Maxwell技术培训：新功能及有限元仿真技术高级应用

• Maxwell V16新功能介绍

• 有限元技术高级培训

− 电磁设计仿真

− 系统设计仿真

− 热设计仿真

− “0D“ 系统集成

内容摘要

Maxwell新功能介绍

电磁/热双向耦合仿真

• 30 mouse clicks for 10 iterations

• Only work for current design point

• Not usable with DX

FLUENT

Mechanical ThermalMaxwell

Transfer Data Refresh

Mesh

Update

H, B, E, J

“Setup 2”“5 GHz”

…

Loss Density

H, B, E, J

Enable Update

Update

UpstreamDownstream

FLUENT

Mechanical Thermal

Update

数据迭代

Downstream of Maxwell

TAU 2D 网格技术Uniform Initial Mesh Better quality

Faster convergence

Improve design automation

# Pass Mesh Size Simulation Time

Classic 11 2715 80 sec

Tau 7 1754 65 sec

Mesh Size

Simulation Time12 time steps

Classic 30516 165 sec

Tau 10016 74 secClassic with Mesh Ops(design created via RMxprt)

Tau Initial Mesh

Classic Tau

8 hrs for

2000 variations

> 2X Speed up

用户控制程序—2D场数据提取

• Allow user defined core loss calculation

• B, H and A Field

• Values at each mesh node plus mid-point

• At each solved time step

• Additional inputs in the “user.ctl” file

– exportFieldAtMeshNodeAllObjects

– exportFieldAtMeshNodeOnObject <object ID>

2D/3D 用户定义磁导率

• The non-linear characteristic of many materials are too complex to be defined using BH curve

• Allow users to control the permeability at each mesh element

• Build on permeability link and user control program

输出场数据到柱坐标系或者球坐标系

• Applicable in 3D products

在Non-model模型上进行场数据后处理

• Maxwell, HFSS and Q3D

• Extended from line (1D) to sheet (2D)

• Workaround for 3D object– Surface plot Select faces of the object

– Volume plot

定义任意旋转部件

• Both band and moving objects were restricted to solid model object

• Restriction on moving objects removed

• Manually add non-model or non-solid object as moving will NOT invalidate solution

• Automatic moving objects detection

V15 V16

Assign band Solid model All model

New solid model object

Solid non-model switched to model

定义任意旋转面

在场图中添加探针

• Marker table displays location and field value

• Most effective in surface and cutplane plot

• Vector and line plot not supported

在场图中添加探针

• Additional menus at project tree, top product menu and view window

• “Measure Data” displays field value and position

• Position and color can be edited at property window

Icepak耦合仿真分析能力

Icepak Development Contact:Manoj Nagulapallymanoj.nagulapally@ansys.com

• R14 only supports volume loss

• Go hand-in-hand with impedance boundary

Surface Loss Distribution Temperature Distribution

Fluent可导入Maxwell面损耗

RMxprt一键创建Maxwell2D/3D模型

• Geometry related variables used in RMxprt design

• All machine types

• Pre-V16 solutions

其它新功能

• Design Toolkits

• Ansys Toolkit UI

• User Defined Documents

• User Defined Outputs

• …

• EKM download for project archives and files

• Non-graphical “extractor” batch mode

• Large “matrix” post processing

用户自定义输出文档

SDM求解

•We can solve 4 frequencies at the time in an Eddy Current problem.

•The frequency sweep is defined in the Solve Setup; Optimetrics does not need to be involved.

30:20 vs. 14:16 with 8 cores, 2.13 X Speed up with 8 cores

3D瞬态HPC功能

• The Multi-Threading includes:

- Initial Tau Mesh

- Non Linear Newton-Raphson Loop

- Matrix Assembly

- Matrix Solving

- Matrix Postprocessing

• Use OpenMP with shared memory

Terminology:

A desktop possesses one or several Processors.

Each Processor can have multiple cores

In Maxwell, you specify the number of cores you want to use; these cores can be located over several processors but they have to share the same memory.

