FEA IN MAGNETIC COMPONENTS MODELING · 2020. 6. 15. · ANSYS Simplorer HFSS Q3D SIwave Icepak...

MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki

2020-06-16 – Tomasz Kądziołka, Marek Ryłko, Marcin Kącki

FEA IN MAGNETIC COMPONENTS MODELING

SMA Magnetics Sp. z o.o/ MESco Sp. z o.o.


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Introduction

Magnetic component modeling

FEA vs. Experimental - Impedance & Inductance

FEA vs. Experimental - Flux propagation

Conclusion and future workConclusion and future workConclusion

Content

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Introduction

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Simulation – why invest ?

…to turn your design concepts into successful, innovative products faster and at lower cost!


Introduction

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Classical design approach supported

by a virtual prototype

Simulation-Driven Product Development

*M. Kącki, M.S. Ryłko, J.G Hayes, C.R. Sullivan, E. Herbert, “Magnetic core dimensional effects - flux propagation in ferrites,” PSMA Workshop during IEEE Applied Power Electronics Conference, 2018


Ansys simulation platform

ANSYS

Enterprise

Simplorer

HFSS

SIwave

Q3D

Icepak

Maxwell

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Right tool for the purpose

6

High or Low FrequencyPower or Signal

> transmit or convert power - power

→ ANSYS Maxwell

> transmit information - signal

→ HFSS

ANSYS

Simplorer

HFSS

Q3D

SIwave

Icepak

Maxwell

HFSS: full-waveMaxwell:Quasi-static

ANSYS

ENTERPRISE

Simplorer

HFSS

Q3D

SIwave

Icepak

Maxwell



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Equations Extended to Each SolverJames Clerk Maxwell


Solve


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Create/import geometry

Assign MaterialsAssign Boundary

ConditionsDefine

ExcitationsSetup the Solution

Post Processing

Simulation Process Flow

DRAW IN ANSYS

CAD

IMPORTED FROM CAD

SPACECLAIM

Mesh


Solve


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ConditionsDefine


Post Processing


> Pre-defined material library available in Maxwell

> User can customise material database

> Solvers support number of material models

Mesh


Solve


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ConditionsDefine


Post Processing


> PSMA-SMA special projects show importance of magnetic material data quality for core modeling

> Material’s permeability, permittivity and conductivity drives magnetic flux distribution in the core

> Detailed knowledge on magnetic material conductivity and permittivity frequency characteristic is fundamental for prediction of magnetic flux distribution in ferrite cores

Mesh



Solve


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ConditionsDefine


Post Processing


> Boundary conditions are linked with solver type

> Improve your modeling by selection of boundary conditions to model part of a structure to reduce complexity and computation time

InsulationVector

PotentialBaloon

Odd / EvenMaster/Slave Symmetry

Tangential HZero

Tangential H… and more

½ Model

Mesh


Solve


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ConditionsDefine


Post Processing


> Each field solver requires to specify excitations of electric or magnetic fields and references forcomputing these fields

The eddy current solver allows to define the following sources of AC magnetic fields

Volatge /Current winding

Maxwell circuitSimplorer

Current/Current density

Mesh


Solve

Measured


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ConditionsDefine


Post Processing


> In Maxwell’s Static Solvers, the mesh is automatically optimized to achieve required level of accuracy

Adaptive Mesh Refinement

> Maxwell offers wide range of operations on mesh that refines model for required accuracy

Calculate localSolution error

Generate InitialMesh

Solve fields using theFinite Element Method

End criteria reached ?

Refine Mesh

Calculate Outputs (Force, Inductance, etc.)

no

yes

Start

Maxwell Solution Flow Chart

Initial Mesh AdaptivelyRefined Mesh

Mesh


Solve


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ConditionsDefine


Post Processing


> Skin Depth Based meshing is optimized to resolveinduced eddy current near the surface of theconductors/semiconductors

> Eddy current in ferrites are characterized by the skin effect that results in a non-uniform flux distribution in the core cross-section

Frequency = 50 Hz Frequency = 1 MHz

Mesh


Solve


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ConditionsDefine


Post Processing


ANSYS Maxwell allows for flexible data management and plotting capabilities.

