LF Electromagnetics. Marius Rosu, PhD. Vincent Delafosse. EM Lead Product Manager. EM Senior Product Manager ANSYS, Inc.

Transcription

1 LF Electromagnetics 14.0 Updates 1 Marius Rosu, PhD EM Lead Product Manager Vincent Delafosse EM Senior Product Manager

2 2 R14 Highlights Simplorer 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 Eddy high h order elements Nonlinear anisotropic and lamination material in Maxwell2D 64 bit UI Q3D Magnetic materials capability RMxprt 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]

3 Introduction Electromechanical Perspective 3

4 ANSYS, Inc. All rights reserved. ANSYS, Inc. Proprietary

5 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 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 Leveraging the high fidelity h of 3D simulations into the 0D system simulation design 5

6 Maxwell Design Flow Field Coupling ANSYS CFD Fluent RMxprt Motor Design HFSS Maxwell 2-D/3-D Electromagnetic Components ANSYS Mechanical Thermal/Stress PExprt Magnetics Field Solution Model Generation 6

7 D2D GAIN J Simplorer Design Flow System Coupling ANSYS CFD Icepack/Fluent Simplorer System Design RMxprt Motor Design IA PMSYNC Torque A IB ICA: A A IC PP := 6 A HFSS, Q3D, SIwave PExprt pt Magnetics ANSYS Mechanical Thermal/Stress Maxwell 2-D/3-D Electromagnetic Components Model order Reduction Co-simulation Push-Back Excitation 7

8 Simplorer Multi Domain Circuit and System Simulation Package 8

9 Cosimulation with Rigid Body Dynamic Landing Gear Application Hydraulic Circuit Piston Position 9

10 Simplorer Fluent Cosimulation 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 Simulation results available in both Simplorer and Fluent 10

11 Cosimulation Example: Battery Cooling Single battery cell Inputs: Inlet Flow Rate (Kg/s) and Heat Source(W/m 3 ) Output: Outlet Temperature (K) Battery Element (HeatSource) Inlet Outlet 11

12 Simulation Results: No Control 12 Flow Temperature Change Heat Source Sec k k (double) k k (double) Results verified with Fluent alone Non linear dependency on Flow Rate

13 Simulation Results: Linear Controls 13

14 Simulation Results: Non linear Control Fluent Control Co Simulation 14

15 IGBT Characterization Accurate models of the semiconductors are needed to achieve a good circuit simulation Simplorer offers a parameterization tool for IGBTs The user can import the data from the datasheet and created an accurate IGBT model Ansoft Corporation switch_on Simplorer R2.I [A] U1.VCE VM2.V [V] Curve Info U1.VCE TR VM2.V TR TR R2.I Time [us] 15

16 IGBT Characterization Improvements It is possible to customize test circuits in the characterization tool: Every Manufacturer uses different measurement Criteria on their datasheets More optimization and extraction settings have been added 16

17 Push Back Excitation for EMC/EMI Push excitations to SIwave and HFSS: Allows feedback of transient simulation resultsinform of excitations for 3DFEA State Space Model Excitation data 17 Radiated Fields can now be calculated based on actual conductive mode analysis Both conductive and radiative analysis EMC/EMI can be performed

18 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 sub bcircuitit Perform a transient analysis Right click to push excitation UI. 3 UI converts timedomainsignaltofrequency to domain Excitation files get written Voltage and current for each frequency and port Import files back to SIwave External source excitations 18

19 Maxwell 2D/3D Finite Element Low Frequency Electromagnetics 19

20 Full Parallelization of 3D non transient solvers Magnetostatic solver: 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 20

21 Full Parallelization of 3D non transient solvers OpenMP is used to speed up the field solver using different cores sharing same memory 3D Magnetostatic Problem Adaptive Analysis with 6 iterative steps (energy error = 0.03%) 606,758 tetrahedra 817,274 matrix 150 Real Time Computation 64 bit 2.67 GHz 12GB of RAM Time [min.] CPU 2 CPU 4 CPU 6 CPU 8 CPU 21