Note:

Maxwell cannot run a single design simulation over a cluster

Full Parallelization of 3D Transient

Enabled through EBU HPC license

较小规模设计

• 3D IPM synchronous machine with motion

• Mesh size: 120,000 tets – around 2 GB of RAM

• Machine: 4 x Xeon CPU E7-4830@2.13GHz processors

• (32 cores total – 512 GB of RAM)

Number of Cores Average Time per Non linear Iteration

Average Speed-upCompared w/1 core

1 70s -

2 41 1.7

4 21s 3.33

8 18s 3.88

12 18s 3.88

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

1 Core 2 Cores 4 Cores 8 Cores 12 Cores

Speed up

较小规模设计加速性能

MP

New HPC

中等规模设计

• 3D IPM synchronous machine with motion, Eddy current in Magnets

• Mesh size: 515,000 tets – around 10GB of RAM

• Machine: 8 x Xeon CPU E7-4830@2.13GHz processors -32 cores total

Number of cores Average Time per Non linear Iteration

Average Speed-up

Compared w/1core

Average Speed-up per core

1 15 min -

4 5 min36 2.67 0.67

8 3m55 3.82 0.48

12 3min 25 4.40 0.37

16 2min 52 5.24 0.32

24 2m37 5.73 0.24

中等规模设计加速性能

Note: each processor has 8 cores, hence using 12 cores is the least favorable scenario

0

1

2

3

4

5

6

7

1 Core 4 Cores 8 Cores 12 Cores 16 Cores 24 Cores

Speed up

MP

New HPC

大规模设计

• 3D IPM synchronous machine with motion

• Mesh size: 1,350,000 tets – around 35GB of RAM

• Machine: 8 x Xeon CPU E7-4830@2.13GHz processors – 32 cores total

Number of cores Average Time per Non linear Iteration

Average Speed-up

Compared w/1core

Average Speed-up per core

1 8h43 -

8 1h19 6.62 0.82

16 1h04 8.17 0.5

24 1h03 8.30 0.34

32 58m 9 0.28

大规模设计加速性能

MP

New HPC

0

1

2

3

4

5

6

7

8

9

10

1 Core 8 Cores 16 Cores 24 Cores 32 Cores

Speed up

电磁作动器设计面临的挑战

• Design Requirements

• How do I meet the force vs stroke requirements for a device?

• How do I maintain the sizes while still meeting the force requirements?

• How do I reduce closing time?

• How do I design for thermal management

constraints ?• The challenge :

• To develop the valve in the context of electrical, magnetic, mechanical and fluid dynamic aspects

Electrical

Coil

Moving Plunger

Pole

Typical Solenoid

Electrical

Coil

Moving Plunger

Pole

System Integration

CFD

Embedded Software

Mechanical

Magnetics

Model Extraction

Co-simulation

ANSYS 系统集成设计流程

CAD Integration

Robust Design

CAD Integration

Robust Design

• Maxwell 2D and 3D models characterize

the performance of the device.

• Magnetostatic models determine Force vs

Stroke performance.

• Transient models determine closing time.

• Simplorer System models determine

control system impact on device.

• Device Description

• Hydraulic Valve

• Moving Parts

• Stationary Parts

• Coil Design

Moving

Armature

Modeling Approach

Coil

Pole

Housing

创建模型

线圈采用参数化设置

• Coil design equations are incorporated as Design Variables in Maxwell.

• Input:

– Wire Gauge

• Based on coil space, automatically calculates:

– Number of turns

– Coil Resistance

Baseline Modeling:

Coil Design Equations

Now for Parametric or Optimization studies, as the available

coil size changes, the coil design is automatically calculated.

添加参数扫描Parametric Sweep

•Compare simulation to measurements

•Current: 0.1 to 1pu, D 0.2pu

•Position: 0 to 1pu, D 0.25pu

Any Design or Project Variable can be used in a Parametric Sweep to

study Positions, Shapes, Excitations, Material Properties, etc.

