Maxwell and HFSS Coupling to ANSYS 12.
Martin Vogel, PhD
Product Management
2009 ANSYS, Inc. All rights reserved.
ANSYS, Inc. Proprietary
Why couple simulators for electromagnetics and multi-physics?
Electronics produce heat, which can cause malfunctions. Courtesy of
2
ANSYS, Inc. Proprietary
2009 ANSYS, Inc. All rights reserved.
Existing Electromagnetics Multiphysics Links
Electromagnetic simulators: Maxwell SIwave
HFSS
ANSYS Mechanical Thermal Solvers
ANSYS FLUENT Thermodynamics and fluid flow
ANSYS ICEPAK cooling of electronics
ANSYS Mechanical Stress Solver
2009 ANSYS, Inc. All rights reserved.
ANSYS, Inc. Proprietary
Example 1 Raytheon High-Power Connector
Microstrip terminated by shorting diode Copper housing Kovar and glass More connector, gold, Teflon Semi-rigid coaxial cable, silver, Teflon, copper
Port
2009 ANSYS, Inc. All rights reserved.
ANSYS, Inc. Proprietary
Cross section of critical part:
Gold pin Kovar Glass Air Teflon Gold pin
Microstrip
2009 ANSYS, Inc. All rights reserved.
ANSYS, Inc. Proprietary
Before turning power on
Co-axial pin connecting to microstrip trace Courtesy of
6
ANSYS, Inc. Proprietary
2009 ANSYS, Inc. All rights reserved.
Soon after turning power on
Excessive heat has destroyed the connector. Courtesy of
7
ANSYS, Inc. Proprietary
2009 ANSYS, Inc. All rights reserved.
Analyze the model in HFSS
Pin connecting to trace
2009 ANSYS, Inc. All rights reserved.
ANSYS, Inc. Proprietary
Export info from HFSS
Geometry, e.g. in STEP format
Small file with link info
9
ANSYS, Inc. Proprietary
2009 ANSYS, Inc. All rights reserved.
Request thermal simulation(s) in Workbench. Import the geometry.
2009 ANSYS, Inc. All rights reserved.
10
ANSYS, Inc. Proprietary
Specify volume and surface losses. Workbench will access HFSS.
HFSS Volume loss HFSS Surface Loss
Simply picked all metal faces
2009 ANSYS, Inc. All rights reserved.
11
ANSYS, Inc. Proprietary
Add boundary conditions for convection and cooling.
Convection on many faces Cooling on bottom face
2009 ANSYS, Inc. All rights reserved.
12
ANSYS, Inc. Proprietary
Temperature reaches almost 300 deg C in kovar and glass.
2009 ANSYS, Inc. All rights reserved.
13
ANSYS, Inc. Proprietary
Transient simulation gives same final temperature after 20 seconds.
2009 ANSYS, Inc. All rights reserved.
14
ANSYS, Inc. Proprietary
Use one of the thermal solutions as input for a structural analysis.
2009 ANSYS, Inc. All rights reserved.
15
ANSYS, Inc. Proprietary
Deformation up to 2 m
2009 ANSYS, Inc. All rights reserved.
16
ANSYS, Inc. Proprietary
Stress mostly in inner conductor
2009 ANSYS, Inc. All rights reserved.
17
ANSYS, Inc. Proprietary
Finalize the design.
Kovar, responsible for the high temperatures, has been replaced by a different metal. Temperatures may still be high, which Teflon cannot handle. Accurate analysis wanted.
Involve CFD to analyze the cooling. Use the two-way thermal coupling to account for temperature-dependent materials.
2009 ANSYS, Inc. All rights reserved.
18
ANSYS, Inc. Proprietary
Use CFD to determine the film coefficient for the water cooling at the bottom.
Convection on many faces Cooling on bottom face
2009 ANSYS, Inc. All rights reserved.
19
ANSYS, Inc. Proprietary
Connector array with water cooling
Water, velocity 1 ft/s
2009 ANSYS, Inc. All rights reserved.
20
ANSYS, Inc. Proprietary
Mesh in Fluent
2009 ANSYS, Inc. All rights reserved.
21
ANSYS, Inc. Proprietary
Fluent velocity results
2009 ANSYS, Inc. All rights reserved.
22
ANSYS, Inc. Proprietary
Fluent temperature results
2009 ANSYS, Inc. All rights reserved.
23
ANSYS, Inc. Proprietary
Replace water cooling by film coefficients
Film coefficient ranges from 5700 to 2300 W/(m2 K) depending on position.
24
ANSYS, Inc. Proprietary
2009 ANSYS, Inc. All rights reserved.
Why two-way thermal?
Teflon loss tangent increases with temperature. Run-away effect possible.
Glass transition
2009 ANSYS, Inc. All rights reserved.
25
ANSYS, Inc. Proprietary
Two-way thermal link Ansoft Workbench Mechanical
Solve in Ansoft at initial temperature. Export electromagnetic loss to WB Mechanical. Determine temperatures in WB Mechanical. Export temperatures to HFSS. Material parameters change. T < threshold? Yes Done
26
ANSYS, Inc. Proprietary
Solve in Ansoft with new temperatures.
No
2009 ANSYS, Inc. All rights reserved.
Two-way thermal analysis:
Final temperatures with normal Teflon
2009 ANSYS, Inc. All rights reserved.
27
ANSYS, Inc. Proprietary
EM Power Losses as function of two-way thermal iteration
Volume Loss in normal Teflon Surface Loss on metals
Volume Loss in low-loss Teflon
2009 ANSYS, Inc. All rights reserved.
28
ANSYS, Inc. Proprietary
Temperatures as function of two-way thermal iteration
Tmax Normal Teflon
Tmax Low-Loss Teflon Tmin Normal Teflon Tmin Low-Loss Teflon
2009 ANSYS, Inc. All rights reserved.
29
ANSYS, Inc. Proprietary
Two-way thermal analysis:
Final temperatures with low-loss Teflon
2009 ANSYS, Inc. All rights reserved.
30
ANSYS, Inc. Proprietary
Example 2, with Ansoft Maxwell: battery charger for medical implants
Battery Titanium case, implanted in body Coil outside body, on skin, powered by external source Coil in implant, inductively coupled, picks up power to charge battery
Electronics
2009 ANSYS, Inc. All rights reserved.
31
ANSYS, Inc. Proprietary
Induced current has maximum at 50 kHz.
Maximum
Limited by losses in coil
Limited by skin effect in titanium case
2009 ANSYS, Inc. All rights reserved.
32
ANSYS, Inc. Proprietary
Magnetic field coupling
Induced currents in second coil reduce the magnetic field here. This is the intended behavior.
33
ANSYS, Inc. Proprietary
2009 ANSYS, Inc. All rights reserved.
Final temperature at 50 kHz
Maximum 43.8 0C
Due to skin effect in titanium, temperature exceeds 43 deg C after a few minutes. This would be uncomfortable and probably violates safety regulations.
34
ANSYS, Inc. Proprietary
2009 ANSYS, Inc. All rights reserved.
Final temperature at 10 kHz
Maximum 38.4 0C
At 10 kHz, final temperature is safe. Secondary coil picks up about as much power, but skin effect heats the titanium case much less.
35
ANSYS, Inc. Proprietary
2009 ANSYS, Inc. All rights reserved.
Conclusions
Links between HFSS/Maxwell and ANSYS Workbench are available in the graphical user interfaces -> easy to set up. Advanced applications can be handled.
2009 ANSYS, Inc. All rights reserved.
36
ANSYS, Inc. Proprietary
