v14.

0 LF Electromagnetics Update

Mark Christini
ANSYS, Inc

1 © 2011 ANSYS, Inc. September 21,

2011
 What is the ANSYS Solution?

2 © 2011 ANSYS, Inc. September 21,

© 2010 ANSYS, Inc. All rights reserved. ANSYS, Inc. Proprietary
2011
 Introduction: Electromechanical Perspective

• ANSYS has a comprehensive portfolio of simulation

packages.
• Our goal is to provide tools that enable Electrical 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 of 3D simulations into the “0D”
system simulation design

3 © 2011 ANSYS, Inc. September 21,

2011
 Maxwell Design Flow – Field Coupling
ANSYS CFD RMxprt
Fluent Motor Design

Maxwell 2-D/3-D
HFSS Electromagnetic Components

PExprt
ANSYS Magnetics
Mechanical
Thermal/Stress

Field Solution

Model Generation
4 © 2011 ANSYS, Inc. September 21,
2011
 Simplorer Design Flow – System Coupling
ANSYS CFD Simplorer
Icepack/Fluent System Design RMxprt
Motor Design
IA PMSYNC Torque J

A A D2D

IB ICA:
A
PP := 6
IC
A

GAIN

HFSS, Q3D, SIwave

PExprt
Magnetics

ANSYS Maxwell 2-D/3-D

Mechanical Electromagnetic Components
Thermal/Stress
Model order Reduction

Co-simulation

Push-Back Excitation
5 © 2011 ANSYS, Inc. September 21,
2011
 ANSYS Workbench R14 Highlights
Simplorer
• Co-simulation with Rigid Body Dynamics
• 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 Current high order elements
• Nonlinear anisotropic and lamination materials in Maxwell2D
• 64-bit UI
Q3D
• Magnetic materials capability
RMxprt
• Axial-flux permanent magnet machine
• Setup capability for Interior permanent magnet machines
• Setup capability for Solid-rotor induction motors
6 © 2011 ANSYS, Inc. September 21,
2011
 Simplorer
Multi-Domain Circuit and System Simulation Package

7 © 2011 ANSYS, Inc. September 21,

2011
 Simplorer - Overview
Circuits
• Multi-domain, system simulator for designing
high performance systems R1 50
R2 1k R3 1k
C2
R4
50
C1
N0002
3.3u

• Three Basic Simulation Engines: Circuits, Block 12 3.3u

V0 := 5 N0003 V0 := 0
N0004

Diagrams, State Machines N0005

• Mixed Signal – Mixed Mode Modeling

• Digital / Analog Block Diagrams
I_PART_id

• Magnetic, Mechanical, Thermal … UL := 9

I
CONST

LL := -9 P_PART_id id_ref
id
• Integrated analysis with electromagnetic LIMIT GAIN G(s) GAIN

GS2
simulation tools (Maxwell, PExprt, RMxprt, Q3D) yd KP := 0.76
SUM2_6

State Machines
• Analysis Types: AC, DC, Transient
IMP = 0 and RLine.I <= ILOW
SET: CS1:=-1

• Co-simulation with Maxwell and Simulink

SET: CS1:=-1
SET: CS2:=-1 SET: CS2:=1
SET: CS3:=-1 SET: CS3:=-1
SET: CS4:=-1 SET: CS4:=-1
IMP = 0 and RLine.I >= IUP

IMP = 0

• Statistical Analysis and Optimization

IMP = 1
IMP = 0 IMP = 1

• VHDL-AMS Capability SET: CS1:=1

SET: CS2:=-1
SET: CS3:=-1
SET: CS4:=-1
IMP = 1 and RLine.I <= ILOW SET: CS1:=-1
SET: CS2:=-1
SET: CS3:=-1
SET: CS4:=-1
IMP = 1 and RLine.I >= IUP

8 © 2011 ANSYS, Inc. September 21,

2011
 Cosimulation with Rigid Body Dynamic Position

Landing Gear Application

vs Force

Hydraulic Circuit

Piston Position

9 © 2011 ANSYS, Inc. September 21,

2011
 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
– Simulation results available in both Simplorer and Fluent

10 © 2011 ANSYS, Inc. September 21,

2011
 Cosimulation Example: Battery Cooling

Single battery cell

Inputs: Inlet Flow Rate (Kg/s) and Heat Source(W/m3)
Output: Outlet Temperature (K)

Battery Element Inlet

(HeatSource)

Outlet

11 © 2011 ANSYS, Inc. September 21,

2011
 Simulation Results: No Control

Flow Temperature Change

Heat Source
Rate @250 Sec @1200 Sec
0.01 400k 37.9155 64.8926
800k 75.8207 129.787
0.02 400k 29.7525 39.201
800k 59.4059 78.402