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4stroke [mm]

4

6

8

10

12

14

16

18

20

Fo

rce

TRW / Ansoft

Force vs Stroke

Curve Info

Measurements

Simulation

Fo

rce

Normalized Distance

0.0 0.5 1.0 1.5 2.0 2.5 3.0Coil Current [A]

0

2

4

6

8

10

12

14

Fo

rce

TRW / Ansoft

Force vs Coil Current

Curve Info

Measurements

Simulation

Fo

rce

Normalized Current

Measurement Hysteresis(due to mechanical friction)

Baseline Modeling: 和试验结果对比Comparison to Measurements

• Results of parametric sweeps easily reported.

• Import of measurement data in Maxwell.

Excellent

Correlation

仿真数据与测试数据对比

Baseline Modeling: Saturation Effects

考虑饱和效应

• Saturation effect at rated coil current is considered . . . Corresponds to where measurements begin to deviate from simulation.

• An accurate nonlinear BH curve is critical (~20 points with smooth transition).

• Simulation can deviate from measurements if different material is used.

考虑饱和效应

运动及时间效应影响

• Transient “time-stepping” or time-domain

solver solves time-varying magnetic fields

• Fully Coupled FEA solver with external

circuit and motion equations

• Includes time-induced effects such as:

– Eddy Effects

– Proximity Effects

– Time Diffusion of Magnetic fields

• Includes motion-induced eddy effects

AHA

JA

vV

tcs

Baseline Modeling: Transient Simulation

• External circuit schematic directly coupled to FEA solution.

• Incorporates more complicated control of device.

• Created using Maxwell Circuit Editor.

瞬态仿真

0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00Time [ms]

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

Po

sitio

n [m

m]

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

Co

il C

urr

en

t [m

ete

r]

TRW / Ansoft Position & Current Hysteresis Control Close/Open1

Curve Info

Position

Coil Current

Diode Current

Baseline Modeling: Transient Simulation

• Simulation results with external circuit

• Shows use of hysteresis control to limit current within upper and lower limits.

• Independent setting of Circuit Time Step captures switching event.

Upper Current Limit

Lower Current LimitCircuit time step

captures switching event

瞬态仿真

参数化扫描

• Optimetrics:– Parametric

– Optimization

– Sensitivity

– Statistical

• Distributed Solve– Solves over several machines

– Reduces total solution time

Introduction to Optimetrics and

Distributed Solve

Optimetrics / Distributed Solve

0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00Stroke (Normalized Distance)

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

5.00

5.50

6.00

Sp

rin

gC

urv

e

TRW / Ansoft Spring Curve

Curve Info

SpringCurve

满足设计要求的曲线

Problem #1: Shape the pole of a linear actuator to meet Force vs. Stroke requirements

Open Closed

Optimization #1: Meeting Spring Curve

优化#1：满足弹簧的特性曲线

优化#1：满足弹簧的特性曲线

Solution: Use Maxwell transient solver and Optimetrics• Special Transient Setup

– Transient model is used to effectively sweep Gap.

– Set initial and final position.

– Define a constant velocity, e.g. 1mm/sec.

– Set Time Step to capture desired position points.

ArmStepHeight

CoreStepHeightGap

• Optimization Variables

– Gap

– Core Step Height

– Core Step Radius

– Armature Step Height

– Armature Step Radius

Optimization #1: Meeting Spring Curve

优化#1：满足弹簧的特性曲线优化#1：满足弹簧的特性曲线

• Create the Optimization

– Select Optimization type

– Set variable limits

Optimizer Types:

Sequential Nonlinear Programming

Sequential Mixed Integer Nonlinear Programming

Quasi Newton

Patten Search

Genetic Algorithm

Used to achieve a specific cost Function:

•Meet an Inductance, Force, or field value.

•Minimize a value.

•Maximize a value.

优化#1：满足弹簧的特性曲线

Gap Force (N)

0.2 F1

0.6 F2

0.8 F3

1.0 F4

0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00Stroke (Normalized Distance)

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

5.00

5.50

6.00

Sp

rin

gC

urv

e

TRW / Ansoft Spring Curve

Curve Info

SpringCurve • Map the Force requirements . . .

to the Optimization Cost Function

• YatXVal function used to evaluate

force at desired position (Time).

