LF Electromagnetics14.0 Updates0 Upda es
Marius Rosu, PhDEM Lead Product Manager
© 2011 ANSYS, Inc. August 25, 20111
Vincent DelafosseEM Senior Product Manager
SimplorerR14 HighlightsSimplorer
• Co‐simulation with RBD
• Push‐Back excitations for EMI/EMC (to SIwave and HFSS)
• Co‐simulation with Fluent (Beta feature)
• Improvements in IGBT characterization tool
Maxwell
• Parallelization of Maxwell 3D non‐transient solvers
• 2‐way thermal link with Fluent (Beta feature)
• Deformed mesh support for 2‐way stress link
• Nonlinear permanent magnets characteristic temperature dependency
• 3D Edd hi h d l t• 3D‐Eddy high order elements
• Nonlinear anisotropic and lamination material in Maxwell2D
• 64‐bit UI
Q3DQ3D
• Magnetic materials capability
RMxprt
• Axial flux permanent magnet machine
© 2011 ANSYS, Inc. August 25, 20112
• Axial‐flux permanent magnet machine
• Interior permanent magnet machine [set‐up for M2D/3D only]
• Solid‐rotor induction motor [set‐up for M2D/3D only]
IntroductionIntroduction‐
Electromechanical PerspectiveElectromechanical Perspective
© 2011 ANSYS, Inc. August 25, 20113
Introduction: Electromechanical Perspective
ANSYS has a comprehensive portfolio of simulation packages. Our goal is to provide tools that enable Electric Engineers to solve their problems in theprovide tools that enable Electric Engineers to solve their problems in the most efficient way
ANSYS focus:
‐ Developing cutting‐edge technology solving real world problems faster
‐ Enabling couplings between 3D physics solvers where it is relevant
L i th hi h fid lit f 3D i l ti i t th “0D” t‐ Leveraging the high‐fidelity of 3D simulations into the “0D” system simulation design
© 2011 ANSYS, Inc. August 25, 20115
Maxwell Design Flow – Field Coupling
ANSYS CFDFluent
RMxprtMotor Design
2 /3
g
Maxwell 2-D/3-DElectromagnetic ComponentsHFSS
PExprtANSYS
MechanicalThermal/Stress
pMagnetics
© 2011 ANSYS, Inc. August 25, 20116
Field Solution
Model Generation
Simplorer Design Flow – System Coupling
SimplorerSystem Design
ANSYS CFD Icepack/Fluent RMxprt
M t D i
PP := 6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
JPMSYNCIA
IB
IC
Torque JPMSYNCIA
IB
IC
TorqueD2D
Motor Design
HFSS, Q3D, SIwave
PExprtp tMagnetics
Maxwell 2-D/3-DElectromagnetic Components
ANSYS MechanicalThermal/Stress
Model order Reduction
© 2011 ANSYS, Inc. August 25, 20117
Co-simulation
Push-Back Excitation
SimplorerSimplorer
Multi‐Domain Circuit and System Simulation Package
© 2011 ANSYS, Inc. August 25, 20118
Cosimulation with Rigid Body DynamicLanding Gear ApplicationLanding Gear Application
Hydraulic Circuit
Piston Position
© 2011 ANSYS, Inc. August 25, 20119
Simplorer‐Fluent Cosimulation
Typical Application: Battery Cooling
Transient co‐simulation for non‐linear CFD models
Typical Application: Battery Cooling
Design Flow:
– Fluent User• Creates Fluent design
• Creates Boundary Conditions (defining Parameters) for cosimulation interface
– Simplorer User• Uses UI to connect to Fluent design: Schematic component and Pins are created automatically
• Wires up the rest of the schematic
• Sets up the Transient Analysis and Simulates
– Cosimulation is OS independent
– Cosimulation may use local machine or run over the network
