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© 2011 ANSYS, Inc. June 24, 20131

Introduction to Low

Frequency ElectromagneticsSimulation

Olivier Roll

Application Engineer

ANSYS France



© 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



© 2011 ANSYS, Inc. June 24, 20133

Electromechanical (EM)

Applications

Definitions



© 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





© 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



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.)



Finite Element Solvers (3D/2D)• Transient with Motion

• Eddy Current

• DC Magnetic

• Electrostatic

Coupled Drive & Control Circuit

Equivalent Circuit Generation

Parametric/Optimization

Maxwell®



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



© 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



© 2011 ANSYS, Inc. June 24, 201312

Example: Team Problem #20

Small Air Gaps



© 2011 ANSYS, Inc. June 24, 201313

Automatic Adaptive Meshing

Measured



© 2011 ANSYS, Inc. June 24, 201314

Comparison to Measurement

Measured



© 2011 ANSYS, Inc. June 24, 201316

Modeling Capabilities

Equation-

based

surfaces

Equation-based

polylines

Fillet and Chamfer



© 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



© 2011 ANSYS, Inc. June 24, 201318

Specific Capabilities



© 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



© 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



© 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



© 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





© 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





© 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



© 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





© 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







© 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





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



35 © 2013 ANSYS, Inc. June 24, 2013 ANSYS Confidential© 2013 ANSYS, Inc. June 24, 2013 ANSYS Confidential

Specific pre/postprocessing

through UDO (User DefinedOutputs)







© 2012 ANSYS, Inc. June 24, 201338

Electric Machines Design Toolkit



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