优化#1：满足弹簧的特性曲线

0.20 0.40 0.60 0.80 1.00Stroke (Normalized Distance)

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

Y1

TRW / Ansoft Force vs Stroke

Curve Info

ArmStepHeight1='0mm' ArmStepRad1='2

ArmStepHeight1='0.000130288001891299

0.20 0.40 0.60 0.80 1.00Stroke (Normalized Distance)

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

Y1

TRW / Ansoft Force vs Stroke

Curve Info

Moving1.Force_z

SpringCurve

• The Optimization runs through

Variable combinations to reduce

Cost function – meet spring curve.

Co

st

Iteration

Optimization #1: Meeting Spring Curve

优化#1：满足弹簧的特性曲线优化#1：满足弹簧的特性曲线

0.00 1.00 2.00 3.00 4.00 5.00Time [ms]

0.00

0.20

0.40

0.60

0.80

1.00

1.20

Mo

vin

g1

.Po

sitio

n [m

m]

0.00

0.50

1.00

1.50

2.00

2.50

3.00

Cu

rre

nt(

Win

din

g1

) [A

]

TRW / Ansoft Position Quick Report

Curve Info

Moving1.Position

Setup1 : Transient

Current(Winding1)

Setup1 : Transient

Optimization #2: Reducing Closing Time

优化#2：减小关断时间

Problem #2: Shape the pole of a linear actuator

to Reduce Closing Time

Solution: Use Maxwell transient model and Optimetrics.

优化#2：减小关断时间

• Create / Use Transient Model with appropriate moving mass, spring

force, and excitation (or external circuit), etc.

• Add Optimization

• Select Variables to be optimized.

• Use XatYMax function to capture closing time of actuator.

• Minimize the Cost function to reduce closing time.

Optimization #2: Reducing Closing Time

优化#2：减小关断时间优化#2：减小关断时间

0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00Time [ms]

0.00

0.20

0.40

0.60

0.80

1.00

Mo

vin

g1

.Po

sitio

n [m

m]

0.00

0.50

1.00

1.50

2.00

2.50

3.00

Cu

rre

nt(

Win

din

g1

) [A

]

TRW / Ansoft Position Quick Report

Curve Info

Moving1.Position

ArmStepHeight1='0mm' ArmStepRad1='1.28864

Moving1.Position

ArmStepHeight1='0.00326671530467659mm' Ar

• The Optimization runs through Variable

combinations to reduce Cost function –

Reduce Closing Time

优化#2：减小关断时间

• Statistical Study of the

number of coil turns

Statistical Analysis: Coil Turns Impact on Closing Time

统计分析：线圈匝数对关断时间的影响

0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00Time [ms]

0.00

0.20

0.40

0.60

0.80

1.00

Mo

vin

g1

.Po

sitio

n [m

m]

TRW / Ansoft Closing Time Statistical Results

Curve Info

Moving1.Position

Time (pu)

Positio

n (

pu)

D Closing Time

统计分析：线圈匝数对关断时间的影响

Thermal Performance using ePhysics

利用ePhysics分析热性能

1. Losses from Electromagnetic Solution

• Automatically map the losses– Magnetostatic

– Transient

– Eddy Current

• Assign lumped parameter losses from Power Loss Calculation

2.Heat Transfer

• Basic - Free Horizontal or Vertical Convection

• Forced Convection (Air, Water, oil, etc. @ flow rate).– Automatic Calculation of Coefficients

3.Thermal Solutions

• Static Steady State

• Transient Thermal – Thermal Rise times

– Thermal cycling studies

热性能分析

Complete System Model:

Transient to Transient Simulation

• Maxwell 2D/3D FEA model is dynamically linked to a Simplorer

System Simulation

• Magnetic model links Electrical to Mechanical and Hydraulic domains.

• Nonlinear saturation, AC and motion induced eddy current, back-

emf, and time-diffusion of magnetic fields considered.