22 3D Eddy Current High Order Elements Goal: Improve accuracy for current density field (J) J field is derived quantityfromt Ω Ω formulation Higher order elements gives first order approximation for currents Zero order approximation for currents 22 First order approximation for currents

23 3D Eddy Current High Order Elements Coil Plate Mesh on the plate 23 Induced eddy current Zero order vector shape functions Induced eddy current First order vector shape functions

24 Core Loss in Eddy Current Solver Core loss evaluation in linear mode without a transient analysis Steel and Power Ferrite Core loss available Typical Application: Ferrite Electronic Transformer 24

25 Core Loss in Eddy Current Solver Enter Core Loss coefficient as in Transient Disable Eddy Current calculation as Core Loss contains Eddy Loss 25 Ferrite Core

26 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 Loss = e 6 * 11 * (100,000)^1.3000)^1 * (0.2)^2.5 = 08W 0.8 The core loss can be numerically validated using the 3D magnetic transient solver employing linear BH characteristic 26

27 Maxwell Integration in Workbench What was already possible in R13: Two way way thermal coupling with ANSYS Mechanical (Static and Transient) One way force coupling with ANSYS Mechanical (Static and Transient) One way thermal coupling with Fluent through UDF Use Design Explorer within WB idi i l i i Unidirectional CAD integration 27

28 Maxwell ANSYS Stress Coupling Two way coupling non transient solvers and ANSYS stress solver is possible in R14 Approach: The Force distribution is transferred as load into ANSYS Mechanical The node displacement information is sent back to Maxwell as deformed mesh Force Distribution Maxwell ANSYS Mechanical Deformed Mesh 28

29 Maxwell ANSYS Stress Coupling Example: Air inductor 29

30 Maxwell ANSYS Stress Coupling B Field Force Distribution Magnetic Forces Field Calculation Updated Mesh Displacements Stress Calculation Displacements of mesh nodes 30

31 Maxwell Fluent Two Way Coupling Approach: The Loss distribution is transferred as load into Fluent The Temperature distribution is sent back to Maxwell Loss Distribution Maxwell ANSYS Fluent Temperature 31

32 Maxwell Fluent Two Way Coupling Example: Busbars Electrical, Thermal, Structural 32

33 PM Temperature Dependent Model Maxwell 2D/3D can account for Permanent Magnet temperature dependency. The law works directly on intrinsic B i H curve with remanent flux density B r and intrinsic i i coercivity ii H ci B Bi 0H The Two temperature dependent parameters are remanent flux density B r and intrinsic coercivity H ci B r and H ci can be described by second order polynomials as B r H T T0 2 T T0 Br ( T ) P( ) 2 T T T T H ( T ) Q ( ( T ) Br ( T ) 0 ci 0 T ) ( T ) H ci ( T ) ci 0 0 Q T where T 0 is the reference temperature, and α 1, α 2, β 1 and β 2 are coefficients which are provided in supplier datasheets 33

34 PM Temperature Dependent Model Copied from vendor datasheet Derived based on the temperature dependent demagnetization model 34

35 PM Temperature Dependent Model Coercivitychange it shows dynamic irreversible ibl demagnetization during a transient process in one element 35

36 Performance Enhancements in 2D Transient Post Processing 4096 variations, with 200 time step per variation 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 36

37 RMxprt Analytical Seizing package for Electrical Machines Design 37

38 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 Simplorerdesign 38

39 RMxprt IPM Machine RMxprt can set up the Maxwell 2D/3D project for IPM Machines RMxprt does not (yet) solve for it Multi duct layers supported 39

40 RMxprt Axial Flux Machine New machine topology: Axial Flux Machine AC or PM Rotor Single or Double Side Stator Maxwell 3D auto setup 40

41 Q3D Quick RLC Extractor for 2D and 3D Structures 41

42 Q3D Magnetic Materials Q3D can handle Magnetic Materials (in the linear part of B H curve) Permeability can be frequency dependent Typical Applications: Transformers Design Shielding Design PCB with Magnetic Core Design Q3D uses Boundary elements method To compute RLC parameters. It captures partial inductance in open loops 42

