Models - Acdc.rotating Machinery 3d Tutorial
Models - Acdc.rotating Machinery 3d Tutorial
This model is licensed under the COMSOL Software License Agreement 6.3.
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Introduction
This application serves as a general introduction to the Rotating Machinery, Magnetic
interface in 3D. The circular motion of a cylindrical copper rotor near a stationary
permanent magnet generates induced eddy currents in the rotor. The rotor has an axial cut
representing an optional lamination. Figure 1 shows the geometry with the rotor and
stator.
Figure 1: Drawing showing how thde rotor and stator with the permanent magnet are
defined.
Model Definition
This COMSOL Multiphysics application 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. For the solid (nonlaminated) rotor the
conducting part is modeled using Ampère’s law:
A
------- + --- A = 0
1
t
The nonconducting parts of both the rotor and stator are modeled using a magnetic flux
conservation equation for the scalar magnetic potential:
– 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 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 terminology, 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 nonconforming
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 Ampère’s law for the magnetic vector potential, current
conservation is an implicit requirement that is violated if the identity boundary pair would
involve interpolation of the magnetic vector potential. The resulting interpolation errors
unconditionally make such a model numerically unstable. Thus, special care has to be
exercised when setting up the geometry using assemblies in an application like this.
Modeling Instructions
From the File menu, choose New.
NEW
In the New window, click Model Wizard.
MODEL WIZARD
1 In the Model Wizard window, click 3D.
2 In the Select Physics tree, select AC/DC > Electromagnetics and Mechanics >
Rotating Machinery, Magnetic (rmm).
3 Click Add.
4 Click Study.
Add a stationary study to compute initial conditions. The time-dependent study will be
added later before solving.
5 In the Select Study tree, select General Studies > Stationary.
6 Click Done.
GEOMETRY 1
The geometry must be segmented in at least two parts, the stator and the rotor, to allow
relative rotation. The geometry sequence for this tutorial can be imported from a separate
mph file.
1 In the Geometry toolbar, click Insert Sequence and choose Insert Sequence.
2 Browse to the model’s Application Libraries folder and double-click the file
rotating_machinery_3d_tutorial_geom_sequence.mph.
DEFINITIONS
Parameters 1
1 In the Model Builder window, under Global Definitions click Parameters 1.
2 In the Settings window for Parameters, locate the Parameters section.
3 In the table, enter the following settings:
ADD MATERIAL
1 In the Materials toolbar, click Add Material to open the Add Material window.
2 Go to the Add Material window.
3 In the tree, select Built-in > Air.
4 Click the Add to Component button in the window toolbar.
5 In the tree, select AC/DC > Copper.
6 Right-click and choose Add to Component 1 (comp1).
7 In the tree, select AC/DC > Hard Magnetic Materials >
Sintered NdFeB Grades (Chinese Standard) > N35 (Sintered NdFeB).
8 Right-click and choose Add to Component 1 (comp1).
9 In the Materials toolbar, click Add Material to close the Add Material window.
MATERIALS
Copper (mat2)
1 Select Domains 4 and 5 only.
2 In the Settings window for Material, locate the Geometric Entity Selection section.
3 Click Create Selection.
4 In the Create Selection dialog, type Rotating disk in the Selection name text field.
5 Click OK.
Nonconducting Magnet 1
1 In the Physics toolbar, click Domains and choose Nonconducting Magnet.
2 Select Domain 2 only.
North 1
1 In the Model Builder window, click North 1.
2 Select Boundary 10 only.
South 1
1 In the Model Builder window, click South 1.
2 Select Boundary 5 only.
COMPONENT 1 (COMP1)
Rotating Domain 1
1 In the Physics toolbar, click Moving Mesh and choose Rotating Domain.
2 Select Domains 3–5 only.
3 In the Settings window for Rotating Domain, locate the Rotation section.
4 From the Rotation type list, choose Specified rotational velocity.
5 In the text field, type omega.
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. Pairs
with moving (nonconforming) mesh are allowed only between Magnetic Flux Conservation
domains.
Continuity 1a
1 In the Physics toolbar, click Pairs and choose Continuity.
2 In the Settings window for Continuity, locate the Pair Selection section.
3 Click Add.
4 In the Add dialog, select Identity Boundary Pair 1 (ap1) in the Pairs list.
5 Click OK.
The scalar potential also needs a point constraint, which is readily available as a standard
point feature.
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 boundary layer mesh for the copper domain to better
resolve the expected velocity skin effect.
