v14.0 LF Electromagnetics Update

Transcription

1 v14.0 LF Electromagnetics Update and HF Introduction o Mark Christini ANSYS, Inc 1 ANSYS, Inc. September 12,

2 2 ANSYS Workbench R14 Highlights Simplorer Co simulation with RBD 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 thigh h 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, Inc. September 12,

3 Introduction Electromechanical Perspective 3 ANSYS, Inc. September 12,

4 4 ANSYS, Inc. September 12, 2010 ANSYS, Inc. All rights reserved. ANSYS, Inc. Proprietary

5 Introduction: Electromechanical Perspective ANSYS has a comprehensive portfolio of simulation packages. Our goal is to provide tools that enable Electric 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 h of 3D simulations into the 0D system simulation design 5 ANSYS, Inc. September 12,

6 Maxwell Design Flow Field Coupling ANSYS CFD Fluent RMxprt Motor Design HFSS Maxwell 2-D/3-D Electromagnetic Components ANSYS Mechanical Thermal/Stress PExprt Magnetics Field Solution Model Generation 6 ANSYS, Inc. September 12,

7 D2D GAIN J Simplorer Design Flow System Coupling ANSYS CFD Icepack/Fluent Simplorer System Design RMxprt Motor Design IA PMSYNC Torque A IB ICA: A A IC PP := 6 A HFSS, Q3D, SIwave PExprt pt Magnetics ANSYS Mechanical Thermal/Stress Maxwell 2-D/3-D Electromagnetic Components Model order Reduction Co-simulation Push-Back Excitation 7 ANSYS, Inc. September 12,

8 Simplorer Multi Domain Circuit and System Simulation Package 8 ANSYS, Inc. September 12,

9 Simplorer Overview Circuits Multi-domain, system simulator for designing high performance systems R1 50 R2 1k R3 1k R4 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 N C1 3.3u V0 := 5 Block Diagrams UL := 9 LL := -9 LIMIT yd I_PART_id I P_PART_id GAIN KP := 0.76 State Machines SET: CS1:=-1 SET: CS2:=-1 SET: CS3:=-1 SET: CS4:=-1 IMP = 1 IMP = 0 SET: CS1:=1 SET: CS2:=-1 SET: CS3:=-1 SET: CS4:=-1 IMP = 0 and RLine.I <= ILOW IMP = 0 and RLine.I >= IUP IMP = 1 and RLine.I <= ILOW IMP = 1 and RLine.I >= IUP N0003 SUM2_6 CONST 3.3u id_ref G(s) GS2 IMP = 1 C2 V0 := 0 N0005 SET: CS1:=-1 SET: CS2:=1 SET: CS3:=-1 SET: CS4:=-1 SET: CS1:=-1 SET: CS2:=-1 SET: CS3:=-1 SET: CS4:=-1 IMP = 0 GAIN 50 N0004 id 9 ANSYS, Inc. September 12,

10 Cosimulation with Rigid Body Dynamic Landing Gear Application Position vs Force Hydraulic Circuit Piston Position 10 ANSYS, Inc. September 12,

11 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 11 ANSYS, Inc. September 12,

12 Cosimulation Example: Battery Cooling Single battery cell Inputs: Inlet Flow Rate (Kg/s) and Heat Source(W/m 3 ) Output: Outlet Temperature (K) Battery Element (HeatSource) Inlet Outlet 12 ANSYS, Inc. September 12,

13 Simulation Results: No Control 13 Flow Temperature Change Heat Source Sec k k k k Results verified with Fluent alone Non linear dependency on Flow Rate ANSYS, Inc. September 12,

14 Simulation Results: Linear Controls 14 ANSYS, Inc. September 12,

15 Simulation Results: Non linear Control Fluent Control Co Simulation Flow is adjusted to maintain constant temperature 15 ANSYS, Inc. September 12,

16 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 Simplorer R2.I [A] U1.VCE VM2.V [V] Curve Info U1.VCE TR VM2.V TR TR R2.I Time [us] 16 ANSYS, Inc. September 12,

17 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 17 ANSYS, Inc. September 12,

18 Push Back Excitation for EMC/EMI Push excitations to SIwave and HFSS: Allows feedback of transient simulation resultsinform of excitations for 3DFEA State Space Model Excitation data 18 Radiated Fields can now be calculated based on actual conductive mode analysis Both conductive and radiative analysis EMC/EMI can be performed ANSYS, Inc. September 12,

19 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 bcircuitit Perform a transient analysis Right click to push excitation UI. 3 UI converts timedomainsignaltofrequency to domain Excitation files get written Voltage and current for each frequency and port Import files back to SIwave External source excitations 19 ANSYS, Inc. September 12,

20 Maxwell 2D/3D Finite Element Low Frequency Electromagnetics 20 ANSYS, Inc. September 12,

21 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 21 ANSYS, Inc. September 12,

22 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 22 ANSYS, Inc. September 12,

