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CADFEM 2017
Simulation of Electric Machines with ANSYS
Jens Otto CADFEM GmbH
1
CADFEM 2017
Why Simulation with ANSYS ? Challenges for electric machines
- 2 -
Electromagnetic Design:
Rated power/ Power-Volume-Ratio
Material consumption
Losses/Efficiency
Torque ripple
Circuit interaction
Structural Design:
Housing integrity
Active steel integrity
Winding-end design
Cooling Design
Air/Fluid flow
Coupled Analyses:
Temperature prediction
Vibroacoustics
CADFEM 2017
Simulation Driven Product Development Customer Workflow
3
Marc Brck EM-motive a Bosch + Daimler Company
CADFEM 2017
Virtual Prototype: Simulation is Everywhere!
4
Electromagnetic is just
one aspect of design
EADT also part of
Workbench environment
Thermal
Fluid-flow
Structural
Coupled Simulation
CADFEM 2017
Electromagnetic FEM Solution in ANYS Maxwell
- 5 -
Maxwell:
Static
Time-Dependent
Time domain (Transient)
Frequency domain (Harmonic)
Motion (Linear, Rotational)
Advanced physics capability
2D; 2.5D; 3D
Materials
Circuit coupling
Source: CADFEM
CADFEM 2017
- 6 -
Translate differential equation to
algebraic equations
Discretize space by
tetrahedrons/triangles
Quantities are interpolated between
nodes
Solution
computed
on nodes
Source:CADFEM
CADFEM 2017
Automatic Adaptive Meshing
- 7 -
Generate efficient mesh without
expert mesh know-how
Find a compromise accuracy vs
simulation time
User defined convergence criteria
Global energy error (default)
Torque
Force
Inductance
Adaptive meshing available
for all non-transient solvers
Calculate local
Solution error
Generate Initial
Mesh
Solve fields using the
Finite Element Method
End criteria
reached ?
Refine Mesh
Calculate Outputs
(Force, Inductance, etc.)
no
yes
Start
CADFEM 2017
Automatic Adaptive Meshing Example
- 8 -
Source ANSYS Inc.
CADFEM 2017
Mesh Operations
- 9 -
Can be combined with adaptive
approach
Fewer iterations
Faster solution times
Mesh refinement for transient
simulations
Manual mesh refinement
Import mesh from static/harmonic
Source CADFEM
CADFEM 2017
True Motion in Electromagnetic Simulation
10
User friendly configuration
Velocity dependent effects
Eddy currents (effect on field)
PMs
Squirrel cage
Conducting slot wedges/
mechanical parts
External particles
CADFEM 2017
3D Vector Hysteresis Modeling
Lamination support
Optimization to minimize total error
of major & minor loop
Non-zero initial condition support
footer 11
CADFEM 2017
Material properties
- 12 -
Nonlinear and/or anisotropic permeability
Anisotropic conductivity
Core loss model
Steinmetz approach
electrical steel
power ferrite
Solid or lamination model
Scaling of B-H curve
Temperature dependent
CADFEM 2017
User Friendly Extraction of Steinmetz Coefficients
- 13 -
Select extraction method
Core loss versus frequency
Core loss at one frequency
Lamination thickness needed
Input datasheet data from supplier
Manual
csv, txt import
Sheet scan
Automatic calculation of coefficients
Automatic update in material properties
CADFEM 2017
Simulation Dimensionality
14
2D Simulation
Planar B-field
General machine sizing
2.5D for skewing approximation
Stepwise approximation
3D
Full flexibility
Detailed eddy current paths
End effects (Stray fields)
Non planar flux
CADFEM 2017
Since R17: Time Decomposition Method
HPC-Method for transient magnetic
designs
Simultaneous calculation of k time
steps
N-Tasks containing k-time steps each
N-Tasks can be distibuted in DMP
mode
T1 Tk
k Time Steps
n Parallel
Distribued Tasks
Matrix Size
X k
T1
T2
T3
T(k-2)
T(k-1)
T(k)
Source: ANSYS Inc.