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1 © 2017 ANSYS, Inc. May 1, 2017
Overview of Electronic Transformer
Simulations
Gerd Prillwitz
May 1, 2018
ANSYS, Inc
2 © 2017 ANSYS, Inc. May 1, 2017
Conduction
Convection
Radiation
Phase Change
Mass Transport
More…
Thermal
Compressible
Incompressible
Laminar Flow
Turbulence
Multiphase Flow
Non-Newtonian Fluids
More…
Fluids
Quasi static (Low Freq)
Full Wave
Joule Heating
Eddy currents
Current flow
Circuit Coupling
More…
ElectromagneticsStructural
Large Displacements
Finite Strain
Contact
Multibody Dynamics
Random Vibration
Implicit & Explicit
More…
Simplorer System Simulation Framework
Reduced order Models, Co-Simulation3rd-party Coupling, Scripting Automation
Simulation Coupling Framework
ANSYS Simulation Environment
3 © 2017 ANSYS, Inc. May 1, 2017
What are some of the challenges which will be covered?
• Electric Field effects:• varying dielectric permitivities
• varying dimensions and shape
• 3D field effects
• Magnetic effects: • nonlinear materials
• eddy currents
• proximity effects
• time diffusion of magnetic fields
• transient excitations
• 3D field effects
Technical Issues for Transformer Design
4 © 2017 ANSYS, Inc. May 1, 2017
• ANSYS provides an electromagnetic, multi-physics and system solution for both Power and Electronictransformers:
– Electromagnetic performance (losses, forces, impedances, …)
– Multi-physics capability (thermal, structural, acoustics)
– System Level models (ECE and frequency dependent ROMs)
• For Power Transformer applications (50-60Hz, kW-MW power), the eddy current and electrostatic solvers are used primarily. Cores use laminated steel.
• For Electronic Transformer applications (kHz, mW-W power), where analysis over a wide frequency range is needed (DC-MHz), the Eddy Current solver is used primarily. The transient solver can also be used for non-sinusoidal excitation to study losses. Cores use solid ferrites with linear permeability.
• Fast and accurate solution, easy-to-use with automatic adaptive meshing and high performance computing (HPC)
Electronic Transformer
Power Transformer
Two Categories for Transformers
5 © 2017 ANSYS, Inc. May 1, 2017
• For Power and Electronic transformers, ANSYS provides various electromagnetic, multi-physics and system solutions:
• Electromagnetic performance (losses, forces, impedances, …)
• Multi-physics capability (thermal, structural, acoustics)
• System Level models (ECE and frequency dependent ROMs)
• Fast and accurate solution, easy-to-use with automatic adaptive meshing and high performance computing (HPC)
Electronic Transformer Power Transformer
Transformer Design Methodology
6 © 2017 ANSYS, Inc. May 1, 2017
SimplorerSystem Analysis
Q3DRLCG Parasitics
ANSYS Mechanical
Thermal
Model order Reduction
Co-simulation
Field Solution
Model Generation
Icepak Thermal
with air flow
Maxwell 3D3D FEA
Overall Transformer Solution Flow
PExprtModel Creation
ETKElectronic
Transformer Kit