Size 1
1 Right-click Free Triangular 1 and choose Size.
2 In the Settings window for Size, locate the Element Size section.
3 Click the Custom button.
4 Locate the Element Size Parameters section.
5 Select the Maximum element size checkbox. In the associated text field, type 2e-3.
Free Triangular 2
1 In the Mesh toolbar, click More Generators and choose Free Triangular.
2 In the Settings window for Free Triangular, locate the Boundary Selection section.
3 From the Selection list, choose dst.
Size 1
1 Right-click Free Triangular 2 and choose Size.
2 In the Settings window for Size, locate the Element Size section.
3 Click the Custom button.
4 Locate the Element Size Parameters section.
5 Select the Maximum element size checkbox. In the associated text field, type 7e-4.
Free Tetrahedral 1
In the Mesh toolbar, click Free Tetrahedral.
Size 1
1 Right-click Free Tetrahedral 1 and choose Size.
2 In the Settings window for Size, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Boundary.
4 Select Boundaries 5–10, 21–27, and 29–32 only.
5 Locate the Element Size section. Click the Custom button.
6 Locate the Element Size Parameters section.
7 Select the Maximum element size checkbox. In the associated text field, type 7e-4.
Boundary Layers 1
1 In the Mesh toolbar, click Boundary Layers.
2 In the Settings window for Boundary Layers, locate the Geometric Entity Selection
section.
3 From the Geometric entity level list, choose Domain.
4 From the Selection list, choose Rotating disk.
Free Tetrahedral 2
1 In the Mesh toolbar, click Free Tetrahedral.
Configure the first study to simulate half a revolution with a sufficient number of time
steps to resolve losses from induced currents.
RESULTS
DEFINITIONS
View 1
1 In the Model Builder window, under Component 1 (comp1) > Definitions click View 1.
2 In the Settings window for View, locate the View section.
3 Clear the Show grid checkbox.
RESULTS
Surface 1
1 In the Model Builder window, right-click
Currents and Solid Domain Boundaries Representation and choose Surface.
2 In the Settings window for Surface, locate the Expression section.
3 In the Expression text field, type 1.
4 Locate the Coloring and Style section. From the Coloring list, choose Uniform.
5 From the Color list, choose Gray.
Selection 1
1 Right-click Surface 1 and choose Selection.
2 Select Boundaries 5–10, 23, and 29–32 only.
Arrow Volume 1
1 In the Model Builder window, right-click
Currents and Solid Domain Boundaries Representation and choose Arrow Volume.
2 In the Settings window for Arrow Volume, click Replace Expression in the upper-right
corner of the Expression section. From the menu, choose Component 1 (comp1) >
Rotating Machinery, Magnetic > Currents and charge > rmm.Jx,...,rmm.Jz -
Current density (spatial frame).
Selection 1
1 Right-click Arrow Volume 1 and choose Selection.
2 In the Settings window for Selection, locate the Selection section.
3 From the Selection list, choose Rotating disk.
Color Expression 1
1 In the Model Builder window, right-click Arrow Volume 1 and choose Color Expression.
2 In the Settings window for Color Expression, locate the Expression section.
3 In the Expression text field, type rmm.normJ.
4 In the Currents and Solid Domain Boundaries Representation toolbar, click Plot.
5 Click the Zoom Extents button in the Graphics toolbar.
TABLE 1
1 Go to the Table 1 window.
Plot the tabulated dissipated power for the bulk copper disc.
2 Click the Table Graph button in the window toolbar.
ADD PHYSICS
1 In the Home toolbar, click Add Physics to open the Add Physics window.
2 Go to the Add Physics window.
3 In the tree, select AC/DC > Electric Fields and Currents > Electric Currents (ec).
4 Click the Add to Component 1 button in the window toolbar.
5 In the Home toolbar, click Add Physics to close the Add Physics window.
rmm.Jix x
rmm.Jiy y
rmm.Jiz z
Electric Insulation 2
1 In the Physics toolbar, click Boundaries and choose Electric Insulation.
2 Select Boundary 26 only.
In the absence of external boundary conditions on the electric potential, its level has to be
fixed by point conditions on both sides of the internal electrically insulating boundary.
Electric Potential 1
1 In the Physics toolbar, click Points and choose Electric Potential.
2 Select Points 27 and 29 only.
ec.Jx-rmm.Jix x
ec.Jy-rmm.Jiy y
ec.Jz-rmm.Jiz z
Set up a second study for the solution with the insulating layer in the copper disk.