• Transient to Transient link preformed at each time-step.

• Currents, Forces/Torques, Inductances are passed.

Co-simulation

瞬态协同仿真分析

典型的开关瞬态特性

• 12VDC Constant supply

• Air Flow not considered

0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]

0.00

2.50

5.00

7.50

10.00

12.50

15.00

17.50

20.00

Y1

[n

ew

ton

]

0.00

25.00

50.00

75.00

100.00

125.00

150.00

175.00

200.00

Mo

vin

g1

.Po

sitio

n [u

m]

0.00

0.02

0.04

0.06

0.08

0.10

Cu

rre

nt(

Win

din

g1

) [A

]

04_2D_TransientSwitching_Transient ANSOFT

Curve Info Y Axis

Current(Winding1)Setup1 : Transient

Current(Winding1)

Moving1.PositionSetup1 : Transient

Moving1.Position

Moving1.Force_zSetup1 : Transient

Y1

Moving1.LoadForceSetup1 : Transient

Y1

Position

Current

Mag. Force

Load Force

典型开关瞬态特性

典型开关瞬态特性

流体设计仿真

CFD-基本理论

Extraction of Geometry between the Solids

CFD-基本理论

Every cell has Properties

– Density

– Viscosity

– Thermal Conductivity

Setup

– Boundary Conditions

• Inlet and Outlet Pressure

• Inlet Velocities

– Material Properties

– Initial Conditions

Solution

– Solving of Transport Equations

• Continuity

• Momentum

• Energy

• Turbulence

Meshing the Domain

CFD-瞬态仿真

• Why should we run Transient Valve Simulations ?

• Hysteresis effects

• Transient Boundary Conditions

• Detailed Turbulence Modeling –LES

• What is the Difference to Steady-State Simulation?

• Transient Term in Transport Equations

• Mesh has to be modified per Time Step

CFD-瞬态仿真分析

Definition of Time Step Size

− Normal Motion of Walls per Time Step not larger thanadjecent Cell Size

− Courant Criteria

• Information moves onlyone Cell per Time Step

Implicit Coupling can help toincrease the Time Step Size

− Motion is updated severaltimes per Time Step

− Really important for Materials with high Density

• Strong Inertial Forces

系统设计仿真

多物理域系统仿真分析

Which Questions should we ask, if we run Multiphysics Simulation?

• How strong is Coupling?

• Do we have 2-way Effects?

• Is there a preferred Simulation Order?

Examples:

Thermal management usign Fields Coupling

Magnetic – Pneumatic force coupling via Co-simulation

电磁阀热特性仿真分析

Influence at Thermal Situation in Valve– Electromagnetic Sources in Coil and Anchor

• Ohmic Losses

– Heat Transfer in Valve

– Heat Transfer to Ambient Air and Process Medium

• Convective Heat Transfer

• Radiation

电磁阀热特性仿真分析方法

Maxwell Static Thermal

Maxwell

Static ThermalCFD

Maxwell CFD

Acc

urr

acy

Cal

cula

tio

nTi

me

Maxwell 与 Static Thermal

Iterative Data Transfer

Boundary Condition:HTC

EmissivityAmbient Temperature

Boundary Condition:Current

Mapping of Ohmic Loss

Mapping of Temperature

Advantage

• Fast because of Small Number of Elements and Easy Mesh Generation

• Fast because of Easy Radiation Modelling

• Only Two Sets of Material Databases

Maxwell 与 Static Thermal

0, 22.0

1, 71.8

2, 79.1 3, 80.1 4, 80.3

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Tem

pe

ratu

re [

°C]

Magnetic-Thermal Iteration

Convergence of Thermal Solution

Coil Temp.

