Solved with COMSOL Multiphysics 4.

Rotating Machinery 3D Tutorial

Introduction
This model serves as a general introduction to the Rotating Machinery, Magnetic
physics in 3D. The circular motion of a cylindrical copper rotor near a stationary
permanent magnet generates induced eddy currents in the rotor. Figure 1 shows the
geometry with the rotor and stator.

Figure 1: Drawing showing how the rotor and stator with permanent magnet are defined.

Model Definition
This COMSOL Multiphysics model is a time-dependent 3D problem. It is a true
time-dependent model where the motion of the rotor is accounted for in the boundary
condition between the stator and rotor geometries. The conducting part of the rotor
is modeled using Ampres law;
A
1
------- + --- A = 0
t

whereas the non conducting parts of both the rotor and stator are modeled using a
magnetic flux conservation equation for the scalar magnetic potential:

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( V m B r ) = 0
Rotation is modeled using a ready-made physics interface for rotating machinery. The
central part of the geometry, containing the rotor and part of the air-gap, is modeled
as rotating relative to the coordinate system of the stator. The rotor and the stator are
created as two separate geometry objects, so it is possible to use an assembly (see the
Geometry chapter in the COMSOL Multiphysics Reference Manual for further
details). This has several advantages: the coupling between the rotor and the stator is
done automatically, the parts can be meshed independently, and it allows for a
controlled discontinuity in the scalar magnetic potential at the interface between the
two geometry objects. The rotor problem is solved in a rotating coordinate system
where the rotor is fixed (the rotor frame), whereas the stator problem is solved in a
coordinate system that is fixed with respect to the stator (the stator frame). Using
COMSOL notation, they are both solved in the material frame. An identity pair
connecting the rotating rotor frame with the fixed stator frame is created between the
rotor and the stator. The identity pair enforces continuity for the magnetic scalar
potential in the global fixed coordinate system (the stator frame relative to which the
rotor rotates). However, this means that in the frame on which continuity in the scalar
magnetic potential is enforced, the meshes on either side of the rotor-stator interface
cannot be made identical except for the case without any rotation so some
interpolation between non-conforming meshes is involved. The resulting interpolation
errors have little numerical impact if the assembly is created such that the resulting
identity boundary pair only involves the scalar magnetic potential. In Ampres law for
the magnetic vector potential, current conservation is an implicit requirement that will
be violated if the identity boundary pair would involve interpolation of the magnetic
vector potential. The resulting interpolation errors will unconditionally make such a
model numerically unstable. Thus, special care has to be exercised when setting up the
geometry using assemblies in a model like this.

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Results and Discussion

The generated eddy current distribution in the rotor winding is shown after 0.1 s for
a constant rotation speed of 600 rpm.

Figure 2: Eddy current distribution after 0.1 s.

Model Library path: ACDC_Module/Motors_and_Actuators/

rotating_machinery_3d_tutorial

Modeling Instructions
From the File menu, choose New.
NEW

1 In the New window, click the Model Wizard button.

MODEL WIZARD

1 In the Model Wizard window, click the 3D button.

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2 In the Select physics tree, select AC/DC>Rotating Machinery, Magnetic (rmm).

3 Click the Add button.
4 Click the Study button.

A stationary study is needed to compute initial conditions. You will add a

time-dependent study later before solving.
5 In the tree, select Preset Studies>Stationary.
6 Click the Done button.
GLOBAL DEFINITIONS

Parameters
1 On the Home toolbar, click Parameters.
2 In the Parameters settings window, locate the Parameters section.
3 In the table, enter the following settings:
Name

Expression

rpm

600[rpm]

GEOMETRY 1

Start building the geometry. It has to be segmented into at least two parts: rotor and
stator.

Cylinder 1
1 On the Geometry toolbar, click Cylinder.
2 In the Cylinder settings window, locate the Size and Shape section.
3 In the Radius edit field, type 0.04.
4 In the Height edit field, type 0.03.
5 Locate the Position section. In the z edit field, type -0.015.
6 Click the Build Selected button.

It is easier to see the interior geometry details by switching to wireframe rendering.

7 Click the Wireframe Rendering button on the Graphics toolbar.

Cylinder 2
1 Right-click Component 1>Geometry 1>Cylinder 1 and choose Duplicate.
2 In the Cylinder settings window, locate the Size and Shape section.
3 In the Radius edit field, type 0.0235.

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4 Click the Build Selected button.

5 Right-click Component 1>Geometry 1>Cylinder 2 and choose Duplicate.

Difference 1
1 On the Geometry toolbar, click Difference.
2 Select the object cyl1 only.
3 In the Difference settings window, locate the Difference section.
4 Select the Objects to subtract toggle button.
5 Select the object cyl3 only.
6 Click the Build Selected button.