ADD STUDY
1 In the Home toolbar, click Add Study to open the Add Study window.
2 Go to the Add Study window.
3 Find the Studies subsection. In the Select Study tree, select General Studies > Stationary.
4 Click the Add Study button in the window toolbar.
5 In the Home toolbar, click Add Study to close the Add Study window.
Step 1: Stationary
1 In the Model Builder window, under Solid Copper Disk click Step 1: Stationary.
2 In the Settings window for Stationary, locate the Physics and Variables Selection section.
3 Select the Modify model configuration for study step checkbox.
4 In the tree, select Component 1 (comp1) > Rotating Machinery, Magnetic (rmm),
Controls spatial frame > External Current Density 1.
5 Right-click and choose Disable.
RESULTS
Add a plot representing the z-component of the current which is zero on the insulating
gap. It should reproduce figure below.
Volume 1
1 Right-click Current Perpendicular to the Insulating Plane and choose Volume.
2 In the Settings window for Volume, locate the Expression section.
3 In the Expression text field, type rmm.Jz.
4 In the Unit field, type A/mm^2.
8 Click Plot.
Verify that for the nonlaminated case, the z-component of the current is high on the
midplane as shown in the plot below.
Add a new column to the previously generated table and update the corresponding plot
with the losses for the laminated disk. The latter case, features decreased losses as expected.
Volume Integration 2
1 In the Model Builder window, under Results > Derived Values right-click
Volume Integration 1 and choose Duplicate.
2 In the Settings window for Volume Integration, locate the Data section.
3 From the Dataset list, choose Laminated Copper Disk/Solution 3 (sol3).
4 Click next to Evaluate, then choose Table 1 - Volume Integration 1.
Table Graph 1
1 In the Model Builder window, under Results > 1D Plot Group 3 click Table Graph 1.
2 In the Settings window for Table Graph, click to expand the Legends section.
3 Select the Show legends checkbox.
4 From the Legends list, choose Manual.
5 In the table, enter the following settings:
Legends
Solid copper disk
Laminated copper disk
6 Locate the Legend section. From the Position list, choose Lower right.
7 In the Losses in the Copper Disk toolbar, click Plot.
For the final analysis, add a Passive Conductor feature in order to compare with manual
A+V coupling. The default setting for constraining of induced currents, Within each
domain, imposes an electrically insulating boundary on all internal as well as external
boundaries of the selected domains.
Passive Conductor 1
1 In the Physics toolbar, click Domains and choose Passive Conductor.
2 In the Settings window for Passive Conductor, locate the Domain Selection section.
3 From the Selection list, choose Rotating disk.
The following steps ensure that the already added studies do not include the Passive
Conductor feature if re-solved.
Step 1: Stationary
1 In the Model Builder window, under Solid Copper Disk click Step 1: Stationary.
2 In the Settings window for Stationary, locate the Physics and Variables Selection section.
3 In the tree, select Component 1 (comp1) > Rotating Machinery, Magnetic (rmm),
Controls spatial frame > Passive Conductor 1.
4 Click Disable.
Step 1: Stationary
1 In the Model Builder window, under Laminated Copper Disk click Step 1: Stationary.
2 In the Settings window for Stationary, locate the Physics and Variables Selection section.
3 Select the Modify model configuration for study step checkbox.
4 In the tree, select Component 1 (comp1) > Rotating Machinery, Magnetic (rmm),
Controls spatial frame > Passive Conductor 1.
5 Click Disable.
Add a study for analysis with Passive Conductor feature and configure according to
previous studies.
ADD STUDY
1 In the Home toolbar, click Add Study to open the Add Study window.
2 Go to the Add Study window.
3 Find the Studies subsection. In the Select Study tree, select General Studies > Stationary.
4 Click the Add Study button in the window toolbar.
5 In the Home toolbar, click Add Study to close the Add Study window.
STUDY 3
Step 1: Stationary
1 In the Settings window for Stationary, locate the Physics and Variables Selection section.
Finalize the addition of the plot and verify that it is similar to the one below.
RESULTS
Volume Integration 3
1 In the Model Builder window, under Results > Derived Values right-click
Volume Integration 2 and choose Duplicate.
2 In the Settings window for Volume Integration, locate the Data section.
3 From the Dataset list, choose Laminated Copper Disk with Passive Conductor/
Solution 5 (sol5).
4 Click Evaluate.
Legends
Solid copper disk
Laminated copper disk
Laminated copper disk with Passive Conductor