ANSYS Maxwell2019 R1 Highlights

2018 2019 2020

Outline

3

• 2019 R1 Story – NVH for Traction Applications

• Core Technology

• HPC Enhancements

• Multiphysics

• Meshing Enhancements

• Usability Enhancements

2019 R1 Story – NVH for Traction Applications

• Objective

• Challenges

• Workflow

Objective

Efficient Simulation of Noise and Vibration originated from Electrical Machines

❑ Reduced development cost

❑ Comprehensive and robust solution

❑ Faster development cycles

Challenges

Efficient Simulation of Noise and Vibration originated from Electrical Machines

❑ Identification and modeling of contributing noise sources

❑ Access to desired outputs

❑ Efficient and Accurate prediction

❑ Performance optimization

Gap

Forces

➢ Electromagnetic

➢ Mechanical

➢ Air flow

Multiphysics Workflow

Electromagnetic Field Structural Dynamics Acoustic Field

Electromagnetics

Modal and Harmonic Response Harmonic Acoustic

Single-RPM

Multiple-RPM

• Automatic creation of Waterfall diagram which gives the full noise fingerprint

• Competitive computation time with object-based harmonic force/harmonic response coupling

Mode 1

Mode 2

Mode 3

Fast Multi-RPM Vibration and Acoustic Analysis

VelocityForce

Equivalent Radiated Power

Waterfall diagram

Modal analysis

Core Technology

• Electrical Machine Design Workflow Improvements• Electrical Machine Toolkit

• New Pre-Processing Workflow

• AEDT Post-Processing Integration of Customized Solution

• Full Model Visualization from Partial Model Solution

• 2D Skewing Improvements

• Magnetization and Demagnetization Based on Hysteresis Modeling

• Multi-motion Modeling in 3D Transient

• Core Loss Manufacturing Dependency – Parameter Extraction

Electrical Machine Toolkit

• Use periodic TDM as solution method for induction machine

- More than 10X speed up

- Significantly improve reliability

• Better sampling strategies and more engineering data in output

• Significant improvement in post processing

TDM + linear sampling TDM + nonlinear samplingNon TDM + linear sampling

Before: profile did not change with leakage impedance

End leakage inductance = 2.811 mH End leakage inductance = 0.811 mH

Now: profile changes with leakage impedances

Efficiency Map Improvement

Allow RMxprt to import custom CAD geometry for stator and/or rotor

Electrical Machine Pre-processing Improvement

Imported

• Complete design setup:• Add remaining geometry, winding

arrangement, housing, etc• Rigid motion• Material setup including

magnetizing direction• Excitations, and boundaries• Transient setup and outputs

RMxprt

Final

AEDT Post-processing Integration of Customized Solution for Electrical Machines

• Provide with customized, efficient and accurate results for electrical machines

• Any n-phase machine is supported including electrical machines with field windings

• Calculate average and RMS parameters• Calculate Transient D-Q parameters

Electrical Machine Quantity Parameters

Full Model Visualization from Partial Model Solution

3D - Continuous skew

3D - Step skew

2D Skewing Improvements

• Support both Continuous Skew and Step Skew

− Continuous skew is normally used to model skewed slots

− Step skew is normally used to model shifted bulk magnets or multi-staged rotor

• Support both even and odd number of slices

Magnetization and Demagnetization Based on Hysteresis Modeling

Hysteresis model based approach

• •(0,0)

Model both magnetization (Hc> 0) & demagnetization (Hc <0)

Non-Hysteresis PM approach

•(0,0)

Hc cannot exceed zero to model only demagnetization

• Based on vector hysteresis modeling capability with the specification of initial magnetization direction working in all four quadrants

• Model magnetization and demagnetization process at the same time

• Consider magnetization/demagnetization in all directions

• Applicable to all nonlinear permanent magnets to model real physics with reasonable computational cost

Multi-motion Modeling in 3D Transient

Axial magnetic gearBand1Band2

• Allow the combination of different motion types in one design (cylindrical rotational motion, non-cylindrical rotational motion, periodic translational motion and non-periodic translational motion)

• Different motion types can be mixed as long as the bands between each motion type do not touch

• Typical applications:

• Electrical motors, such as multi-rotor motors for optimal performance under different speed ranges

• System simulation – normally involving more than one motion components

• Magnetic gears

Two cut edges are produced by each cut

Input parameter

“Equiv. Cut Depth”

Extracted

“Equiv. Cut Depth”

Display input curves, or

regression curves, or both

Launch toolExtract Equiv.

Cut Depth

Core Loss Manufacturing Dependency – Parameter Extraction

• Considers decrease in permeability and increase of local hysteresis in the vicinity of cut edges

• Use “Edge Cut…" mesh operation in both 2D/3D to refine mesh near edge

• Tool determines “Equiv. Cut Depth” based on multiple core-loss-curve with different number of cut-edges

• Extracted “Equiv. Cut Depth” used to construct regression curves vs input curves

High Performance Computing

• Half-Periodic TDM in 2D and 3D

• 3D Transient Source - Target Link using TDM

• 3D Eddy Current – MPI-based Domain Decomposition Method

Periodic Half-periodic

Memory 331.7 GB 189.1 GB

CPU 295 mins 168 mins

31 cores/tasks, 120 time steps per one period

Three phase synchronous generator

Half-Periodic TDM in 2D and 3D

• Cut memory usage about half, solving large problems using limited hardware resource