© 2011 ANSYS, Inc. August 25, 201110
y
– Simulation results available in both Simplorer and Fluent
Cosimulation Example: Battery Cooling
Single battery cell
Inputs: Inlet Flow Rate (Kg/s) and Heat Source(W/m3)
Output: Outlet Temperature (K)
InletBattery Element
Outlet
y(HeatSource)
Outlet
© 2011 ANSYS, Inc. August 25, 201111
Simulation Results: No Control
Flow Rate
Heat SourceTemperature Change
@250 Sec @1200 Sec
0.01 400k 37.9155 64.8926
800k (double) 75.8207 129.787
0.02 400k 29.7525 39.201
800k (double) 59.4059 78.402
© 2011 ANSYS, Inc. August 25, 201112
Results verified with Fluent aloneNon‐linear dependency on Flow Rate
Simulation Results: Non‐linear Control
Fluent Control Co‐Simulation
© 2011 ANSYS, Inc. August 25, 201114
IGBT Characterization
• Accurate models of the semiconductorsare needed to achieve a good circuitare needed to achieve a good circuit simulation
• Simplorer offers a parameterization toolfor IGBTsfor IGBTs
• The user can import the data from the datasheet and created an accurate IGBT modelmodel
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IGBT Characterization Improvements
It is possible to customize test circuits in the characterization tool:Every Manufacturer uses different measurement Criteria on their datasheetsEvery Manufacturer uses different measurement Criteria on their datasheets
More optimization and extraction settings have been added
© 2011 ANSYS, Inc. August 25, 201116
Push‐Back Excitation for EMC/EMI
Push excitations to SIwave and HFSS: Allows feedback of transient simulation results in form of excitations for 3D FEAresults in form of excitations for 3D FEA
State Space Model
Excitation data
© 2011 ANSYS, Inc. August 25, 201117
Radiated Fields can now be calculated based on actual conductive mode analysisBoth conductive and radiative analysis EMC/EMI can be performed
SIwave and HFSS Flow
1 Export an equivalent circuit model for the SIwave design as a Simplorer SML netlist
2 Import the SML netlist as a s b circ it2 Import the SML netlist as a sub circuit
• Perform a transient analysis
• Right click to push excitation UI.
3 UI converts time domain signal to frequency domain3 UI converts time domain signal to frequency domain
• Excitation files get writtenExcitation files get written– Voltage and current for each
frequency and port• Import files back to SIwave
l
© 2011 ANSYS, Inc. August 25, 201118
– External source excitations
MaxwellMaxwell
2D/3D Finite Element Low Frequency Electromagnetics/ q y g
© 2011 ANSYS, Inc. August 25, 201119
Full Parallelization of 3D non‐transient solvers
Magnetostatic solver:bl– Matrix Assembly
– Energy computation for post processing in field solver
Eddy current solver:– Energy computation for post processing in field solver
– Power loss and stress computation for post processing
© 2011 ANSYS, Inc. August 25, 201120
Full Parallelization of 3D non‐transient solvers
OpenMP is used to speed up the field solver using different cores sharing same memory
64‐bit XP @ 2.67 GHz 12GB of RAM
3D Magnetostatic Problem‐ Adaptive Analysis with 6 iterative steps (energy error = 0.03%)‐ 606,758 tetrahedra
150
Real Time Computation
‐ 817,274 matrix
100
150
[min.]