Cylinder 4
1 In the Model Builder window, under Component 1>Geometry 1 right-click Cylinder 1

and choose Duplicate.

2 In the Cylinder settings window, locate the Size and Shape section.
3 In the Radius edit field, type 0.02.
4 In the Height edit field, type 0.01.
5 Locate the Position section. In the z edit field, type -0.005.
6 Click the Build Selected button.

Union 1
1 On the Geometry toolbar, click Union.
2 Select the objects cyl4 and cyl2 only.
3 Click the Build Selected button.

Work Plane 1
Draw the magnet cross section in a work plane and then extrude into a 3D solid.
1 On the Geometry toolbar, click Work Plane.
2 In the Work Plane settings window, locate the Plane Definition section.
3 In the z-coordinate edit field, type -0.005.
4 Click the Build Selected button.

Rectangle 1
1 In the Model Builder window, under Component 1>Geometry 1>Work Plane 1

right-click Plane Geometry and choose Rectangle.

2 In the Rectangle settings window, locate the Size section.

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3 In the Width edit field, type 0.006.

4 In the Height edit field, type 0.004.
5 Locate the Position section. In the xw edit field, type -0.03.
6 In the yw edit field, type -0.002.
7 Click the Build All button.
8 On the Work Plane toolbar, click Close.

Extrude 1
1 On the Geometry toolbar, click Extrude.
2 In the Extrude settings window, locate the Distances from Plane section.
3 In the table, enter the following settings:
Distances (m)
0.01

4 Click the Build Selected button.

Finish the geometry build by creating an assembly from single stator and rotor objects.

Union 2
1 On the Geometry toolbar, click Union.
2 Select the objects ext1 and dif1 only.

Form Union
1 In the Model Builder window, under Component 1 >Geometry 1 click Form Union.
2 In the Form Union/Assembly settings window, locate the Form Union/Assembly section.
3 From the Action list, choose Form an assembly.
4 Click the Build Selected button.

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5 Click the Go to Default 3D View button on the Graphics toolbar.

DEFINITIONS

A boundary Identity Pair is automatically created between rotor and stator when
forming an assembly.
MATERIALS

On the Home toolbar, click Add Material.

ADD MATERIAL

1 Go to the Add Material window.

2 In the tree, select Built-In>Air.
3 In the Add material window, click Add to Component.
MATERIALS
ADD MATERIAL

1 Go to the Add Material window.

2 In the tree, select AC/DC>Copper.
3 In the Add material window, click Add to Component.

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MATERIALS

Copper
1 In the Model Builder window, under Component 1>Materials click Copper.
2 Select Domain 4 only.
3 Close the Add Material window.
R O T A T I N G M A C H I N E R Y, M A G N E T I C

Use Magnetic Flux Conservation in the non-conducting domains and Ampre's Law in the
conducting domains. Set up the permanent magnet as a user defined domain with
remanence and permeability.

Magnetic Flux Conservation 1

1 On the Physics toolbar, click Domains and choose Magnetic Flux Conservation.
2 Select Domains 1 and 3 only.

Magnetic Flux Conservation 2

1 On the Physics toolbar, click Domains and choose Magnetic Flux Conservation.
2 Select Domain 2 only.
3 In the Magnetic Flux Conservation settings window, locate the Magnetic Field section.
4 From the r list, choose User defined. From the Constitutive relation list, choose
Remanent flux density.
5 In the r edit field, type 1.05.
6 Specify the Br vector as
1.2

Gauge Fixing for A-Field 1

Rotating machinery in 3D needs explicit gauge fixing of the vector potential.
1 On the Physics toolbar, click Domains and choose Gauge Fixing for A-Field.
2 Select Domain 4 only.

The gauge fixing needs to be constrained in at least one point. You need to set this
up manually because the gauge fixed domain and its boundaries are interior to the
geometry.

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3 In the Gauge Fixing for A-Field settings window, locate the Gauge Fixing for A-Field

section.
4 Select the Constrain variable in at least one point check box.

Prescribed Rotational Velocity 1

Set up rotation of the rotor domain.
1 On the Physics toolbar, click Domains and choose Prescribed Rotational Velocity.
2 Select Domains 3 and 4 only.
3 In the Prescribed Rotational Velocity settings window, locate the Prescribed Rotational
Velocity section.
4 In the rps edit field, type rpm.

Mixed Formulation Boundary 1

The scalar and vector potentials are connected via a special boundary condition, that
is applied by default at the interface between the two formulations.