23 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%) 606,758 tetrahedra 817,274 matrix 150 Real Time Computation 64 bit 2.67 GHz 12GB of RAM Time [min.] CPU 2 CPU 4 CPU 6 CPU 8 CPU 23 ANSYS, Inc. September 12,

24 3D Eddy Current High Order Elements Goal: Improve accuracy for current density field (J) J field is derived quantityfromt Ω Ω formulation Higher order elements gives first order approximation for currents Zero order approximation for currents 24 ANSYS, Inc. September 12, First order approximation for currents

25 3D Eddy Current High Order Elements Coil Plate Mesh on the plate 25 Induced eddy current Zero order vector shape functions ANSYS, Inc. September 12, Induced eddy current First order vector shape functions

26 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 26 ANSYS, Inc. September 12,

27 Core Loss in Eddy Current Solver Enter Core Loss coefficient as in Transient Disable Eddy Current calculation as Core Loss contains Eddy Loss 27 ANSYS, Inc. September 12, Ferrite Core

28 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 = e 6 * 11 * (100,000)^1.3000)^1 * (0.2)^2.5 = 08W 0.8 The core loss can be numerically validated using the 3D magnetic transient solver employing linear BH characteristic 28 ANSYS, Inc. September 12,

29 Maxwell Integration in Workbench What was already possible in R13: Two way 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 idi i l i i Unidirectional CAD integration 29 ANSYS, Inc. September 12,

30 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 30 ANSYS, Inc. September 12,

31 Maxwell ANSYS Stress Coupling Example: Air inductor 31 ANSYS, Inc. September 12,

32 Maxwell ANSYS Stress Coupling B Field Force Distribution Magnetic Forces Field Calculation Updated Mesh Displacements Stress Calculation Displacements of mesh nodes 32 ANSYS, Inc. September 12,

33 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 33 ANSYS, Inc. September 12,

34 Maxwell Fluent Two Way Coupling Example: Busbars Electrical, Thermal, Structural Deformation Loss Distribution Temperature 2 way 34 ANSYS, Inc. September 12,

35 PM Temperature Dependent Model Maxwell 2D/3D can account for Permanent Magnet temperature dependency. The law works directly on intrinsic B i H curve with remanent flux density B r and intrinsic i i coercivity ii H ci B Bi 0H The Two temperature dependent parameters are remanent flux density B r and intrinsic coercivity H ci B r and H ci can be described by second order polynomials as B r H T T0 2 T T0 Br ( T ) P( ) 2 T T T T H ( T ) Q ( ( T ) Br ( T ) 0 ci 0 T ) ( T ) H ci ( T ) ci 0 0 Q T where T 0 is the reference temperature, and α 1, α 2, β 1 and β 2 are coefficients which are provided in supplier datasheets 35 ANSYS, Inc. September 12,

36 PM Temperature Dependent Model Copied from vendor datasheet Derived based on the temperature dependent demagnetization model 36 ANSYS, Inc. September 12,

37 PM Temperature Dependent Model Coercivity (Hc) Flux Density Coercivitychange it shows dynamic irreversible ibl demagnetization during a transient process in one element 37 ANSYS, Inc. September 12,

38 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 38 ANSYS, Inc. September 12,

39 RMxprt Analytical Sizing package for Electrical Machine Design 39 ANSYS, Inc. September 12,

40 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 40 ANSYS, Inc. September 12,

41 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 Simplorerdesign 41 ANSYS, Inc. September 12,

42 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 42 ANSYS, Inc. September 12,

43 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 43 ANSYS, Inc. September 12,

44 Q3D Quick RLC Extractor for 2D and 3D Structures 44 ANSYS, Inc. September 12,

45 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 45 ANSYS, Inc. September 12,

46 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) L dc Rdc R ac f Lac log(f) log(f) 46 ANSYS, Inc. September 12,

47 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 47 ANSYS, Inc. September 12,

48 Q3D Magnetic Materials Inductor Example Goal: Get R(f), L(f) DC < f < 1 MHz Magnetic Core (µ = 500, σ= ) Solid Copper Coil 48 ANSYS, Inc. September 12,

49 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) 49 ANSYS, Inc. September 12,

50 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) Using Q3D: BEM Surface mesh only Only 1 resolution for DC, 1 resolution for AC Rest of the spectrum determined by blended algorithm No need to mesh for skin depth Easier setup but may not give best accuracy in transition region 50 ANSYS, Inc. September 12,

51 Q3D Magnetic Materials Q3D AC 10 s Maxwell 50 min Q3D DC 6min 30 s Sweep (regardless of # of Freqs) 2 s (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 Curve Info ACL(Coil:Coil_in,Coil:Coil_in) Setup1 : Sw eep Maxwell oil:coil_in) [nh] ACL(Coil:Coil_in,Co Freq [MHz] 51 ANSYS, Inc. September 12, L(f) HFSS

52 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 the SPICE netlist or the Simplorer circuit The feature has been extended to 2D Extractor 52 ANSYS, Inc. September 12,