7 © 2017 ANSYS, Inc. May 1, 2017
• Solves 2-D and 3-D electromagnetic
field problems using FEA
• Five Solution Types: Electrostatic,
Magnetostatic, Eddy Current, Transient
Electric, Transient Magnetic
• Determines R,L,C, forces, torques,
losses, saturation, time-induced effects
• Simulation of: Power Magnetics,
Inductors, Transformers, Motors, Generators, Actuators, Bus bars
• Co-simulation with Simplorer, Simulink
• Direct link from PExprt, RMxprt
• Direct link to ANSYS Mechanical
Maxwell Introduction
8 © 2017 ANSYS, Inc. May 1, 2017
• Three Basic Simulation Types:- Circuits- Block Diagrams- State Machines
• Multi-domain simulator for electrical, magnetic, mechanical, fluid, and thermal systems
• Integrated analysis with EM tools (Maxwell, PExprt, Q3D, RMxprt, HFSS) and thermal tools (ANSYS CFD, ANSYS Icepack)
• Co-simulation with Maxwell and Simulink• Optimization and Statistical analysis • VHDL-AMS capability
SUM2_6
CONST
id_ref
G(s)
GS2
I
I_PART_id
GAIN
idLIMIT
yd
UL := 9
LL := -9
GAIN
P_PART_id
KP := 0.76
IMP = 0
IMP = 1IMP = 0
IMP = 1
IMP = 0 and RLine.I <= ILOW
IMP = 1 and RLine.I >= IUP
IMP = 0 and RLine.I >= IUP
IMP = 1 and RLine.I <= ILOW
SET: CS1:=-1SET: CS2:=-1SET: CS3:=-1SET: CS4:=-1
SET: CS1:=-1SET: CS2:=1SET: CS3:=-1SET: CS4:=-1
SET: CS1:=1SET: CS2:=-1SET: CS3:=-1SET: CS4:=-1
SET: CS1:=-1SET: CS2:=-1SET: CS3:=-1SET: CS4:=-1
Circuits
Block Diagrams
State Machines
12
R1 R2 R3 R450
1k 1k50
C1 C2
3.3u
3.3u
V0 := 5 V0 := 0
N0005
N0003N0004
N0002
Simplorer Introduction
9 © 2017 ANSYS, Inc. May 1, 2017
SIMPLORER
PExprt
Maxwell
• Magnetic Design and Optimization tool for Ferrite and Laminated Transformers and Inductors including: multi-winding transformers, coupled inductors, and flyback components
• Contains seven manufacturer libraries for common components:
• Cores, Bobbins, Wires
• Toroidal, Planar, Wire-wound
• Analytical or FEA based solution includes skin and proximity effects, gap effects, thermal effects
• Winding Losses, Core Losses, R,L,C Parameters and Temperature Rise
• Couples to Simplorer using frequency dependent netlist for device
PExprt Introduction
10 © 2017 ANSYS, Inc. May 1, 2017
• Coupled Thermal and Stress Analysis for electromagnetic devices including: • Static Thermal• Transient Thermal• CFD• Static Stress• Acoustical Analysis
• Steady-state and transient thermal-flow simulations considering all modes of heat transfer
• ANSYS CFD – includes ANSYS FLUENT and ANSYS CFX multi-purpose fluid flow solvers
• Icepak – specifically for electronics thermal management at component, board and system level
• Acoustical Solver
ANSYS Mechanical-Icepak Introduction
11 © 2017 ANSYS, Inc. May 1, 2017
• Q3D is a tool streamlined for quickly characterizing electrical parasitics
• Q3D includes two tools:
• Q3D Extractor: 3-D quasi-static lumped RLC parameter extractor. Linear permeability = 1.
• 2D Extractor: 2-D T-line RLGC parameter extractor. Linear permeability.
DC 1.5 GHz 15 GHz ???