Results verified with Fluent alone

Non-linear dependency on Flow Rate
12 © 2011 ANSYS, Inc. September 21,
2011
 Simulation Results: Linear Controls

13 © 2011 ANSYS, Inc. September 21,

2011
 Simulation Results: Non-linear Control

Fluent Control Co-Simulation

Flow is adjusted to
maintain constant
temperature
14 © 2011 ANSYS, Inc. September 21,
2011
 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 Simplorer1
50.00 3000.00 15.00

40.00 2500.00 10.00

30.00 2000.00 5.00

VM2.V [V]
U1.VCE
R2.I [A]

20.00 1500.00 0.00

10.00 1000.00 -5.00

Curve Info
U1.VCE
TR
VM2.V
0.00 500.00 TR -10.00
R2.I
TR

-10.00 0.00 -15.00

499.90 499.95 500.00 500.05 500.10 500.15 500.20 500.25 500.30
Time [us]

15 © 2011 ANSYS, Inc. September 21,

2011
 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 © 2011 ANSYS, Inc. September 21,

2011
 Push-Back Excitation for EMC/EMI

Push excitations to SIwave and HFSS: Allows feedback of transient simulation

results in form of excitations for 3D FEA

State Space Model

Excitation data

Radiated Fields can now be calculated based on actual conductive mode analysis
Both conductive and radiative analysis EMC/EMI can be performed
17 © 2011 ANSYS, Inc. September 21,
2011
 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 circuit
• Perform a transient analysis
• Right click to push excitation UI.
3 UI converts time domain signal to frequency domain

• Excitation files get written

– Voltage and current for each
frequency and port
• Import files back to SIwave
– External source excitations

18 © 2011 ANSYS, Inc. September 21,

2011
 Maxwell
2D/3D Finite Element Low Frequency Electromagnetics

19 © 2011 ANSYS, Inc. September 21,

2011
 Maxwell Overview
• Solves 2D and 3D electromagnetic field
problems using FEA
• Five Solution Types: Electrostatic,
Magnetostatic, Eddy Current, Transient
Electric, Transient Magnetic
• Linear and non-linear, isotropic and
anisotropic, and laminated materials
• Determines R,L,C, forces, torques,
losses, saturation, time-induced effects
• Parametric and Optimization capabilities
• Co-simulation with Simplorer
• Direct link from RMxprt
• Direct link to ANSYS Mechanical
20 © 2011 ANSYS, Inc. September 21,
2011
 Full Parallelization of 3D non-transient solvers

Magnetostatic solver:
– Parameter extractions for inductance
– Energy computation for post processing in field solver

Eddy current solver:

– Power loss and stress computation for post processing
– Energy computation for post processing in field solver

21 © 2011 ANSYS, Inc. September 21,

2011
 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%) 64-bit XP @ 2.67 GHz 12GB of RAM
- 606,758 tetrahedra
- 817,274 matrix

Real Time Computation

150
Time [min.]

100

50

0
1-CPU 2-CPU 4-CPU 6-CPU 8-CPU
22 © 2011 ANSYS, Inc. September 21,
2011
 3D Eddy Current High Order Elements

Goal: Improve accuracy for current density field (J)

- J field is derived quantity from T-Ω formulation
- Higher order elements gives first order approximation for currents

Zero order approximation First order approximation

for currents for currents
23 © 2011 ANSYS, Inc. September 21,
2011
 3D Eddy Current High Order Elements

Coil

Plate
Mesh on the plate

Induced eddy current Induced eddy current

Zero order vector shape functions First order vector shape functions
24 © 2011 ANSYS, Inc. September 21,
2011
 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

25 © 2011 ANSYS, Inc. September 21,

2011
 Core Loss in Eddy-Current Solver

Enter Core Loss coefficient as in Transient

Disable Eddy Current calculation as Core Loss contains Eddy Loss

Ferrite Core
26 © 2011 ANSYS, Inc. September 21,
2011
 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 = 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
employing linear BH characteristic

27 © 2011 ANSYS, Inc. September 21,

2011
 Maxwell Integration in Workbench

What was already possible in R13:

• Two-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
• Unidirectional CAD integration

