Maxwell and Simplorer

Tips and Tricks

Ryan Magargle, PhD

Ansys, Inc.
1 © 2011 ANSYS, Inc. September 8, 2011
 Electromechanical Simulation
ANSYS Icepack Simplorer
System Design RMxprt
Motor Design
IA PMSYNC Torque J

A A D2D

IB ICA:
A
PP := 6
IC
A

GAIN

Q3D
Parasitics

PExprt
Magnetics

ANSYS Maxwell 2-D/3-D

Mechanical Electromagnetic Components
Thermal/Stress
Model order Reduction

Co-simulation

Field Solution

2 © 2011 ANSYS, Inc. September 8, 2011 Model Generation

 Maxwell Description

Solution Type
Project Manager

Modeler Window

Post-Processing
Properties Window

Message Manager Progress Window

3 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Highlights

4 © 2011 ANSYS, Inc. September 8, 2011

 Outline

Maxwell
– Geometry
– Transient
– Post-Processing
Simplorer
– Transient Solver
– Post-Processing
– Advanced Analysis

5 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Geometry Interface

Topic
• Remove geometry commands in any order to reduce the need for redrawing
geometry

6 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Geometry Interface

Example
• Create motor coils for symmetry, then change mind and undo symmetry

7 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Geometry Interface

Topic
• Increase geometry visibility with split planes

8 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Geometry Interface

Steps
•1 Click Draw Clip Plane
•2 Click Add-> Specify Center, Normal

9 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Geometry Interface

Steps
• Grab and drag to change clip plane view

10 © 2011 ANSYS, Inc. September 8, 2011

 Outline

Maxwell
– Geometry
– Transient
– Post-Processing
Simplorer
– Transient Solver
– Post-Processing
– Advanced Analysis

11 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Transient Solver

Topic
• Multiple objects with independent motion

Actuated magnet has Free magnet moves with its

motion prescribed by user own inertia to align with
actuated magnet

12 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Transient Solver

Setup
• Draw a “band” around each object
1 band1 band2
1
with independent motion
Axis of Axis of
•
2 Assign axis of rotation and type of rotation1 rotation2
motion
magnet1 magnet2

Air region

13 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Transient Solver

Setup
3• Apply mesh operations
4• Specify time step and stop time 3

14 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Transient Solver

Setup
3• Plot flux lines
4• Plot motion and animate

3
Magnet Motion Maxwell2DDesign1 ANSOFT
300.00 Curve Info
Victim Magnet
Setup1 : Transient
Source Magnet
4 200.00 Setup1 : Transient

Position [deg]
100.00

0.00

-100.00
0.00 50.00 100.00 150.00 200.00
Time [ms]
15 © 2011 ANSYS, Inc. September 8, 2011
 Maxwell Transient Solver

Topic
• Define complex transient excitation with functions and datasets

Input Current Waveform Maxwell2DDesign1 ANSOFT

1.25 Curve Info
InputCurrent(Winding1)
Setup1 : Transient

0.63 1A Sinusoid + .15A Triangle

InputCurrent(Winding1) [A]

0.00

-0.63

-1.25
0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00
Time [ms]

16 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Transient Solver

Steps
1• Define coil cross section as a ‘coil’ with turns.
2• Define winding with current function:
– 1A*Sin(2*Pi*50*time)+
0.15A*pwl_periodic(ds1,time) 1

Periodic piecewise linear

interpolation function of
numeric dataset, defined by user 2

17 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Transient Solver

Steps
• pwl_periodic(ds1,time) causes Maxwell to prompt for dataset definition

Unit Amplitude
Triangle Wave

18 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Transient Solver

Resulting Current Waveforms

Input Current Waveform ANSOFT Coil Back EMF ANSOFT

1.25 Curve Info 100.00 Curve Info
InputCurrent(Winding1) InducedVoltage(Winding1)
Setup1 : Transient Setup1 : Transient

InducedVoltage(Winding1) [V]
InputCurrent(Winding1) [A]

0.63 50.00

0.00 0.00

-0.63 -50.00

-1.25 -100.00
0.00 5.00 10.00 15.00 20.00 0.00 5.00 10.00 15.00 20.00
Time [ms] Time [ms]

1A*Sin(2*Pi*50*time)+
0.15A*pwl_periodic(ds1,time)

19 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Transient Solver

Topic
• Define variable timestep to capture complex waveform shape.