Mesh



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Post ProcessingExperimental

validation


> In the first step three phase CMC was simulated, built and experimentality tested. Basic parameters as inductance, impedance and capacitance are compared between simulation and prototype

> Simulation was performer based on ferrite material manufacturers specification and material characteristic obtained from PSMA-SMA special project

*M. Kącki, M.S. Ryłko, E. Herbert, “PSMA-SMA special project phase II – investigation on magnetic flux

propagation in ferrite cores,” PSMA, 2020

vs.



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validation


Test inductor specification

Parameter Unit

Material - 3E10 Mn-Zn

Dimensions OD x ID x H

mm 50 x 30 x 16.5

Core total cross section

mm² 165

Core volume cm³ 20.7

Number of turns - 5/phase

Inductance frequency characteristic

0

100

200

300

400

500

600

700

800

0.01 0.1 1

Induct

ance

(µ

H)

Frequency f (MHz)

Prototype FEA - Mnf. data FEA - PSMA data

L @ 50kHz L @500kHz

Prototype 656 µH 42 µH

Mnf. data 628 µH 342 µH

PSMA data 639 µH 85 µH

Δ Mnf. Data 4.2 % 814 %

Δ PSMA data 2.6 % 202 %



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validation


Prototype FEA Simulation

Winding capacitance

5.2 (pF) 7.4 (pF)

Impedance frequency characteristic

0

200

400

600

800

1 000

1 200

1 400

1 600

1 800

0.01 0.1 1

Imped

ance

(Ω

)

Frequency f (MHz)

Prototype FEA - Mnf. data FEA - PSMA data

Z @ 50kHz Z @500kHz

Prototype 187 Ω 1075 Ω

Mnf. data 193 Ω 1417 Ω

PSMA data 192 Ω 999 Ω

Δ Mnf. Data 3.2 % 32 %

Δ PSMA data 2.6 % 7 %



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validation


In the next step flux distribution measurement are contrasted with simulation.

The flux density ratio frequency characteristics are normalised by main flux density for each frequency

Magnetic flux density ratio(𝑓) =𝐵𝐴(𝑓)

𝐵𝐸(𝑓)

where:

BA(f ) –flux density in section A

BE(f )– flux density in the entire area of the core

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

0 200 400 600 800 1000 1200 1400 1600

Mag

net

ic f

lux

den

sity

rat

io

Frequency (kHz)Section A Section B




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validation


f = 500 kHzf = 500 kHz

Flux distribution based on FEA simulation, material characteristic form ferrite manufacturers datasheet

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

0 200 400 600 800 1000 1200 1400 1600

Mag

net

ic f

lux

den

sity

rat

io

Frequency (kHz)Section A Section B Section A - FEA Section B - FEA




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validation


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

0 200 400 600 800 1000 1200 1400 1600

Mag

net

ic f

lux

den

sity

rat

io

Frequency (kHz)Section A Section B Section A - FEA Section B - FEA

f = 500 kHzf = 500 kHz

Flux distribution based on FEA simulation,material characteristic from PSMA-SMA special project



Summary

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> Ansys software with its specialized packages allows for solving multi physical problems

> Number of dedicated solutions addresses individual areas of the interest

> Use of Ansys is simplified and intuitive, the interfaces are improved and user friendly

> The use of the FEA solvers and its interfacing is not a barrier for practicing engineers

> FEA solvers results quality depends on the input data quality

> FEA solvers aid design process and visualize component operation allowing for advance prediction of

potential design failures


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FEA IN MAGNETIC COMPONENTS MODELING · 2020. 6. 15. · ANSYS Simplorer HFSS Q3D SIwave Icepak...

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