28 © 2011 ANSYS, Inc. September 21,

2011
 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

29 © 2011 ANSYS, Inc. September 21,

2011
 Maxwell – ANSYS Stress Coupling

Example: Air inductor

30 © 2011 ANSYS, Inc. September 21,

2011
 Maxwell – ANSYS Stress Coupling
B Field Force Distribution

Magnetic
Forces

Field Calculation Stress Calculation

Updated Mesh Displacements

Displacements
of mesh nodes

31 © 2011 ANSYS, Inc. September 21,

2011
 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

32 © 2011 ANSYS, Inc. September 21,

2011
 Maxwell – Fluent Two-Way Coupling
Example: Busbars – Electrical, Thermal, Structural

Deformation

Loss Distribution Temperature

2-way
33 © 2011 ANSYS, Inc. September 21,
2011
 PM Temperature Dependent Model
Maxwell 2D/3D can account for Permanent Magnet temperature
dependency. The law works directly on intrinsic BiH curve with
remanent flux density Br and intrinsic coercivity Hci

B = Bi + µ 0 H
The Two temperature dependent parameters are remanent flux
density Br and intrinsic coercivity Hci
Br and Hci can be described by second order polynomials as
( )
Br (T ) = Br (T0 ) 1 + α1 (T − T0 ) + α 2 (T − T0 ) = Br (T0 ) P (T )
2

H ci (T ) = H ci (T )(1 + β (T − T ) + β (T − T ) ) = H
2
0 1 0 2 0 ci (T0 ) Q(T )
where T0 is the reference temperature, and α1, α2, β1 and β2 are
coefficients which are provided in supplier datasheets

34 © 2011 ANSYS, Inc. September 21,

2011
 PM Temperature Dependent Model
Copied from vendor datasheet

Derived based on the temperature dependent demagnetization model

35 © 2011 ANSYS, Inc. September 21,

2011
 PM Temperature Dependent Model
Coercivity (Hc)

Flux
Density

Coercivity change shows dynamic irreversible

demagnetization during a transient process in one element
36 © 2011 ANSYS, Inc. September 21,
2011
 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

37 © 2011 ANSYS, Inc. September 21,

2011
 RMxprt

Analytical Sizing package for Electrical Machine Design

38 © 2011 ANSYS, Inc. September 21,

2011
 RMxprt - Overview
• Analytical Design Software for Electric Machines
• User can calculate machine performance, make material and size decisions
• Flexible design and optimization process for rotating electric machines which
perform hundreds of "what if" analyses in a matter of seconds
• Machine Types
• Induction Machines : Three-Phase,
Single-Phase
• Synchronous Machines : Line-Start
PM, Adjustable Speed PM, Salient
Pole, Non-Salient Pole
• Brush commutated: DC, Permanent
Magnet DC, Universal, Claw-pole
Alternator
• Electronically commutated: Brushless
PM, Switched Reluctance
39 © 2011 ANSYS, Inc. September 21,
2011
 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

40 © 2011 ANSYS, Inc. September 21,

2011
 RMxprt – Interior Permanent Magnet
Machines
RMxprt can set up the Maxwell 2D/3D project for IPM Machines
• Multi duct layers supported
• No analytical solution provided yet

41 © 2011 ANSYS, Inc. September 21,

2011
 RMxprt – Axial Flux Machine

New machine topology: Axial Flux Machine

• AC or PM Rotor
• Single or Double Side Stator
• Maxwell 3D auto-setup
• No analytical solution provided yet

42 © 2011 ANSYS, Inc. September 21,

2011
 Q3D

Quick RLC Extractor for 2D and 3D Structures

43 © 2011 ANSYS, Inc. September 21,

2011
 Q3D Extractor - Overview
• Q3D is a tool streamlined for quickly characterizing
electrical parasitics (R,L,C,G) of interconnects,
busbars, and cables.
• Typical Applications:
• Switch Mode Power Supplies
• Cables, Connectors and Busbar Modeling
• Ground Plane Modeling
• EMI Prediction in Electric Drive Systems

44 © 2011 ANSYS, Inc. September 21,

2011
 Q3D Extractor - AC vs DC Resistance & Inductance
• Both R and L depend on frequency
• Q3D solves only the low and high frequency asymptotes
• Behavior in between is estimated

log R(f) L(f)

Ldc

Rac f
Rdc Lac

log(f) log(f)

45 © 2011 ANSYS, Inc. September 21,

2011
 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
• Calculates partial inductance in open
loops
46 © 2011 ANSYS, Inc. September 21,
2011
 Q3D – Magnetic Materials

Inductor Example

Goal: Get R(f), L(f)

DC < f < 1 MHz

Magnetic Core
(µ = 500, σ= 100000)

Solid Copper Coil

47 © 2011 ANSYS, Inc. September 21,

2011
 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)
48 © 2011 ANSYS, Inc. September 21,
2011
 Q3D – Magnetic Materials

Using Maxwell:
• FEM - Need to mesh to account for skin depth at each frequency
• Can lead to huge mesh for higher frequencies as skin depth decreases but
gives best accuracy in transition region
• Two Matrix solutions at each frequency (one for Fields, one for R-L matrix)