Broadband excitation for sensing

applications
20 © 2011 ANSYS, Inc. September 8, 2011
 Maxwell Transient Solver

Steps
1• Define coil cross section as a ‘coil’ with turns.
2• Define winding with current function:
– 1A*Sin(2*Pi*(1250*time+50)*time)

Frequency increases linearly

1
from 50Hz to 150Hz in 8
fundamental periods

21 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Transient Solver

Steps
• Capture 30 steps per period, for 8 fund. periods
3
– 1/30/(1250*time+50)

22 © 2011 ANSYS, Inc. September 8, 2011

 Outline

Maxwell
– Geometry
– Transient
– Post-Processing
Simplorer
– Transient Solver
– Post-Processing
– Advanced Analysis

23 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Post-Processing

Topic Flux Density Contour

• Use fields calculator to plot only Br in airgap for electric
machine

Flux Density Vector Radial Flux Density Vector

24 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Post-Processing

Calculator
 
• Scalar Field: Br  B  ir  Bxix  By i y  cos ix  sin i y 
• Vector Field:
Br  Br ir  Br cos ix  sin i y 
Steps
• Define Br
• Save Br as a new Field Expression
• Define Br_vec using Br
• Save Br_vec as a new Field Expression

25 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Post-Processing

Calculator: Define Br Calculator: Define Br_Vector

• Input -> Quantity -> B • Named Expressions -> Br ->
• Vector -> Scalar? -> ScalarX Library -> Copy to Stack
• Input -> Function -> Phi • Input -> Function -> Phi
• Scalar -> Trig -> Cos • Scalar -> Trig -> Cos
• General -> *
• General -> *
• Scalar -> Vec? -> VecX
• Input -> Quantity -> B
• Named Expressions -> Br->
• Vector -> Scalar? -> ScalarY Library -> Copy to Stack
• Input -> Function -> Phi • Input -> Function -> Phi
• Scalar -> Trig -> Sin • Scalar -> Trig -> Sin
• General -> * • General -> *
• General -> + • Scalar -> Vec? -> VecY
• General -> Smooth • General -> +
• Library -> Add… -> “Br” • Library -> Add… -> “Br_vec”

26 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Post-Processing

Topic
• Graph the radial flux density in the gap

Radial Flux Density in Air Gap Over One Pole ANSOFT

0.88

0.67

Br [ T ]
0.47

0.27

0.07

-0.13
0.00 10.00 20.00 30.00 40.00 50.00 60.00
Distance [mm]

27 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Post-Processing

Steps
• Draw-> Arc -> 3 point Arc 1
• Create Fields Report
• Select the arc and Br

Radial Flux Density in Air Gap Over One Pole ANSOFT

0.88

0.67
Br [ T ]

0.47 3
0.27

0.07

-0.13
0.00 10.00 20.00 30.00 40.00 50.00 60.00
Distance [mm]
28 © 2011 ANSYS, Inc. September 8, 2011
 Maxwell Post-Processing

Take Spatial FFT 1

Steps:
1• Right click Setup1 and select Perform FFT on
Report
2• Select the flux density plot and select
magnitude for the spectral plot.

FFT Radial Flux Density in Air Gap Over One Pole

0.50
ANSOFT

2
0.40

0.30
FFT Br

0.20

0.10

0.00
0.00 100.00 200.00 300.00 400.00 500.00
FFT Distance Harmonic

29 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Post-Processing

Topic
• Display magnet operating point on BH curve

BH Operating Point in Iron and Air ANSOFT

1.40

1.20

1.00
Curve Info
Imported BH
Imported
0.80
B[T]

Operating Point Iron

Setup1 : LastAdaptive

0.60

0.40

0.20

0.00
-60.00 -40.00 -20.00 0.00 20.00 40.00
H [A / m] [kA_per_m]

30 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Post-Processing

Steps 1
1• Export BH curve for Alnico5
2• Add header to BH text file
3• Solve design in iron or air fixture

3
2

31 © 2011 ANSYS, Inc. September 8, 2011

 Maxwell Post-Processing
4
Steps
4• Use calculator to define Hx and Bx
5• Draw a point to evaluate fields
6• Create fields report of Bx vs Hx at defined
point
7• Import BH curve into report
5
8• Paste results from other simulations

1.40
BH Operating Point in Iron and Air 7
ANSOFT

1.20
Curve Info
Imported BH
6
1.00 Imported
Operating Point Iron
0.80 Setup1 : LastAdaptive
B[T]

Operating Point Air

Imported
0.60

0.40

0.20

0.00
-60000.00
8
-40000.00 -20000.00 0.00 20000.00 40000.00
H [A / m]
32 © 2011 ANSYS, Inc. September 8, 2011
 Outline

