v14.0 LF Electromagnetics Update - ANSYS Customer · PDF file• ANSYS has a comprehensive...

© 2011 ANSYS, Inc. September 21, 2011

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v14.0 LF Electromagnetics Update

Mark ChristiniANSYS, Inc


2© 2010 ANSYS, Inc. All rights reserved. ANSYS, Inc. Proprietary

What is the ANSYS Solution?


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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


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Maxwell 2-D/3-DElectromagnetic Components

Field Solution

Model Generation

HFSS

ANSYS MechanicalThermal/Stress

ANSYS CFDFluent

PExprtMagnetics

RMxprtMotor Design

Maxwell Design Flow – Field Coupling


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SimplorerSystem Design

PP := 6

ICA:

A

A

A

GAIN

A

A

A

GAIN

A

JPMSYNCIA

IB

IC

Torque JPMSYNCIA

IB

IC

TorqueD2D

HFSS, Q3D, SIwave

ANSYS CFD Icepack/Fluent

Maxwell 2-D/3-DElectromagnetic Components

ANSYS MechanicalThermal/Stress

PExprtMagnetics

RMxprtMotor Design

Simplorer Design Flow – System Coupling

Model order Reduction

Co-simulation

Push-Back Excitation


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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

ANSYS Workbench R14 Highlights


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Simplorer

Multi-Domain Circuit and System Simulation Package


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• Multi-domain, system simulator for designing high performance systems

• Three Basic Simulation Engines: Circuits, Block Diagrams, State Machines

• Mixed Signal – Mixed Mode Modeling

• Digital / Analog

• Magnetic, Mechanical, Thermal …

• Integrated analysis with electromagnetic simulation tools (Maxwell, PExprt, RMxprt, Q3D)

• Analysis Types: AC, DC, Transient

• Co-simulation with Maxwell and Simulink

• Statistical Analysis and Optimization

• VHDL-AMS Capability

SUM2_6

CONST

id_ref

G(s)

GS2

I

I_PART_id

GAINid

LIMIT

yd

UL := 9

LL := -9

GAIN

P_PART_id

KP := 0.76

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R1 R2 R3 R450 1k 1k50

C1 C2

3.3u3.3u

V0 := 5 V0 := 0

N0005

N0003N0004

N0002

IMP = 0

IMP = 1IMP = 0IMP = 1

IMP = 0 and RLine.I <= ILOW

IMP = 1 and RLine.I >= IUP

IMP = 0 and RLine.I >= IUP

IMP = 1 and RLine.I <= ILOW

SET: CS1:=-1SET: CS2:=-1SET: CS3:=-1SET: CS4:=-1

SET: CS1:=-1SET: CS2:=1SET: CS3:=-1SET: CS4:=-1

SET: CS1:=1SET: CS2:=-1SET: CS3:=-1SET: CS4:=-1

SET: CS1:=-1SET: CS2:=-1SET: CS3:=-1SET: CS4:=-1

Circuits

Block Diagrams

State Machines

Simplorer - Overview


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Cosimulation with Rigid Body DynamicLanding Gear Application

Piston Position

Hydraulic Circuit

Position vs Force


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Simplorer-Fluent Cosimulation

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

Transient co-simulation for non-linear CFD models


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Cosimulation Example: Battery Cooling

Single battery cell

Inputs: Inlet Flow Rate (Kg/s) and Heat Source(W/m3)

Output: Outlet Temperature (K)

Inlet

Outlet

Battery Element(HeatSource)


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Simulation Results: No Control

Flow Rate

Heat SourceTemperature Change

@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 aloneNon-linear dependency on Flow Rate


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Simulation Results: Linear Controls


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Simulation Results: Non-linear Control

Fluent Control Co-Simulation

Flow is adjusted to maintain constant temperature


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IGBT Characterization

• Accurate models of the semiconductorsare needed to achieve a good circuit simulation

• Simplorer offers a parameterization toolfor IGBTs

• The user can import the data from the datasheet and created an accurate IGBT model

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

0.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

U1.

VC

E

-15.00

-10.00

-5.00

0.00

5.00

10.00

15.00

VM

2.V

[V]

-10.00

0.00

10.00

20.00

30.00

40.00

50.00

R2.

I [A

]

Ansoft Corporation Simplorer1switch_on

Curve InfoU1.VCE

TRVM2.V

TRR2.I

TR


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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


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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 analysisBoth conductive and radiative analysis EMC/EMI can be performed


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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


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Maxwell

2D/3D Finite Element Low Frequency Electromagnetics


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• 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

Maxwell Overview


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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


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Full Parallelization of 3D non-transient solvers

OpenMP is used to speed up the field solver using different cores sharing same memory

0

50

100

150

1-CPU 2-CPU 4-CPU 6-CPU 8-CPU

Tim

e [m

in.]

Real Time Computation

64-bit XP @ 2.67 GHz 12GB of RAM

3D Magnetostatic Problem- Adaptive Analysis with 6 iterative steps (energy error = 0.03%)- 606,758 tetrahedra- 817,274 matrix


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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

3D Eddy Current High Order Elements

First order approximation for currents

Zero order approximation for currents


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Induced eddy current Zero order vector shape functions

Induced eddy currentFirst order vector shape functions

Coil

Mesh on the plate

Plate

3D Eddy Current High Order Elements


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Core Loss in Eddy-Current Solver

Steel and Power Ferrite Core loss available

Typical Application: Ferrite Electronic Transformer

Core loss evaluation in linear mode without a transient analysis


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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


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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 solveremploying linear BH characteristic


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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

Maxwell Integration in Workbench


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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

