New Facilities for Multiphysics Modelling in Opera-3d version 16 By Chris Riley

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1 FEA ANALYSIS General-purpose multiphy sics design and analy sis softw are for a w ide range of applications OPTIMIZER A utomatically selects and manages multiple goalseeking algorithms INTEROPERABILITY Built-in circuit modelling and interfaces to leading C A D packages SERVICE Technical support, training and consultancy serv ices av ailable for softw are usage and applications New Facilities for Multiphysics Modelling in Opera-3d version 16 By Chris Riley

2 Outline Multiphysics is it new? What do we mean by multiphysics? What is driving the requirement for multiphysics in software? New software tools in Opera 16 Solver linking Material, boundary conditions, volume properties, model symmetry Examples What happens next? 1

3 Multiphysics is it new? Opera-3d has supported multiphysics at some level since the introduction of the Tempo solver for thermal analysis about 10 years ago Allowed users to import heat calculated in electromagnetic simulations as a source for thermal analysis Followed by introduction of Stress solvers Small displacement static Modal Material properties could be dependent on values from another type of physics Permeability as steel approaches Curie temperature 1+sqrt((800-min(T;800))/800)*(#MU_RT-1) => 2

4 Multiphysics was it difficult? Required the user to keep track of table files passed from one simulation to another in Post Values to be passed at (X,Y,Z) of nodes / element centroids Typical scenario: Calculate electromagnetic solution Create thermal model OP3 but do not solve Read thermal OP3 into Post Create table of element centroids Read solved electromagnetic OP3 into Post Create new table file with loss values from electromagnetics at thermal centroids Re-read thermal OP3 into Post Import loss values from second table file Unload OP3 from Post to allow job submission 3

5 Multiphysics was it difficult? Answer is probably Yes Easy to lose track of which table file is which Easy to submit job before adding all the sources / values Easy to forget to set volume properties to import values or to make an error specifying the name Elektra, with symmetry Advantage is that can use different meshes for each type of physics Tempo, no symmetry 4

6 What do we mean by multi-physics? Simple definition Continuum physics that depends on the behaviour of one or more other continuum physics May be sequential EM analysis => Forces => Stress analysis => Deflection End winding stresses under fault conditions May have mutual dependence EM analysis => Heat => Thermal => Temperature rise => EM analysis with updated material properties =>.. Iterate until converged 5

7 What does it require? Requirements Results from any continuum physics must be available to any other continuum physics whose governing equations rely directly or indirectly on them Material properties and other attributes (such as boundary conditions) for a particular continuum must be expressible in terms of any other required continuum physics results Expressions Look up tables 6

8 Why is it becoming so important? Drivers in the 21 st century Rare earth magnets Temperature dependent behaviour Insulation fatigue Harsh environments in transport Reliability Safety More electric aircraft and other transport applications Cost Off shore wind energy High speed machines Significant rotational forces Computer hardware Multi-core PC s ideal for spreading physics 20 C 300 C 7

9 New facilities in Opera 16 New type of analysis Multiphysics List of analyses to be performed Analysis parameters for each simulation Fields passed directly to any subsequent analysis Automatic calculation New style dialogs for multiphysics Materials, boundary conditions, volume properties, model symmetry Same mesh for all simulations Stress / thermal will ignore AIR 8

10 Multiphysics simulation 9

11 Multiphysics simulation dialogs (1) 10

12 Multiphysics simulation dialogs (2) 11

13 Analyses available in Multiphysics All non-transient analysis simulations Statics (TOSCA) Steady-state AC (ELEKTRA-SS) Velocity (ELEKTRA-VL) HF (SOPRANO-SS / SOPRANO-EV) Space Charge (SCALA) Static Thermal (TEMPO-ST) Static Stress (STRESS-ST) Transient electromagnetic (ELEKTRA-TR) also included Time = 0 solution only Allows deflections of meshed coils to be calculated in static stress analysis 12

14 Fields available INPUTS USED BY Electromagnetic Thermal Stress FIELDS CALCULATED BY Electromagnetic - Heat density calculated from coil currents, eddy currents or beam current Magnetic flux density Element force density Thermal Temperature - Temperature Stress Displacements Displacements - 13

15 Multiphysics tabbed Set dialogs 14

16 Example 1 Coupled SS eddy current / thermal 15

17 Example 1 Coupled SS eddy current / thermal 16

18 Example 1 Coupled SS eddy current / thermal EM Thermal ht None Heat Transfer tm Tangential Magnetic Perfect Insulator 17

19 Example 1 Coupled SS eddy current / thermal 18

20 Example 2 Multiphysics optimization Objectives Maximize gap flux density Minimize deflection of poles Parameters Major and minor radii of torus 19

21 Example 2 Multiphysics optimization 20

22 Example 2 Multiphysics optimization 21

23 Example 2 Multiphysics optimization 22

24 Example 2 Multiphysics optimization Pareto optimal design with maximum flux density Major radius = mm Minor radius = 2.5 mm 23

25 Example 2 Multiphysics optimization Pareto optimal design with minimum difference in flux density Major radius = mm Minor radius = mm 24

26 Multiphysics next steps Inclusion of all analysis types Include post-processing of transient simulations during simulation Average values for forces, losses etc Development of new solution methods to solve tightly coupled multiphysics Quench Electromagnetic + thermal Forced vibration? Electromagnetic + dynamic stress More about both later in the EUGM 25

27 Summary Multiphysics has been available in Opera for more than 10 years Thermal Stress Require any results from one physics to be available in subsequent simulations Ability to specify material properties, boundary conditions in terms of other physics New tools Developments for time-stepping and other multi-case simulations 26