50
Time [
© 2011 ANSYS, Inc. August 25, 201121
0
1‐CPU 2‐CPU 4‐CPU 6‐CPU 8‐CPU
3D Eddy Current High Order Elements
Goal: Improve accuracy for current density field (J)
‐ J field is derived quantity from T‐Ω formulationJ field is derived quantity from T Ω formulation
‐ Higher order elements gives first order approximation for currents
© 2011 ANSYS, Inc. August 25, 201122
First order approximation for currents
Zero order approximation for currents
3D Eddy Current High Order Elements
C ilCoil
Mesh on the plate
Plate
© 2011 ANSYS, Inc. August 25, 201123
Induced eddy current Zero order vector shape functions
Induced eddy currentFirst order vector shape functions
Core Loss in Eddy‐Current Solver
Steel and Power Ferrite Core loss available
Core loss evaluation in linear mode without a transient analysis
Typical Application: Ferrite Electronic Transformer
© 2011 ANSYS, Inc. August 25, 201124
Core Loss in Eddy‐Current Solver
Enter Core Loss coefficient as in Transient
Disable Eddy Current calculation as Core Loss contains Eddy Loss
© 2011 ANSYS, Inc. August 25, 201125Ferrite Core
Core loss in Eddy‐Current Solver
Maxwell 3D results: 0.85 W
Formula used:
Validation with hand calculation:
• Core volume = 1.29e‐6 [m^3], frequency= 100KHz
• B ~ 0.2 Tesla
• L 1 29 6 * 11 * (100 000)^1 3 * (0 2)^2 5 0 8 W• Loss = 1.29e‐6 * 11 * (100,000)^1.3 * (0.2)^2.5 = 0.8 W
The core‐loss can be numerically validated using the 3D magnetic transient solver
© 2011 ANSYS, Inc. August 25, 201126
y g gemploying linear BH characteristic
Maxwell Integration in Workbench
What was already possible in R13:• Two way thermal coupling with ANSYS Mechanical• Two‐way thermal coupling with ANSYS Mechanical (Static and Transient)
• One‐way force coupling with ANSYS Mechanical (Static and Transient)and Transient)
• One‐way thermal coupling with Fluent through UDF
• Use Design Explorer within WB
idi i l i i• Unidirectional CAD integration
© 2011 ANSYS, Inc. August 25, 201127
Maxwell – ANSYS Stress Coupling
Two way coupling non‐transient solvers and ANSYS stress solver is possible in R14is possible in R14
Approach:• The Force distribution is transferred as load into ANSYS MechanicalThe Force distribution is transferred as load into ANSYS Mechanical
• The node displacement information is sent back to Maxwell as deformed mesh
Maxwell ANSYS Mechanical
Force Distribution
Deformed Mesh
© 2011 ANSYS, Inc. August 25, 201128
Maxwell – ANSYS Stress Coupling
B Field Force Distribution
MagneticForcesForces
Stress CalculationField Calculation
DisplacementsUpdated Mesh
Displacementsof mesh nodes
© 2011 ANSYS, Inc. August 25, 201130
Maxwell – Fluent Two‐Way Coupling
Approach:• The Loss distribution is transferred as load into Fluent
• The Temperature distribution is sent back to Maxwell
Maxwell ANSYS Fluent
Loss Distribution
Temperature
© 2011 ANSYS, Inc. August 25, 201131
p
Maxwell – Fluent Two‐Way Coupling
Example: Busbars – Electrical, Thermal, Structural
© 2011 ANSYS, Inc. August 25, 201132
PM Temperature Dependent Model
Maxwell 2D/3D can account for Permanent Magnet temperature dependency. The law works directly on intrinsic BiH curve with
fl d i B d i i i i i Hremanent flux density Br and intrinsic coercivity Hci
HBB i 0The Two temperature dependent parameters are remanent flux
density Br and intrinsic coercivity Hci
B and H can be described by second order polynomials asBr and Hci can be described by second order polynomials as
)()(1)()( 02
02010 TPTBTTTTTBTB rrr
)()( 1)()( 02
02010 TQTHTTTTTHTH cicici
where T0 is the reference temperature, and α1, α2, β1 and β2 are coefficients which are provided in supplier datasheets
)()()()( 002010 Qcicici
© 2011 ANSYS, Inc. August 25, 201133
PM Temperature Dependent Model
Copied from vendor datasheet
Derived based on the temperature dependent demagnetization model
© 2011 ANSYS, Inc. August 25, 201134
PM Temperature Dependent Model
C i it h h d i i ibl
© 2011 ANSYS, Inc. August 25, 201135