Process time: 44min 51s

Maxwell, CFD 与 Static Thermal

Boundary Condition:HTC

EmissivityAmbient Temperature

BoundaryCondition:

Current

Map Losses

Boundary Condition:Wall TemperatureInlet Temperature

Ambient Temperature

Map Wall HTC

Map Temperature

Advantage

• Accurate – Heat Transfer Coefficents will be calculated by CFD

• Flexibility by Modularization – You decide which Model Part is calculated accurate and how often from Coupling Point of View

Maxwell, CFD 与 Static Thermal

Process time: 62min 15s

0, 22.0

1, 71.6 2, 73.4

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

0 0.5 1 1.5 2 2.5

Tem

pe

ratu

re [

°C]

Magnetic-Thermal Iteration

Convergence of Thermal Solution

Coil Temp.

Maxwell 与 CFD

Boundary Condition:Inlet Temperature

Ambient Temperature

Boundary Condition:Current

Mapping of Ohmic Loss

Mapping of Temperature

Advantage

• Accurate – Heat Transfer Coefficents will be calculated by CFD

• Only Two Sets of Material Databases

仿真分析方法对比

• Simple Convection BC

•C

on

vect

ion

BC

fro

mC

FD

Outside Temperature

Inside Temperature

Hot Spot 70 oC Hot Spot 65 oC

Hot Spot 81 oC Hot Spot 72 oC

“0D”系统集成

“0D“ 系统集成

Multi-domain system simulation

– Electrical supply

– Digital Control

– Mechanical / fluid behavioural models

Transient Electromagnetic

FEM co-simulation

Multidomain model extraction (ROM) and co-simulation

plunger

limit

spring

F

F

em_force

Battery

- +

bjt1 bjt2

accumulator

Digital Control

TRIG

CTRL2

CTRL1 BS=>Q

BS=>Q

DETECT

PLUNGERI

TRIG

Solenoidmp2

pp1

75

m := 0.0066 s0 := 0.0002

gravity

v alue := 0.0066*9.8

spacer

sul := 0.0002sll_ := 0.0

Digital Electrical

Mechanical Hydraulic

Solenoid

A

orifice

75

ctrl1

ctrl2

plunger_control

瞬态协同仿真——电磁与气动力耦合仿真

• Physical effects

• Magnetic Force on plunger from FEM, transient with motion

• Pneumatic force from CFD flow simulation

• Mechanical aspects as lumped models

– Spring

– Mass

– Damping

– Simulation provides insight info

• Accurate switching time

• Control dynamics (i.e. proportional valves)

• Flutter, Caviation as disturbances

瞬态协同仿真——电磁与气动力耦合仿真

0

0

0

0 0

S

+

SM_TRB1

F

F_TRB2

MASS_TRB1

V0=0m_per_sec

S0=0.5mm

M=1gram

F

F_TRB1

Ide

al

STOP

LOWER_LIM=0.01mm

UPPER_LIM=0.195mm

F

F_mag

F

F_Plunger

F

F_spring

SPRING_TRB1

C=333

S+

S_TRB1

VALUE=0.185mm

E1

R1

T1

T2T3

T4

smpl_lift

cfd_force

S1

CTRL=S1

D1

MaxwellCosimulation

FLUENTCosimulation

0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]

0.00

100.00

200.00

300.00

400.00

500.00

Po

sitio

n [u

m]

0.00

0.01

0.02

0.03

0.04

0.05

0.06

Co

il C

urr

en

t [A

]

-20.00

-15.00

-10.00

-5.00

0.00

5.00

10.00

15.00

20.00

Plu

ng

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02_CoSim_MAgnetic_CFDTransient Switching with CFD ANSOFT

Curve Info Y Axis

Current Current

Plunger Force Plunger Force

Position w. CFD Y3

Position w/o CFD Y3

Simplorer Schematic

Simplorer环境下实现Maxwell与Fluent瞬态协同仿真

总结

• Solenoid design involves consideration of electromagnetic, mechanical, thermal and control aspects

• Various and flexible coupling methods can be applied to:• Speed up the design simulation process maitaining certain/acceptable

level of accuracy (e.g. simple BC)

• Increase the level of design accuracy (e.g. BC calculated by CFD)

• Optimize the dynamic performance of the solenoid considering the embedded software

• The ANSYS approach enables the complete system design through appropriate coupling methodologies within ANSYS Workbench