Maxwell

Deformed Mesh

ANSYS Mechanical

Force Distribution


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Example: Air inductor



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B Field

MagneticForces

Displacementsof mesh nodes

Stress CalculationField Calculation

Force Distribution

DisplacementsUpdated Mesh


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Maxwell – Fluent Two-Way Coupling

Approach:• The Loss distribution is transferred as load into Fluent

• The Temperature distribution is sent back to Maxwell

Maxwell

Temperature

ANSYS Fluent

Loss Distribution


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Maxwell – Fluent Two-Way Coupling

Example: Busbars – Electrical, Thermal, Structural

Loss Distribution Temperature

Deformation

2-way


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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

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

where T0 is the reference temperature, and α1, α2, β1 and β2 are coefficients which are provided in supplier datasheets

PM Temperature Dependent Model

HBB i 0µ+=

( ) ( )( ) )()(1)()( 02

02010 TPTBTTTTTBTB rrr =−+−+= αα

( ) ( )( ) )()( 1)()( 02

02010 TQTHTTTTTHTH cicici =−+−+= ββ


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Copied from vendor datasheet

Derived based on the temperature dependent demagnetization model



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Coercivity change shows dynamic irreversible demagnetization during a transient process in one element


Coercivity (Hc)

FluxDensity


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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


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RMxprt

Analytical Sizing package for Electrical Machine Design


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• 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

RMxprt - Overview


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• 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

Integrated Motor Solutions


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RMxprt – Interior Permanent MagnetMachines

RMxprt can set up the Maxwell 2D/3D project for IPM Machines• Multi duct layers supported

• No analytical solution provided yet


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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


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Q3D

Quick RLC Extractor for 2D and 3D Structures


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• 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

Q3D Extractor - Overview


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log(f)

log R(f)

fRacdcR

log(f)

L(f)

acL

dcL

• Both R and L depend on frequency

• Q3D solves only the low and high frequency asymptotes

• Behavior in between is estimated

Q3D Extractor - AC vs DC Resistance & Inductance


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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


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Inductor Example

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

DC < f < 1 MHz

Magnetic Core (µ = 500, σ= 100000)

Solid Copper Coil


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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)


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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


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0.00 0.01 0.10 1.00 10.00 100.00Freq [MHz]

25.00

30.00

35.00

40.00

45.00

50.00

55.00

AC

L(C

oil:C

oil_

in,C

oil:C

oil_

in) [

nH]

Q3DDesign2XY Plot 1 ANSOFT

Curve InfoACL(Coil:Coil_in,Coil:Coil_in)

Setup1 : Sw eep2


Q3D AC 10 s Maxwell 50 min

Q3D DC 6min 30 s

Sweep 2 s

(regardless of # of Freqs) (4 Freq <1MHz)

Total Solution Time < 7 min 50 min

Peak RAM 0.6 Gb 5 Gb

Each Additional Freq 15 min

L(f)

Simulation Time

HFSS

Maxwell

Q3D


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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


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Q3D - 3D Modeler Enhancements

View customization

• Z-stretch• 64-bit user interface

This enhancement is available to all EBU - 3D products


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Geometry and User Interface


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• Possible import DesignModeler geometry directly into Ansoft products

• Geometry and material assignment transfer from Ansoftsystems to ANSYS systems

• Further geometry edits are possible in DM if user has license

Ansoft to ANSYS Geometry Transfer


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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


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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

– Faster post-processing• Improved reporter-dialog response

– No sluggishness

Wave Winding UDP


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CAD Integration on WB Improvements

Added support for parametric analysis and DSO of CAD parameters


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Reliability Engineering Design - DOE

Distribute parametric studies across available hardware to expedite design optimization

Identify key design parameters

Identify variation of performance with respect to variations of parameters


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Reliability Engineering Design – Six Sigma

Input parameters vary!

Output parameters

How performance will vary with design tolerances?

how many parts will likely fail?

which inputs require the greatest control?

A product has Six Sigma quality if only 3.4 parts out of every 1 million manufactured fail


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Reliability Engineering DesignSurface Response Analysis


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

Maxwell 2D/3D ANSYS Static/Transient StructuralTwo-Way Link

ANSYS Static/Transient StructuralOne-Way Link (Maxwell upstream)

Electrostatic

Magnetostatic

Eddy Current

Magnetic Transient

Electric Transient

Maxwell 2D/3D ANSYS Static/Transient ThermalTwo-Way Link

ANSYS Static/Transient ThermalOne-Way Link (Maxwell upstream)

Electrostatic

Magnetostatic

Eddy Current

Magnetic Transient

Electric Transient


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Maxwell-Fluent Field Mapping coupling capabilities available in R14

Maxwell 2D/3D Fluent Steady State(Thermal link)Two-Way Link

Fluent Transient(Thermal link)

One-Way Link (Maxwell upstream)

Electrostatic

Magnetostatic

Eddy Current

Magnetic Transient

Electric Transient


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Simplorer System Coupling capabilities available in R14

Solver Reduce Order Model

Equivalent Circuit/Matrices/Look-Up Tables

Co-Simulation Push BackExcitation

Maxwell 2D/3DElectrostaticMagnetostatic

Maxwell 2D/3DEddy Current

Maxwell 2D/3DTransient

Q3D

HFSS, SIwave

RMxprt, PExprt


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Simplorer system coupling capabilities available in R14

Solver Reduce Order Model

Equivalent Circuit/Matrices/Look-Up Tables

Co-Simulation Push BackExcitation

Fluent Transient

Icepak

ANSYS Mechanical(Modal)

ANSYS RBD

Simulink

ModelSim

Mathcad

v14.0 LF Electromagnetics Update - ANSYS Customer · PDF file• ANSYS has a comprehensive...

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