Continuity 1
A continuity feature has to be added to specify the coupling across the pair. Note that
pair features can be applied only if the same formulation is active on both sides of the
pair.
1 On the Physics toolbar, click Pairs and choose Continuity.
2 In the Continuity settings window, locate the Pair Selection section.
3 In the Pairs list, select Identity Pair 1.
4 Locate the Continuity section. From the Continuity in list, choose Magnetic scalar
potential.

Zero Magnetic Scalar Potential 1

The scalar potential also needs a point constraint, which is readily available as a
standard point feature.
1 On the Physics toolbar, click Points and choose Zero Magnetic Scalar Potential.
2 Select Point 1 only.
MESH 1

Some extra care is needed for the meshing of source and destination boundaries for the
pair; the destination side needs a finer mesh than the source side. To get full control,
mesh these surfaces separately. Use a finer mesh for the copper domain to better resolve
the expected velocity skin effect.

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Free Triangular 1
1 On the Mesh toolbar, click Boundary>Free Triangular.
2 In the Free Triangular settings window, locate the Boundary Selection section.
3 Click Paste Selection.
4 Go to the Paste Selection dialog box.
5 In the Selection edit field, type 11,12,14,15.
6 Click the OK button.

Size 1
1 Right-click Component 1>Mesh 1>Free Triangular 1 and choose Size.
2 In the Size settings window, locate the Element Size section.
3 Click the Custom button.
4 Locate the Element Size Parameters section. Select the Maximum element size check

box.
5 In the associated edit field, type 5e-3.

Free Triangular 2
1 On the Mesh toolbar, click Boundary>Free Triangular.
2 In the Free Triangular settings window, locate the Boundary Selection section.
3 Click Paste Selection.
4 Go to the Paste Selection dialog box.
5 In the Selection edit field, type 17,18,25,28.
6 Click the OK button.

Size 1
1 Right-click Component 1>Mesh 1>Free Triangular 2 and choose Size.
2 In the Size settings window, locate the Element Size section.
3 Click the Custom button.
4 Locate the Element Size Parameters section. Select the Maximum element size check

box.
5 In the associated edit field, type 3e-3.

Free Triangular 3
1 On the Mesh toolbar, click Boundary>Free Triangular.
2 In the Free Triangular settings window, locate the Boundary Selection section.
3 Click Paste Selection.

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4 Go to the Paste Selection dialog box.

5 In the Selection edit field, type 21, 22, 23, 24, 26, 27.
6 Click the OK button.

Size 1
1 Right-click Component 1>Mesh 1>Free Triangular 3 and choose Size.
2 In the Size settings window, locate the Element Size section.
3 Click the Custom button.
4 Locate the Element Size Parameters section. Select the Maximum element size check

box.
5 In the associated edit field, type 5e-3.

Free Tetrahedral 1
1 On the Mesh toolbar, click Free Tetrahedral, then click Build Mesh.

STUDY 1

Add and configure the time-dependent study and then solve. The stationary solution
is automatically used as initial condition.

Step 2: Time Dependent

1 On the Study toolbar, click Study Steps and choose Time Dependent>Time Dependent.

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2 In the Time Dependent settings window, locate the Study Settings section.
3 Click the Range button.
4 Go to the Range dialog box.
5 From the Entry method list, choose Number of values.
6 In the Stop edit field, type 0.1.
7 In the Number of values edit field, type 31.
8 Click the Replace button.
9 On the Study toolbar, click Compute.
RESULTS

Data Sets
Change the frame of the data set to spatial (the fixed laboratory frame) to see the
rotor spin.
1 In the Model Builder window, under Results>Data Sets click Solution 1.
2 In the Solution settings window, locate the Solution section.
3 From the Frame list, choose Spatial (x, y, z).
1 Under Results, click on Magnetic Flux Density (rmm) and click Plot.

Finish the modeling session by plotting the induced eddy currents in the copper disc.

3D Plot Group 2
1 On the Results toolbar, click 3D Plot Group.

For new plot groups, the data set edges are by default plotted on the material frame.
Change to spatial frame.
2 In the 3D Plot Group settings window, locate the Plot Settings section.
3 From the Frame list, choose Spatial (x, y, z).
4 On the 3D Plot Group 2 toolbar, click Volume.
5 In the Volume settings window, click Replace Expression in the upper-right corner of

the Expression section. From the menu, choose Rotating Machinery, Magnetic
(Magnetic Fields)>Currents and charge>Current density norm (rmm.normJ).

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6 On the 3D Plot Group 2 toolbar, click Plot.

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