on the actual user-input B-Hcurve in the 3rd quadrant
• Element by element
B
H0
Load line without
other sources
Demagnetization point
Hc after demagnetization
Load line with
other sources
Initial Br
Br after
demag
B
H0
Br Line b
Line a
p
• Based on the original
non-remnant B-H curve
• Construct line b at the
operating point p, which
is parallel to the line a
• Br is the intersection of
line b with B-axis• Element by element
•Allow functional unitvector magnetization
3rd Quadrant Demagnetization 1st Quadrant Magnetization
Functional Vector Magnetization
Demagnetization / Magnetization
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© 2011 ANSYS, Inc. June 24, 201322
550 W PM generator, 4 pole, 3 phase, 50 Hz AC, ceramic 8D PM
Rated speed, open- to short-circuit fault
Leading edge is weakened significantly
Original
Fault
Dynamic Demagnetization GeneratorFault Example
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© 2011 ANSYS, Inc. June 24, 201324
• Core loss computation includinghysteresis loss with minor loop
• Based on dB/dt instead of f
• Can have impact on torque to
match power balance
Core Loss Field Effects of LaminatedMaterials
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© 2011 ANSYS, Inc. June 24, 201326
• Automatically connect two parts
of a winding separated by
matching boundary
Automatically identify 3D coil terminal
counterparts and connect them together
Enhanced Boundary Capabilities
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© 2011 ANSYS, Inc. June 24, 201327
Nodal Force Computation
Applicable to both local andglobal force
Virtual work method with single
field computation
Using shell element
Allow force-computing objectsto directly touch non-force-
computing objects
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© 2011 ANSYS, Inc. June 24, 201329
Electromechanical Design Flow
Simplorer
System Design
PP:=6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
JPMSYNCIA
IB
IC
Torque JPMSYNCIA
IB
IC
Torque
D2D
PExprtMagnetics
RMxprtMotor Design
Q3DParasitics
ANSYSMechanicalThermal/Stress
Model order Reduction
Co-simulation
Field Solution
Model Generation
Maxwell 2D/3DElectromagnetic Components
ANSYS CFD
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© 2011 ANSYS, Inc. June 24, 201332
The coupling is straightforward and allow the engineer to work like they usually do.
The mesh are independent between Maxwell and Fluent. The Electromagnetic specialist can start the
WorkBench project by creating and doing the simulation of the Electromagnetic part. Once it is done,the CFD specialist will add the Fluent simulation to the WorkBench project, prepare his CFD analysis
like he usually do and simply create the link to use the Maxwell simulation as source for his CFD
simulation.
Coupling between Maxwell and FluentInduction heating example
Design simulated in
Maxwell Thermal results obtained in
Fluent
Results in Maxwell Losses mapped in
Fluent
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34 © 2013 ANSYS, Inc. June 24, 2013 ANSYS Confidential© 2013 ANSYS, Inc. June 24, 2013 ANSYS Confidential
Example: Co-Simulation Magnetic – PneumaticForce Coupling
0
0
0
0 0
S
+
SM_TRB1
F
F_TRB2
MASS_TRB1
V0=0m_per_sec
S0=0.5mm
M=1gram
F
F_TRB1
I d e
a l
STOP
LOWER_LIM=0.01mm
UPPER_LIM=0.195mm
F
F_mag
F
F_Plunger
F
F_spring
SPRING_TRB1
C=333
S
+
S_TRB1
VALUE=0.185mm
E1
R1
T1
T2T3
T4
smpl_lift
cfd_force
S1
CTRL=S1
D1
MaxwellCosimulation
FLUENT
Cosimulation
0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]
0.00
100.00
200.00
300.00
400.00
500.00
P o s i t i o n [ u m ]
0.00
0.01
0.02
0.03
0.04
0.05
0.06
C o i l C u r r e n t [ A ]
-20.00
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
20.00
P l u n g e r F o r c e [ n e w t o n ]
02_CoSim_MAgnetic_CFDTransient Switching with CFD ANSOFT
Curve Info Y Axis
Current Current
Plunger Force Plunger Force
Posit ion w. CFD Y3
Position w/o CFD Y3
Simplorer Schematic
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35 © 2013 ANSYS, Inc. June 24, 2013 ANSYS Confidential© 2013 ANSYS, Inc. June 24, 2013 ANSYS Confidential
Specific pre/postprocessing
through UDO (User DefinedOutputs)
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© 2012 ANSYS, Inc. June 24, 201338
Electric Machines Design Toolkit
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