Introduction to Low Frequency Electromagnetics Simulation
Olivier Roll Application Engineer
ANSYS France
Electromechanical Design Flow Simplorer
Q3D
System Design
Parasitics
RMxprt Motor Design
PMSYNC
IA A
Torque A
IB
J
D2D
ICA:
A
IC
PP:=6
A
GAIN
ANSYS CFD PExprt Magnetics
ANSYS Mechanical
Maxwell 2D/3D Electromagnetic Components
Thermal/Stress Model order Reduction Co-simulation Field Solution Model Generation
Electromechanical Design Flow Simplorer
Q3D
System Design
Parasitics
RMxprt Motor Design
PMSYNC
IA A
Torque A
IB
J
D2D
ICA:
A
IC
PP:=6
A
GAIN
ANSYS CFD PExprt Magnetics
ANSYS Mechanical
Maxwell 2D/3D Electromagnetic Components
Thermal/Stress Model order Reduction Co-simulation Field Solution Model Generation
Electromechanical Electromechanical (EM) Applications
Definitions
EM Application Definitions Electrical Machine Electromechanical devices converting - Electrical power to mechanical power as motor - Mechanical power to electrical power as generator
EM Application Definitions Magnetic Actuators Electromechanical devices that use magnetic field to produce motion - Hydraulic valves (airplanes, cars, robots, etc.) - Fuel injectors in engines - Biomedical prosthesis devices - Head positioners for computer disk drives - Loudspeakers
Solenoid
Relay
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
EM Application Definitions Transformers Electromechanical device that transfers electrical energy from one circuit to another through inductively coupled conductors
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.)
Maxwell® Finite Element Solvers (3D/2D) •
Transient with Motion
•
Eddy Current
•
DC Magnetic
•
Electrostatic
Coupled Drive & Control Circuit Equivalent Circuit Generation Parametric/Optimization
Maxwell’s Approach Edge element
One type of elements
One formulation per solver
All solid objects are meshed
Adaptive Meshing to back-up
Nodal element
slave master
Maxwell – Auto-Adaptive Meshing Initial Geometry (no mesh data)
Create Initial Mesh
Calculate Field
Calculate Field Accuracy
Error Acceptable?
Yes
Postprocess
Final No
Refine Mesh
Example: Team Problem #20
Small Air Gaps
Automatic Adaptive Meshing Measured
Comparison to Measurement
Measured
Modeling Capabilities
Equation-based polylines
Equationbased surfaces
Fillet and Chamfer
Import / Export
Impor ts .sm2 .gds .sm3 .sat .step .iges .dwg .sld .geo .stl .dxf, CATpart, .NAS Exports directly .sat, .dxf, .sm3, .sm2
Specific Capabilities
3D Eddy Current High Order Elements
Coil
Plate
Mesh on the plate
Induced eddy current Zero order vector shape functions
Induced eddy current First order vector shape functions
Higher Capacity Solver Capabilities •
Significant memory saving
•
Allow to solve large problem
•
Develop good pre-conditioners to get efficient speed performance
PCG Iterative Solver
Example: Team Workshop Problem #8 Eddy-Current Problem
64 bit machine (2.83 GHz,16.0 GB of RAM) Residual tolerance 0.00001 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
Demagnetization / Magnetization 3rd Quadrant Demagnetization Load line without other sources
B
B
Line a
Br
p
•
Initial Br Br after demag
Load line with other sources
1st Quadrant Magnetization
0
•
Line b
H •
Hc after demagnetization
Demagnetization point •
•
•
0
Element by element
•
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
Functional Vector Magnetization
Expand the existing algorithm to the 3rd quadrant for demag computation Base on the actual user-input B-H curve in the 3 rd quadrant
H
Based on the original non-remnant B-H curve
•
Allow functional unit vector magnetization
Dynamic Demagnetization Generator Fault Example 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
Core Loss Parameter Extraction from Multi-Frequency Loss Curves 1. Select “Electrical Steel” or “Power Ferrite”
3. Automatically update
2. Select “Core Loss versus Frequency”
Core Loss Field Effects of Laminated Materials •
•
•
Core loss computation including hysteresis loss with minor loop Based on dB/dt instead of f Can have impact on torque to match power balance
Maxwell – Double Armature Motion •
Two Bands in Transient
•
Two independently moving objects
•
Rotational and/or translational
•
Hybrid drive applications
•
Magnetic gearboxes, ... Stator
Rotor I
Rotor II
Enhanced Boundary Capabilities •
Automatically connect two parts of a winding separated by matching boundary
Automatically identify 3D coil terminal counterparts and connect them together
Nodal Force Computation
Applicable to both local and global force Virtual work method with single field computation Using shell element Allow force-computing objects to directly touch non-forcecomputing objects
Example of application
Electromechanical Design Flow Simplorer
Q3D
System Design
Parasitics
RMxprt Motor Design
PMSYNC
IA A
Torque A
IB
J
D2D
ICA:
A
IC
PP:=6
A
GAIN
ANSYS CFD PExprt Magnetics
ANSYS Mechanical
Maxwell 2D/3D Electromagnetic Components
Thermal/Stress Model order Reduction Co-simulation Field Solution Model Generation
Maxwell – Multiphysics Integration Thermal/Mechanical Load Transfer
Losses
Temperature
Maxwell
Geometry Workbench DM Maxwell UDP
Centroids Workbench Mesher
Mapped Losses
Multiphysics Coupling through WB •
Maxwell 3D provide volume/surface forces to ANSYS Structural
•
Solver improvements –
Surface forces are supported Thermal-Stress with Electromagnetic Force load
The electromagnetic force density from Maxwell is used as load in Structural
Deformation of the stator
Thermal deformation of the rotor
Coupling between Maxwell and Fluent Induction heating example 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.