Using Q3D:
• BEM – Surface mesh only
• Only 1 solution for DC, 1 solution for AC
• Transition region determined by blended algorithm
• No need to mesh for skin depth
• Easier setup but may not give best accuracy in transition region

49 © 2011 ANSYS, Inc. September 21,

2011
 Q3D – Magnetic Materials

Q3D AC 10 s Maxwell 50 min

Q3D DC 6min 30 s
Sweep 2s
(regardless of # of Freqs) (4 Freq <1MHz)
Total Solution Time < 7 min 50 min Simulation Time
Peak RAM 0.6 Gb 5 Gb

Each Additional Freq 15 min Q3D

XY Plot 1 Q3DDesign2 ANSOFT
55.00
Curve Info
ACL(Coil:Coil_in,Coil:Coil_in)
Setup1 : Sw eep2

50.00
ACL(Coil:Coil_in,Coil:Coil_in) [nH]

45.00

Maxwell 40.00

35.00

30.00

25.00
0.00 0.01 0.10 1.00 10.00 100.00
Freq [MHz]

L(f) HFSS
50 © 2011 ANSYS, Inc. September 21,
2011
 Q3D – New Features
Circuit Export:
• Q3D can export frequency dependent models to Simplorer
• Q3D can also export R, L at a specific frequency in the sweep and export to
Simplorer as well as to a SPICE netlist
• The feature has been extended to 2D Extractor

51 © 2011 ANSYS, Inc. September 21,

2011
 Q3D - 3D Modeler Enhancements

View customization

• Z-stretch
• 64-bit user interface

This enhancement is available to all EBU - 3D products

52 © 2011 ANSYS, Inc. September 21,

2011
 Geometry and User Interface

53 © 2011 ANSYS, Inc. September 21,

2011
 Ansoft to ANSYS Geometry Transfer

• Possible import DesignModeler geometry directly into

Ansoft products
• Geometry and material assignment transfer from Ansoft
systems to ANSYS systems
• Further geometry edits are possible in DM if user has
license

54 © 2011 ANSYS, Inc. September 21,

2011
 Multiple Geometry Links
Possible to inport geometry from multiple upstream sources
• Source can be any of CAD, DesignModeler or Ansoft products
• Creates UDM for each geometry input

55 © 2011 ANSYS, Inc. September 21,

2011
 Ansoft HPC Enhancements: Fixed Variables
Applications Wave Winding UDP
• 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
– Faster post-processing
• Improved reporter-dialog response
– No sluggishness

56 © 2011 ANSYS, Inc. September 21,

2011
 CAD Integration on WB Improvements

Added support for parametric analysis and DSO of CAD parameters

57 © 2011 ANSYS, Inc. September 21,

2011
 Reliability Engineering Design - DOE

Distribute parametric studies across

Identify key design parameters available hardware to expedite design
optimization

Identify variation of performance with

respect to variations of parameters

58 © 2011 ANSYS, Inc. September 21,

2011
 Reliability Engineering Design – Six Sigma
A product has Six Sigma quality if only 3.4 parts
Input parameters vary! 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?

59 © 2011 ANSYS, Inc. September 21,

2011
 Reliability Engineering Design
Surface Response Analysis

60 © 2011 ANSYS, Inc. September 21,

2011
 Maxwell-ANSYS Structural and Maxwell -ANSYS Thermal
Field Mapping coupling capabilities available in R14

Maxwell 2D/3D ANSYS Static/Transient Structural ANSYS Static/Transient Structural

Two-Way Link One-Way Link (Maxwell upstream)
Electrostatic
Magnetostatic
Eddy Current
Magnetic Transient
Electric Transient

Maxwell 2D/3D ANSYS Static/Transient Thermal ANSYS Static/Transient Thermal

Two-Way Link One-Way Link (Maxwell upstream)
Electrostatic
Magnetostatic
Eddy Current
Magnetic Transient
Electric Transient
61 © 2011 ANSYS, Inc. September 21,
2011
 Maxwell-Fluent
Field Mapping coupling capabilities available in R14

Maxwell 2D/3D Fluent Steady State Fluent Transient

(Thermal link) (Thermal link)
Two-Way Link One-Way Link (Maxwell upstream)
Electrostatic
Magnetostatic
Eddy Current
Magnetic Transient
Electric Transient

62 © 2011 ANSYS, Inc. September 21,

2011
 Simplorer System Coupling 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

63 © 2011 ANSYS, Inc. September 21,

2011
 Simplorer system coupling 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

64 © 2011 ANSYS, Inc. September 21,

2011