Coercivity change shows dynamic irreversible demagnetization during a transient process in one element
Performance Enhancements in 2D Transient Post ProcessingProcessing
• 4096 variations, with 200 time step per variation
• Update and open 2 XY reports• Update and open 2 XY reports
Without Cache With Cache
R13 3 hrs 30 mins 10 mins
R14 32 mins 5 mins 20 secs
Speed up 7X 2X
© 2011 ANSYS, Inc. August 25, 201136
Speed up 7X 2X
RMxprt
Analytical Seizing package for Electrical Machines Design
© 2011 ANSYS, Inc. August 25, 201137
Integrated Motor Solutions
• RMxprt automatic setup with one‐click for Maxwell 2D and 3D Solution• Minimum solving region creation with matching boundary setup • Motion and mechanical setup• Material setup including core loss and lamination• Winding and source setup with drive circuit• Auto‐create Simplorer design
© 2011 ANSYS, Inc. August 25, 201138
RMxprt – IPM Machine
RMxprt can set up the Maxwell 2D/3D project for IPM Machines• RMxprt does not (yet) solve for it• RMxprt does not (yet) solve for it
• Multi duct layers supported
© 2011 ANSYS, Inc. August 25, 201139
RMxprt – Axial Flux Machine
New machine topology: Axial Flux Machine• AC or PM Rotor• AC or PM Rotor
• Single or Double Side Stator
• Maxwell 3D auto‐setup
© 2011 ANSYS, Inc. August 25, 201140
Q3D – Magnetic Materials
Q3D can handle Magnetic Materials (in the linear part of B‐H curve)
Permeability can be frequency dependent
Typical Applications:
• Transformers DesignTransformers Design
• Shielding Design
• PCB with Magnetic Core Design
Q3D uses Boundary elements methodTo compute RLC parameters. It captures partial inductance in open loops
© 2011 ANSYS, Inc. August 25, 201142
p p p
Q3D – Magnetic Materials
Transformer Example
Goal: Get R(f), L(f)
DC< f < 1 MHzDC< f < 1 MHz
Magnetic Core (µ = 500, σ= 100000)
© 2011 ANSYS, Inc. August 25, 201143
Solid Copper Coil
Q3D – Magnetic Materials
Set up For the Coil:
• Cut a very small piece of the Coil (to have loop inductance ≈ Partial• Cut a very small piece of the Coil (to have loop inductance ≈ Partial Inductance)
• Create an active Net with Source/Sink
Set up For the Core:
• Create an active Net (no Source/Sink necessary)
Sink (Sink1)Sink (Sink1)
S
© 2011 ANSYS, Inc. August 25, 201144
Source (Coil_in)
Q3D – Magnetic Materials
Using Maxwell:
• Need to mesh to account for skin depth at each frequency Can lead to huge• Need to mesh to account for skin depth at each frequency. Can lead to huge mesh for higher frequencies as skin depth decreases: at 1 MHz, δ = 0.07mm
• Two Matrix resolutions at each frequency (one for Fields, one for R, L)
Advantages using Q3D:
• Only 1 resolution for DC 1 resolution for ACOnly 1 resolution for DC, 1 resolution for AC
• Rest of the spectrum determined by blended algorithm
• No need to mesh for skin depth
• Easier setup
© 2011 ANSYS, Inc. August 25, 201145
Q3D – Magnetic Materials
Q3D AC 10 s Maxwell 50 min
Q3D DCQ3D DC 6min 30 s
Sweep 2 s
(regardless of # of Freqs) (4 Freq <1MHz)
Total Q3D < 7 min 50 min
Simulation Time
Q3DDesign2XY Plot 1 Q3DDesign2XY Plot 1
Peak RAM 0.6 Gb 5 Gb
Each Additional Freq 15 min Q3D
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oil_
in) [
nH]
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Curve InfoACL(Coil:Coil_in,Coil:Coil_in)
Setup1 : Sw eep2
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Curve InfoACL(Coil:Coil_in,Coil:Coil_in)
Setup1 : Sw eep2
M ll
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© 2011 ANSYS, Inc. August 25, 201146
0.00 0.01 0.10 1.00 10.00 100.00Freq [MHz]
25.00 0.00 0.01 0.10 1.00 10.00 100.00
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Q3D – New Features
Circuit Export:
• User can now pick a frequency in the sweep and export the SPICE netlist or• User can now pick a frequency in the sweep and export the SPICE netlist or the Simplorer circuit. Q3D adjusts for corresponding R(f) and L(f). The exported circuit is valid at the given frequency f.