Maxwell
– Geometry
– Transient
– Post-Processing
Simplorer
– Transient Solver
– Post-Processing
– Advanced Analysis

33 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Highlights

34 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Transient Solver

Topic: Enable on sheet live update for plots

• Tools > Options > Simplorer Options > General Options

35 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Post-Processing

Topic: Create numerical display

• Add display to schematic for instant numeric display of circuit gain

TR_Probe1
Vcc
50kOhm EMF=12V 100kOhm RC
EQU RB1a RB2a RC2 TR
Probe
gain:=TR_Probe1.PKPK /(E1.AMPL *2)
0 Vc2
CC1
SPICE_NPN1 + VM1
Vb1
CC2 V
1uF Vb2 SPICE_NPN2

1uF 0
Ve1 Ve2
E1
50kOhm
RB1b
AMPL=0.01V
FREQ=1000Hz
22kOhm 1kOhm
RE1 RB2b RE2
5kOhm 10uF
CE2

0 Curve Info pk2pk Curve Info pk2pk

0.90 0.90
E1.V Vc2.V
TR TR
E1.V [V]

Vc2.V

0.50 0.50

0.10 0.10
0.10 0.30 0.50 0.70 0.90 0.10 0.35 0.60 0.85
Time [ns] Time [ns]

37 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Post-Processing

Steps
1• Create a data table
2• Pare To: Time Max

38 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Post-Processing

Steps
3• Drag plot onto schematic

39 © 2011 ANSYS, Inc. September 8, 2011

 Outline

Maxwell
– Geometry
– Transient
– Post-Processing
Simplorer
– Transient Solver
– Post-Processing
– Advanced Analysis

40 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Topic: Statistical Analysis

• Vary component parameters to measure manufacturing variation on performance

TR_Probe1
Vcc
50kOhm EMF=12V 100kOhm RC
EQU RB1a RB2a RC2 TR
Probe
gain:=TR_Probe1.PKPK /(E1.AMPL *2)
0 Vc2
CC1
SPICE_NPN1 + VM1
Vb1
CC2 V
1uF Vb2 SPICE_NPN2

1uF 0
Ve1 Ve2
E1
50kOhm
RB1b
AMPL=0.01V
FREQ=1000Hz
22kOhm 1kOhm
RE1 RB2b RE2
5kOhm 10uF
CE2

0 Curve Info pk2pk Curve Info pk2pk

0.90 0.90
E1.V Vc2.V
TR TR
E1.V [V]

Vc2.V

0.50 0.50

0.10 0.10
0.10 0.30 0.50 0.70 0.90 0.10 0.35 0.60 0.85
Time [ns] Time [ns]

41 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Steps
1• Select properties for each resistor.
2• Select distribution for each resistor.
1

42 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Steps
3• Add statistical analysis
4• Define Monte Carlo iterations
5• Define measured output

43 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Steps
6• Execute statistical analysis
7• View analysis results

44 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Topic: Import complex load waveforms from empirical data

• Reduce a complex sub-system to data from measurements.

45 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Steps
1• Import text file as a dataset
2• Use datapairs block for dataset interpolation
3• Select the dataset in (1)
2

1
3

46 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Steps
• Plot interpolated source and output.

47 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Topic: Digitize datasheet information using the sheetscan tool.

• An automated approach to digitizing measured data for use in simulation.

48 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Steps
1• In datasets window select sheetscan source
2• Picture -> Load Picture

1
2

49 © 2011 ANSYS, Inc. September 8, 2011

 Simplorer Advanced Analysis

Steps 3

• Coordinate System -> New, Click to

3
locate coordinate axes
•
4 Curve -> New, click to locate
datapoints
•
5 File -> Export, to export text file
4

50 © 2011 ANSYS, Inc. September 8, 2011

 Workbench Coupling

Topic: Coupling Designs in Workbench

• Link the geometry and transfer heat dissipation from magnetics to thermal.

51 © 2011 ANSYS, Inc. September 8, 2011

 Workbench Coupling

Steps
1• Drag Geometry, Maxwell3D, and Steady State thermal
blocks onto the schematic
2• Link Geometries and solutions by drag and dropping.

52 © 2011 ANSYS, Inc. September 8, 2011

 Workbench Coupling
1
1• Create your geometry
2• Setup and solve Maxwell
3• Setup and solve Thermal.
4– Coupling meshes is automatic, select which
geometries to include.

2 3

53 © 2011 ANSYS, Inc. September 8, 2011

 Questions?

54 © 2011 ANSYS, Inc. September 8, 2011