Verifications of 2D/3D CAE Simulations by a Linear Actuator Case Study

Professor Wang, Pei Jen Department of Power Mechanical Engineering National Tsing Hua University Hsinchu, Taiwan October 5, 2006

CONTENTS
Introduction Theoretical Analysis Maxwell 2D/3D Analysis Results and Discussions Conclusions

INTRODUCTION
Since the early 1990s, computer aided engineering software tools have become the major design gears for EM engineers in the industries. Maxwell 2D/3D has been one the leading and widely accepted programs embedded with many design features and post-process functions for years. Typical questions are How good are these computer tools? and What about the design accuracy and efficacy responded from the shop floor?. Tests by various case study are always effective.

Design Case Study-VCM

Voice-coil motors are employed for speakers, hard disks, and industrial actuators. They are mainly based on simple structures for easy implementation with high responses.

VCM Characteristics
Hard magnetic materials (PM) provide magnetic excitation sources; whereas soft magnetic materials guide the magnetic fluxes to air gap where electric windings are located. Leakage flux and reluctance from soft magnetic materials seem to hurdle the design if the VCMs must be small and compact. New design is sparkled by K. Halbach who initially proposed a ring structure based on ONLY hard magnetic materials to achieve high magnetic field density.

Halbach Magnetic Theory

In 1981, Klauss Halbach at Lawrence Livermore National Lab., UC Berkley, developed the theory and design for wigglers in synchrotron radiation sources.

Halbach Ring

Halbach Magnetic Theory

Halbach Linear Arrays

Better Design Approach

Ofori-Tenkorang et al. [1995] reported higher torque could be achieved with Halbach magnetic structures compared to the conventional designs.

More PM better!

THEORETICAL ANALYSIS
Based on Lorentz Law, a force will be generated on a electrified wire exposed under constant magnetic field.

F mag = ILB g
For air gap flux density Bg and effective length of wire L with N parallel path, Lorentz Law gives the output force as follows.

Fmag = K f I Kf = NLBg

Halbach Magnetic Ring

K. Halbach ,(1980) Design of Permanent Multipole Magnets with Oriented Rare Earth Cobalt Material. From complex analysis, Z = X + iY = rei density of magnetic field as follows.
*

represents

1 0I B (Z0) = . . . . . . . . . . . . (1) 2 i z0 z
By Taylor Series expansion, we have
B ( z0 ) =
*

n =1

n 1

bn z 0

....................... (2 )

Halbach Magnetic Ring

For ideal ring structure with p poles,

B * ( Z0 ) = (

z0 N 1 N r1 ) Br [1 ( ) N 1 ]... forN 2 r1 N 1 r2

r2 B ( Z 0 ) = B r ln ( ) . . . . . . . . . . fo r N = 1 r1
*

where N=p/2; r1 and r2 are the inner and outer radius. Br is the remanent flux density of PM.

Simulation for Flux Vectors

P=2 case

P=4 case

Practical Designs
Considering ring consists of even number M of PMs, then bn is as follows. N 1 i ( N + 1 ) i ( n + 1 ) b n = Cn e e
m=0

Substitute bn into Eq(2), flux density in air gap is given in the following equation.
B ( Z0 ) = Br Kn (
* v =0

r2 z0

n +1

n r1 n +1 [1 ( ) ] n +1 r2

where Kn is a corrective term.

Practical Designs
For two-pole Halbach rings, the simplified formula to calculate flux density is as follows.

2 s in ( M ) r2 ln ( ) B * ( z0 ) = Br 2 r1 M

N1

Case: Eight Pieces of PM

2D/3D SIMULATIONS
2D simulations for 4-piece and 8-piece cases.

4-piece case

8-piece case

Conceptual Design
4-piece Design 8-piece Design

Static Output Characteristics

4-piece Case: Force vs. Position Plot

Static Output Characteristics

8-piece Case: Force vs. Position Plot

RESULTS AND DISCUSSIONS

4-piece case: dimensions of N35 PMs with 15 mm in thickness.
15mm

8-piece case: dimensions of N35 PMs with 25 mm in thickness. 18mm

5mm

18mm

5mm

4-piece PM Prototype

8-piece PM Prototype

Flux Density Measurements

4-piece PM 8-piece PM

Output Force Measurements

Comparisons on Fluxes
4-piece PM B Air (Tesla) Theory 3D Measured 0.860 0.840 0.807 8-piece PM B Air (Tesla) 0.860 0.910 0.944

Errors

Errors

NA -2.3% -6.16%

NA 5.8 % 9.7%

Comparisons on Output Forces

Current at 1A 4-piece @ 5 turn force (g) Errors Theory 12 NA 2.35 NA 3D 12.06 0.50% 2.8847 22.75% Measured 11.5 4.17% 2.78 18.30%

8-piece force (g) @1 turn Errors

Error Analysis
Leakage fluxes for the 8-piece PM structure are more severe than the 4-piece PM Structure.

CONCLUSIONS

In this study, we can make some conclusions on the current state of art CAE programs.
Accuracy and efficacy are enough for EM engineers to handle basic design analysis. Maxwell 2D/3D can be easily learned if fundamentals of electromagnetism and CAD experiences have been fully acquired. High speed PCs can easily solve static, dynamic and transient problems in days so that complete and thoughtful design analysis should be ready before the prototyping. Coupled with multi-domain simulation tools, very complex design problems could be solved at the drawing stage.

 Linear actuators could be design based upon Halbach rings for both of the chosen cases. However, comments for the two cases are as follows.

PM type Flux Density Assembly Fixture 4-piece PM 8-piece PM 3 1 @0.8 T @ 1.0 T Easy Difficult Simple Complex

 By making use of Halbach magnetic theory, cases on design and analysis of linear actuators were studied for verification purposes. Comparisons on the magnetic flux density show that either 2D or 3D simulations given by Maxwell are in good agreement with the experimental results. Static, dynamic and transient simulations are all possible if the basic knowledge of electromagnetism is abundant for the design engineers to plug in correct inputs into the programs.

Thank You for Your Attention