• Only Simplorer supports Frequency dependent models from Q3D• Only Simplorer supports Frequency dependent models from Q3D
The feature has been extended to 2DExtractor
© 2011 ANSYS, Inc. August 25, 201147
Q3D ‐ 3D Modeler Enhancements
View customization
• Z-stretch• 64‐bit user interface
© 2011 ANSYS, Inc. August 25, 201148
This enhancement is available to all 3D products
Ansoft to ANSYS Geometry Transfer
• Geometry and material assignment transfer from Ansoft systems to ANSYS systemsy y
• Possible to consume Ansoft geometry directly in mechanical or through DesignModeler
• Further geometry edits are possible in DM if user has license
© 2011 ANSYS, Inc. August 25, 201150
Multiple Geometry Links
Possible to consume geometry from multiple upstream sources• Source can be any of CAD, DesignModeler or Ansoft products• Creates UDM for each geometry input
© 2011 ANSYS, Inc. August 25, 201151
Ansoft HPC Enhancements: Fixed VariablesApplications• UDPs
– Improves post processing speed because the user can select which variables will actually be indexed for sweeping
Wave Winding UDP
be indexed for sweeping– Previously all variables were selected for
indexing even if they are were not being swept
– Applies to all Desktop products
Desktop supports fixed variables• Solution database is NOT indexed by these variables
• User will not sweep themp• Any change to these variables invalidate existing solutions
Benefits• F t t l ti d t b• Faster access to solution database– Faster post‐processing
• Improved reporter‐dialog response– No sluggishness
© 2011 ANSYS, Inc. August 25, 201152
gg
CAD Integration on WB Improvements
Added support for parametric analysis and DSO of CAD parameters
© 2011 ANSYS, Inc. August 25, 201153
Reliability Engineering Design ‐ DOE
Distribute parametric studies across available hardware to expedite design
i i iIdentify key design parameters
optimization
Identify variation of performance with respect to variations of parameters
© 2011 ANSYS, Inc. August 25, 201154
Reliability Engineering Design – Six Sigma
Input parameters vary!A product has Six Sigma quality if only 3.4 parts out of every 1 million manufactured fail
Output parameters
How performance will vary ith d i t l ?
how many parts will likely fail?
which inputs require the greatest control?
© 2011 ANSYS, Inc. August 25, 201155
with design tolerances? likely fail? the greatest control?
Reliability Engineering DesignSurface Response AnalysisSurface Response Analysis
© 2011 ANSYS, Inc. August 25, 201156
Appendix:Mapping field coupling capabilities available in R14Mapping field coupling capabilities available in R14
Maxwell 2D/3D ANSYS Static/Transient StructuralTwo‐Way Link
ANSYS Static/Transient StructuralOne‐Way Link (Maxwell upstream)y y ( p )
Electrostatic
Magnetostatic
ddEddy Current
Magnetic Transient
Electric Transient
Maxwell 2D/3D ANSYS Static/Transient ThermalTwo‐Way Link
ANSYS Static/Transient ThermalOne‐Way Link (Maxwell upstream)
El t t tiElectrostatic
Magnetostatic
Eddy Current
© 2011 ANSYS, Inc. August 25, 201157
Magnetic Transient
Electric Transient
Appendix:Mapping field coupling capabilities available in R14Mapping field coupling capabilities available in R14
Maxwell 2D/3D Fluent Steady State Fluent TransientMaxwell 2D/3D Fluent Steady State(Thermal link)Two‐Way Link
Fluent Transient(Thermal link)
One‐Way Link (Maxwell upstream)
Electrostatic
Magnetostatic
Eddy Current
M ti T i tMagnetic Transient
Electric Transient
© 2011 ANSYS, Inc. August 25, 201158
Appendix:Mapping Simplorer system coupling capabilities availableMapping Simplorer system coupling capabilities available in R14
Solver Reduce Order Equivalent Co‐Simulation Push BackModel
qCircuit/Matrices/Look‐Up Tables
Excitation
Maxwell 2D/3DElectrostaticMagnetostatic
Maxwell 2D/3Ddd CEddy Current
Maxwell 2D/3DTransient
Q3D
HFSS, SIwave
RMxprt, PExprt
© 2011 ANSYS, Inc. August 25, 201159
Appendix:Mapping Simplorer system coupling capabilities availableMapping Simplorer system coupling capabilities available in R14
Solver Reduce Order Equivalent Co‐Simulation Push BackModel
qCircuit/Matrices/Look‐Up Tables
Excitation
Fluent Transient
Icepak
ANSYS Mechanical(Modal)
ANSYS RBD
SimulinkSimulink
ModelSim
Mathcad
© 2011 ANSYS, Inc. August 25, 201160