53 Q3D 3D Modeler Enhancements View customization Z-stretch 64 bit user interface This enhancement is available to all EBU 3D products 53 ANSYS, Inc. September 12,

54 Geometry and User Interface 54 ANSYS, Inc. September 12,

55 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 55 ANSYS, Inc. September 12,

56 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 56 ANSYS, Inc. September 12,

57 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 dtb Faster post processing Improved reporter dialog response No sluggishness Wave Winding UDP 57 ANSYS, Inc. September 12,

58 CAD Integration on WB Improvements Added support for parametric analysis and DSO of CAD parameters 58 ANSYS, Inc. September 12,

59 Reliability Engineering Design DOE Identify key design parameters Distribute parametric studies across available hardware to expedite design optimization i i Identify variation of performance with respect to variations of parameters 59 ANSYS, Inc. September 12,

60 Reliability Engineering Design Six Sigma Input parameters vary! A product has Six Sigma quality if only 3.4 parts 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? 60 ANSYS, Inc. September 12,

61 Reliability Engineering Design Surface Response Analysis 61 ANSYS, Inc. September 12,

62 Maxwell ANSYS Structural and Maxwell ANSYS Thermal Field Mapping couplingcapabilities capabilities available in R14 Maxwell 2D/3D Electrostatic Magnetostatic Eddy Current Magnetic Transient Electric Transient ANSYS Static/Transient Structural ANSYS Static/Transient Structural Two Way Link One Way Link (Maxwell upstream) Maxwell 2D/3D Electrostatic t ti Magnetostatic Eddy Current Magnetic Transient Electric Transient 62 ANSYS, Inc. September 12, ANSYS Static/Transient Thermal Two Way Link ANSYS Static/Transient Thermal One Way Link (Maxwell upstream)

63 Maxwell Fluent Field Mapping couplingcapabilities capabilities available in R14 Maxwell 2D/3D Fluent Steady State Fluent Transient (Thermal link) Two Way Link (Thermal link) One Way Link (Maxwell upstream) Electrostatic Magnetostatic Eddy Current Magnetic Transient Electric Transient 63 ANSYS, Inc. September 12,

64 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 64 ANSYS, Inc. September 12,

65 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 65 ANSYS, Inc. September 12,

66 High Frequency Introduction 66 ANSYS, Inc. September 12,

67 SI Wave Overview Full wave Printed Circuit Board and IC Package Solver Unique Field Solver Based on FiniteElement Method coupled with transmission lines Handles more compexity than HFSS due to 2D scalar solution Computes electrical behavior of high frequency and high speed PCBs and BGAs Extracts S, Y, and Z parameters Provides electromagnetic fields Circuit Board Resonances 67 ANSYS, Inc. September 12, Model Extraction for Complex Memory Interface

68 Ansoft Designer Ansoft Designer Overview Design Desktop Environment for System Level Electronics Design framework with schematic, layout, and post processing Links to EM field solvers and Circuit Simulation Nexxim Advanced Circuit Solver Transient, Harmonic Balance, and Statistical Eye Simulation 68 ANSYS, Inc. September 12,

69 HFSS Overview Full wave 3D electromagnetic field solver Computes electromagnetic behavior of high frequency and high speed components and systems Extracts S, Y, and Z parameters Provides3Delectromagnetic electromagnetic fields Simulation of RFIC in Package 69 4-port microwave comparitor ANSYS, Inc. September 12, Cavity Filter on cell phone tower Antenna on UAV

70 HFSS Down Hole Sensors Predicting sensor behavior in difficult conditions is more convenient with virtual simulation environments. Coils transmit and receive signals that vary based on position 70 ANSYS, Inc. September 12, Oil

71 HFSS Down Hole Sensors Rigorous FEM simulation allows myriad parametric simulations for the important design variables Mandrel Borehole Invasion Anisotropy Eccentricity Antenna Tilt 71 ANSYS, Inc. September 12,

72 HFSS Down Hole Sensors Simulation provides accurate calibration data for logs Vary Eccentricity mud = S/m mandrel offset formation = 10 S/m Ansoft Corporation Y RX Amplitude XY Plot 1 Ratio HFSSDesign1 Dot = Literature Line = Ansys Curve Info d_mag_imported Imported d_mag Setup1 : LastAdaptive Freq='0.002GHz' dy [in] Ansoft LLC litude Ratio Amp RX Amplitude Ratio XY Plot 4 Colored = HFSS Green = Maxwell Increasing Dip Angle 1_HFSSDesign ANSYS, Inc. September 12, Relative Transmitter Depth [in] Curve Inf o d_mag Setup1 : LastAdaptive dip='0deg' Freq=' d_mag Setup1 : LastAdaptive dip='20deg' Freq=' d_mag Setup1 : LastAdaptive dip='45deg' Freq=' d_mag Dip angle Vary Dip Angle & Displacement Sonde displacement Formation = 1 S/m Formation = 0.1 S/m Mud = S/m Formation = 1 S/m