Design simulated in Maxwell
Results in Maxwell
Losses mapped in Fluent
Thermal results obtained in Fluent
Maxwell – Simplorer System Simulation Wireless power transfer
IGBT1
THREE_PHASE1 D5
D7
D1
IGBT3
D3
D9 WM1
3PHAS
PHI =-120°
~
PHI =-240°
R2
+
Current_1:src Current_2:src 1.72uF
~
R1
W
PHI =0°
~
WM2 Cs
+
A * sin (2 * pi * f * t + PHI +phi_u)
D11
W
D13 Rload
3.6mOhm
7.2mOhm
13ohm
Current_1:snk Current_2:snk C1
Cp
C2
4.96uF
1uF
1000uF IGBT2 D6
D8
D2
IGBT4
D4
D12
-
D14
D10
+ Battery
LBATT_A1
Wireless Power Transformer
0
Rectify
AC400V
Inverter
0
Battery CurveIn fo
700.00
WM1.V TR WM2.V
PWR_Probe1
TR
TRANS1 TRANS2 STATE_11_1 ICA:
0
rms 281.0066 321.9453
PWR
STATE_11_2
Probe
FML_INIT1
200.00 ] V [
PWR_Probe2
Modulation_Index:=0 Carrier_Freq:=20k Frequency:=20k
SET: SET: SET: SET:
Dead_Time:=2u DC_Source:=400
TSV4:=1 TSV3:=0 TSV2:=0 TSV1:=1
SINE1.VAL< TRIANG1.VAL
SET: TSV4:=0 SET: TSV3:=0 DT1 SET: TSV2:=0 SET: TSV1:=0 DEL: DT1##Dead_Time
Controller
SINE1
1 Y
PWR Probe
-300.00
TRANS3
TRANS4
STATE_11_4
AMPL=Modulation_Index FREQ=Frequency
STATE_11_3
-800.00 2.00
2.20
2.40
Time [ms]
2.60
2.80
3.00
TRIANG1 DT4
AMPL=1 FREQ=Carrier_Freq
SET: SET: SET: SET: DEL:
TSV4:=0 SINE1.VAL> TRIANG1.VAL TSV3:=0 TSV2:=0 TSV1:=0 DT4##Dead_Time
SET: SET: SET: SET:
TSV4:=0 TSV3:=1 TSV2:=1 TSV1:=0
150.00
CurveIn fo WM1.I TR
250.00
C ur ve I nf o WM1.I TR WM2.I
125.00 ] A [ 1 Y
TR WM1.V TR
-0.0037
0.00 -40.2840 -64.8250 -408.7847
TR
-315.0105
-319.5653
WM2.V
Y A xi s873.02 r ms Y1
100.00 TR
Y1
34.1140
Y2
276.0822 ]
V [ 0.00 2 316.6292 Y
-53.6971 -377.1247 -500.00
-125.00
rms 41.6165 34.8648
38.9542
500.00
Y2
WM2.I
50.00 ] A [ 1 Y
0.00
-50.00
-100.00 -250.00
2.900
2.925 MX1: 2.9200
2.950 Time [ms]
2.975
3.000
-1000.00 -150.00
0.0610 MX2: 2.9811
2.00
2.20
2.40
Time [ms]
2.60
2.80
3.00
Example: Co-Simulation Magnetic – Pneumatic Force Coupling Maxwell Cosimulation
S1
CTRL=S1
SM_TRB1
S
R1 T1
T4
F F_TRB2
F_mag E1
smpl_lift
+
D1
F
F
F_Plunger
T3
STOP MASS_TRB1 0
0.06 500.00
F_TRB1
I d e a l
SPRING_TRB1
400.00 0.04 ] 300.00 m u [ n o i t i s o P 200.00
] A [ t n e r r0.03 u C l i o C
100.00
0.01
0.02
0
C=333
F LOWER_LIM=0.01mm S_TRB1
V0=0m_per_sec S0=0.5mm M=1gram
UPPER_LIM=0.195mm 0
+ 0
Transient Switching with CFD
VALUE=0.185mm
S 02_CoSim_MAgnetic_CFD
ANSOFT
20.00 Curve Inf o
0.05
FLUENT Cosimulation
T2
0
Simplorer Schematic
cfd_force
F
F_spring
Y Axis
Current Current Plunger Force Plunger Force P os it io n w. C FD Y3 Position w/o CFD Y3
15.00
10.00 ] n o t w e n [ e c 0.00 r o F r e g -5.00 n u l P
5.00
-10.00
-15.00 0.00
0.00 -20.00
Specific pre/postprocessing through UDO (User Defined Outputs)
Electrical Machines Design Flow Maxwell2D
Toolkit
RMXprt
Maxwell3D
Initial Design
FE Design
UDOs &Toolkit
Optimal Design
User Defined Outputs (UDOs)
Electric Machines Design Toolkit