43 Q3D Magnetic Materials Transformer Example Goal: Get R(f), L(f) DC< f < 1 MHz Magnetic Core (µ = 500, σ= ) Solid Copper Coil 43

44 Q3D Magnetic Materials Set up For the Coil: 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) Source (Coil_in) 44

45 Q3D Magnetic Materials Using Maxwell: 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 AC Rest of the spectrum determined by blended algorithm No need to mesh for skin depth Easier setup 45

46 Q3D Magnetic Materials Q3D AC 10 s Maxwell 50 min Q3D DC 6min 30 s Sweep (regardless of # of Freqs) 2 s (4 Freq <1MHz) Total Q3D < 7 min 50 min Peak RAM 0.6 Gb 5 Gb Simulation Time Each Additional Freq 15 min Q3D XY Plot 1 Q3DDesign2 ANSOFT Curve Info ACL(Coil:Coil_in,Coil:Coil_in) Setup1 : Sw eep Maxwell oil:coil_in) [nh] ACL(Coil:Coil_in,Co Freq [MHz] 46 L(f) HFSS

47 Q3D New Features Circuit Export: 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 The feature has been extended to 2DExtractor 47

48 Q3D 3D Modeler Enhancements View customization Z-stretch 64 bit user interface This enhancement is available to all 3D products 48

49 Geometry and User Interface 49

50 Ansoft to ANSYS Geometry Transfer Geometry and material assignment transfer from Ansoft systems to ANSYS systems Possible to consume Ansoft geometry directly in mechanical or through DesignModeler Further geometry edits are possible in DM if user has license 50

51 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 51

52 Ansoft HPC Enhancements: Fixed Variables Applications UDPs Improves post processing speed because the user can select which variables will actually 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 them Any change to these variables invalidate existing solutions Benefits Faster access to solution database dtb Faster post processing Improved reporter dialog response No sluggishness Wave Winding UDP 52

53 CAD Integration on WB Improvements Added support for parametric analysis and DSO of CAD parameters 53

54 Reliability Engineering Design DOE Identify key design parameters Distribute parametric studies across available hardware to expedite design optimization i i Identify variation of performance with respect to variations of parameters 54

55 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 how many parts will which inputs require with design tolerances? likely fail? the greatest control? 55

56 Reliability Engineering Design Surface Response Analysis 56

57 Appendix: Mappingfield couplingcapabilities capabilities available in R14 Maxwell 2D/3D Electrostatic Magnetostatic Eddy Current Magnetic Transient Electric Transient ANSYS Static/Transient Structural ANSYS Static/Transient Structural Two Way Link One Way Link (Maxwell upstream) Maxwell 2D/3D Electrostatic t ti Magnetostatic Eddy Current Magnetic Transient Electric Transient 57 ANSYS Static/Transient Thermal Two Way Link ANSYS Static/Transient Thermal One Way Link (Maxwell upstream)

58 Appendix: Mappingfield couplingcapabilities capabilities available in R14 Maxwell 2D/3D Fluent Steady State Fluent Transient (Thermal link) Two Way Link (Thermal link) One Way Link (Maxwell upstream) Electrostatic Magnetostatic Eddy Current Magnetic Transient Electric Transient 58

59 Appendix: MappingSimplorer system couplingcapabilities capabilities available in R14 Solver Reduce Order Equivalent Co Simulation Push Back Model Circuit/Matrices Excitation /Look Up Tables Maxwell 2D/3D Electrostatic Magnetostatic Maxwell 2D/3D Eddy Current Maxwell 2D/3D Transient Q3D HFSS, SIwave RMxprt, PExprt 59

60 Appendix: MappingSimplorer system couplingcapabilities capabilities available in R14 Solver Reduce Order Equivalent Co Simulation Push Back Model Circuit/Matrices Excitation /Look Up Tables Fluent Transient Icepak ANSYS Mechanical (Modal) ANSYS RBD Simulink ModelSim Mathcad 60