Q3D
2D Extractor
HFSSX
10cm1
L
2mm5
W
Q3D Extractor - Introduction
12 © 2017 ANSYS, Inc. May 1, 2017
SimplorerSystem Analysis
ANSYS Mechanical
Thermal
Model order Reduction
Co-simulation
Field Solution
Model Generation
Icepak Thermal
with air flow
Maxwell 3D3D FEA
Electronics Transformer Solution Flow
PExprtModel Creation
1) PEmag/ETK → Maxwell 3D Eddy Current ROM → Simplorer
2) Maxwell ↔ ANSYS Mechanical
3) Maxwell ↔ Icepak
4) Maxwell 3D Transient with HPC/TDM
ETKElectronic
Transformer Kit
13 © 2017 ANSYS, Inc. May 1, 2017
PEmag → Maxwell 3D → Simplorer
• PExprt/PEmag to create Maxwell 3D Eddy Current model
• Maxwell to create ROM for Simplorer
14 © 2017 ANSYS, Inc. May 1, 2017
Electronic Transformer Kit → Maxwell 3D
• ETK script to create Maxwell 3D Eddy Current model
• Maxwell to create ROM for Simplorer
15 © 2017 ANSYS, Inc. May 1, 2017
Temperature Rise
Losses
Maxwell ↔ ANSYS Mechanical 2-way Thermal Coupling
• Maxwell 3D Eddy Current
• Mechanical Pro steady state thermal (without air flow)
16 © 2017 ANSYS, Inc. May 1, 2017
Maxwell ↔ Icepak 2-way Thermal Coupling
• Maxwell 3D Eddy Current
• Icepak with airflow
17 © 2017 ANSYS, Inc. May 1, 2017
Nonlinear Core
Primary Solid Windings
Secondary Solid Windings
Finite Elements: 900kDOFs’: 1.5MilTime Steps: 1,000Input Voltage Rising Time: 20ns
Input Voltage
Maxwell 3D Transient with HPC/TDM
18 © 2017 ANSYS, Inc. May 1, 2017
Maxwell 3D Transient with HPC/TDM
Induced Voltage
Power Loss
Currents375V
17.5W
15A
19 © 2017 ANSYS, Inc. May 1, 2017
0
2
4
6
8
10
12
14
16
18
20
64 128 256
Spe
ed
Up
Fac
or
Number of Cores
HPC Performance
Maxwell 3D Transient with TDM
No-TDM: 5 days simulation
11 h:20m
08h:40m
06h:30m
20 © 2017 ANSYS, Inc. May 1, 2017
Higher losses near core gap
Proximity Losses and temperature rise in foil windings
21 © 2017 ANSYS, Inc. May 1, 2017
• Frequency dependent netlist
including R,L, C
• Current density plot showing
skin and proximity effects
• Flux lines plot
AC Frequency Effects considered
22 © 2017 ANSYS, Inc. May 1, 2017
• Windings are connected
with a schematic
• All turns are individually
modeled
Core
gap
Bobbin
Insulation (green)
Complicated Multi-Winding Designs
23 © 2017 ANSYS, Inc. May 1, 2017
• Temperature rise using ANSYS Mechanical
alpha can be functional
Temperature dependent convection coefficient
Proximity Losses and temperature rise in foil windings
24 © 2017 ANSYS, Inc. May 1, 2017
0.00 25.00 50.00 75.00 100.00 125.00 150.00Amps [A]
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
Y1 [m
H]
3D Incremental and Apparent Inductance ANSOFT
Curve Info
Incremental InductanceSetup1 : LastAdaptive
Apparent InductanceImported
2D
3D
Incremental Inductance
• Incremental inductance for DC biased cores
• Using differential flux linkage and differential current (dλ/di)
25 © 2017 ANSYS, Inc. May 1, 2017
• Determines capacitance between all
defined voltage sources
• Winding-Winding or turn-turn
• Netlist can be exported for circuit
analysis
Winding Capacitance
26 © 2017 ANSYS, Inc. May 1, 2017
Core Loss Computation
• Steinmetz method used
• Coefficients derived from Loss vs B curves
• Reports Eddy, Hysteresis, Excess losses
27 © 2017 ANSYS, Inc. May 1, 2017
Temperature Dependent Conductivty
• As temp increases, conductivity decreases and loss density increases
Initial Loss Density at 22°C
Final Loss Density
Increased Loss Density at operating temp
28 © 2017 ANSYS, Inc. May 1, 2017
• Analyze 6-winding transformer
using FEA at different
frequencies
• Consider all geometry and field
effects (gap, skin, proximity)
Interconnected Multi-Winding Designs
29 © 2017 ANSYS, Inc. May 1, 2017
• Use PEmag or UDP to draw windings
• Determine leakage inductance, resistance, capacitance, and losses
ODID
TH
Toroidal Transformers and Inductors
30 © 2017 ANSYS, Inc. May 1, 2017
Questions?