• Reduce computation time roughly by half

Three phase induction motor

• Efficiently solve complicated practical problems

• Induction motor design: source at locked speed, target at real speed

• Power electronics design: source using sinusoidal, target using PWM

Sinusoidal source PWM Source

3D Transient Source-Target Link using TDM

3D Eddy Current – MPI-based Domain Decomposition Method

• MPI-based Domain Decomposition for both iterative and direct solvers

• Can use different machines/nodes to solve same design to access more memory

• Multi-level HPC is supported

New Job Distribution Type

MPI OpenMP

Both Iterative and Direct solvers

• OpenMP shared memory

• MPI based DDM̶ Applicable to iterative solver and direct solver

• Multi-level HPC is supported

3D Eddy Current – MPI-based Domain Decomposition Method

1. OpenMp (matrix-solving only, R19.2, 1 task, 10 cores)

2. OpenMp (R19.3, 1 task, 10 cores)

3. DDM (R19.3, 8 tasks, 10 cores/task, totally 80 cores)

Induction machine simulated on EBU cluster

Multiphysics

• Fast Electromagnetically Excited Acoustic Noise and Vibration Modeling

for Electrical Machine Design

• 2-way Maxwell-Icepak Coupling in AEDT

• New Fluent Transient to Maxwell Eddy Current using System Coupling

Maxwell LF Analysis Harmonic Analysis

Transfer Forces Generate ERP and Waterfall plot

Harmonic Acoustic Analysis

Noise-Vibration and Acoustic Modeling for Electrical Machines

Spe

ed

(rp

m)

Acoustic Frequency (Hz)

Waterfall contour map gives the full acoustic fingerprint of the machine

Vertical Line:

• Given by one fixed eigenfrequency excited at different speeds of rotation

Horizontal Line:

• Single rpm load case yielding one frequency response function

Inclined Line:

• Excitation order of the electromagnetic force-density revealing a large ERP zone with its origin in single eigenfrequency that is met by both frequency and spatial load pattern of excitation and system mode

Blue domain in the right part of the plotindicates the modal basis being too short for high frequencies

Noise-Vibration and Acoustic Modeling for Electrical Machines

AEDT Icepak

HFSS – Icepak HFSS – Icepak

Maxwell – Icepak Q3D – Icepak

2-way Maxwell-Icepak Coupling in AEDT

• Easy mapping of Electromagnetic losses into AEDT-Icepak

• 2-Way Coupling element controls number of iterations

• Thermal dependent conductivity considered

New Fluent Transient to Maxwell Eddy Current using System Coupling

• Application target: Induction Heating

• Controlled by command line External Program (outside of Workbench) for tighter bi-directional coupling and more functionality

• System Coupling is controlling the sub-cycling simulation process between Fluent transient analysis and Maxwell eddy-current simulation

Induction Coil with Resulting Core Temperature Distribution

Meshing Enhancements

• 3D Clone Mesh for Moving and Stationary Parts

• 3D Mesh Density Control

• Edge-Cut Mesh

• Skin-Depth Meshing Improvements

Regular Mesh

Clone Mesh

Regular Mesh at moving region (R19.1)

Clone Mesh at moving region (R19.2)

3D Clone Mesh for Moving and Stationary Parts

• Automatically create 2D/3D clone mesh for both rotor and stator

• Dramatically reduces mesh noise

• Beneficial for accurate cogging torque computation

Mesh Density ControlR19.2 2019 R1

No density control Density control on coils and stator Density control on rotor

20 layers8 layers

Mesh density is changed, while clone mesh is still maintained

R19.2 R19.3

Edge Cut mesh on both static and moving side.

CoreLoss with Edge Cut MeshCoreLoss without Edge Cut Mesh

Automatic edge cut on master and slave

No edge cut mesh

Edge-Cut Mesh

Skin-Depth Meshing Improvements

Layers are protected through pass refinement

Assume skin depth thickness values is d

d

d

d

d

• Build layer mesh structure• The layers are protected through pass refinement• Can be applied to the selected faces of solid bodies• Elements stretched parallel to faces• Compressed in the normal direction

• Getting faster to the right answers - convergence on total energy and adaptive refinement energy

Usability Enhancements

• Variable Field Expression Cache

• 2D Distributed Solve Improvements within WB

• New Optimizers available in AEDT 2019 R1

• Maxwell2D Distributes Variation via Solver Licenses

Variable Field Expression Cache• Variables can be used for save fields and expression cache evaluations

• Allow user to only save fields and calculate expressions when desired

• Quicker solution and less memory needed

Variable Field Expression Cache

• Stop and end time can be dependent on rotor speed

• Can specify a window for results to be reported such as last period

RotorSpeed (rpm)

End Time(ms)

2000 10

6000 3.33…

10000 2

14000 1.428…

End Time 1/((RotorSpeed/1rpm)/60)/3

2D Distributed Solve improvements within Workbench

• DesignModeler-Optimetrics batch support in WB

• Allow Distribution Solve in Optimetrics with upstream geometry link in batch mode

Maxwell2D Distributes Variation via Solver Licenses

New “HPC and Analysis Options”

• Provide a consistent licensing model for variation distribution

• Solve in WB and AEDT environment

New Optimizers available in AEDT 2019 R1

1. Screening (Shifted Hammersley) 2. MOGA (Multi-Objective Genetic Algorithm)3. NLPQL (Non-linear Programming by Quadratic Lagrangian)4. MISQP (Mixed-Integer Sequential Quadratic Programming Method)5. Adaptive Multiple-Objective6. Adaptive Single-Objective

• There are six new optimization methods in AEDT coming from DX