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MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
2020-06-16 – Tomasz Kądziołka, Marek Ryłko, Marcin Kącki
FEA IN MAGNETIC COMPONENTS MODELING
SMA Magnetics Sp. z o.o/ MESco Sp. z o.o.
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
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Introduction
Magnetic component modeling
FEA vs. Experimental - Impedance & Inductance
FEA vs. Experimental - Flux propagation
Conclusion and future workConclusion and future workConclusion
Content
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MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Introduction
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Simulation – why invest ?
…to turn your design concepts into successful, innovative products faster and at lower cost!
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Introduction
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Classical design approach supported
by a virtual prototype
Simulation-Driven Product Development
*M. Kącki, M.S. Ryłko, J.G Hayes, C.R. Sullivan, E. Herbert, “Magnetic core dimensional effects - flux propagation in ferrites,” PSMA Workshop during IEEE Applied Power Electronics Conference, 2018
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Ansys simulation platform
ANSYS
Enterprise
Simplorer
HFSS
SIwave
Q3D
Icepak
Maxwell
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MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Right tool for the purpose
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High or Low FrequencyPower or Signal
> transmit or convert power - power
→ ANSYS Maxwell
> transmit information - signal
→ HFSS
ANSYS
Simplorer
HFSS
Q3D
SIwave
Icepak
Maxwell
HFSS: full-waveMaxwell:Quasi-static
ANSYS
ENTERPRISE
Simplorer
HFSS
Q3D
SIwave
Icepak
Maxwell
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Magnetic component modeling
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Equations Extended to Each SolverJames Clerk Maxwell
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Solve
Magnetic component modeling
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Create/import geometry
Assign MaterialsAssign Boundary
ConditionsDefine
ExcitationsSetup the Solution
Post Processing
Simulation Process Flow
DRAW IN ANSYS
CAD
IMPORTED FROM CAD
SPACECLAIM
Mesh
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Solve
Magnetic component modeling
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Create/import geometry
Assign MaterialsAssign Boundary
ConditionsDefine
ExcitationsSetup the Solution
Post Processing
Simulation Process Flow
> Pre-defined material library available in Maxwell
> User can customise material database
> Solvers support number of material models
Mesh
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Solve
Magnetic component modeling
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Create/import geometry
Assign MaterialsAssign Boundary
ConditionsDefine
ExcitationsSetup the Solution
Post Processing
Simulation Process Flow
> PSMA-SMA special projects show importance of magnetic material data quality for core modeling
> Material’s permeability, permittivity and conductivity drives magnetic flux distribution in the core
> Detailed knowledge on magnetic material conductivity and permittivity frequency characteristic is fundamental for prediction of magnetic flux distribution in ferrite cores
Mesh
*M. Kącki, M.S. Ryłko, J.G Hayes, C.R. Sullivan, E. Herbert, “Magnetic core dimensional effects - flux propagation in ferrites,” PSMA Workshop during IEEE Applied Power Electronics Conference, 2019
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Solve
Magnetic component modeling
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Create/import geometry
Assign MaterialsAssign Boundary
ConditionsDefine
ExcitationsSetup the Solution
Post Processing
Simulation Process Flow
> Boundary conditions are linked with solver type
> Improve your modeling by selection of boundary conditions to model part of a structure to reduce complexity and computation time
InsulationVector
PotentialBaloon
Odd / EvenMaster/Slave Symmetry
Tangential HZero
Tangential H… and more
½ Model
Mesh
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Solve
Magnetic component modeling
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Create/import geometry
Assign MaterialsAssign Boundary
ConditionsDefine
ExcitationsSetup the Solution
Post Processing
Simulation Process Flow
> Each field solver requires to specify excitations of electric or magnetic fields and references forcomputing these fields
The eddy current solver allows to define the following sources of AC magnetic fields
Volatge /Current winding
Maxwell circuitSimplorer
Current/Current density
Mesh
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Solve
Measured
Magnetic component modeling
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Create/import geometry
Assign MaterialsAssign Boundary
ConditionsDefine
ExcitationsSetup the Solution
Post Processing
Simulation Process Flow
> In Maxwell’s Static Solvers, the mesh is automatically optimized to achieve required level of accuracy
Adaptive Mesh Refinement
> Maxwell offers wide range of operations on mesh that refines model for required accuracy
Calculate localSolution error
Generate InitialMesh
Solve fields using theFinite Element Method
End criteria reached ?
Refine Mesh
Calculate Outputs (Force, Inductance, etc.)
no
yes
Start
Maxwell Solution Flow Chart
Initial Mesh AdaptivelyRefined Mesh
Mesh
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Solve
Magnetic component modeling
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Create/import geometry
Assign MaterialsAssign Boundary
ConditionsDefine
ExcitationsSetup the Solution
Post Processing
Simulation Process Flow
> Skin Depth Based meshing is optimized to resolveinduced eddy current near the surface of theconductors/semiconductors
> Eddy current in ferrites are characterized by the skin effect that results in a non-uniform flux distribution in the core cross-section
Frequency = 50 Hz Frequency = 1 MHz
Mesh
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Solve
Magnetic component modeling
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Create/import geometry
Assign MaterialsAssign Boundary
ConditionsDefine
ExcitationsSetup the Solution
Post Processing
Simulation Process Flow
ANSYS Maxwell allows for flexible data management and plotting capabilities.
Mesh
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
FEA vs. Experimental - Impedance & Inductance
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Post ProcessingExperimental
validation
Simulation Process Flow
> In the first step three phase CMC was simulated, built and experimentality tested. Basic parameters as inductance, impedance and capacitance are compared between simulation and prototype
> Simulation was performer based on ferrite material manufacturers specification and material characteristic obtained from PSMA-SMA special project
*M. Kącki, M.S. Ryłko, E. Herbert, “PSMA-SMA special project phase II – investigation on magnetic flux
propagation in ferrite cores,” PSMA, 2020
vs.
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
FEA vs. Experimental - Impedance & Inductance
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Post ProcessingExperimental
validation
Simulation Process Flow
Test inductor specification
Parameter Unit
Material - 3E10 Mn-Zn
Dimensions OD x ID x H
mm 50 x 30 x 16.5
Core total cross section
mm² 165
Core volume cm³ 20.7
Number of turns - 5/phase
Inductance frequency characteristic
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100
200
300
400
500
600
700
800
0.01 0.1 1
Induct
ance
(µ
H)
Frequency f (MHz)
Prototype FEA - Mnf. data FEA - PSMA data
L @ 50kHz L @500kHz
Prototype 656 µH 42 µH
Mnf. data 628 µH 342 µH
PSMA data 639 µH 85 µH
Δ Mnf. Data 4.2 % 814 %
Δ PSMA data 2.6 % 202 %
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
FEA vs. Experimental - Impedance & Inductance
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Post ProcessingExperimental
validation
Simulation Process Flow
Prototype FEA Simulation
Winding capacitance
5.2 (pF) 7.4 (pF)
Impedance frequency characteristic
0
200
400
600
800
1 000
1 200
1 400
1 600
1 800
0.01 0.1 1
Imped
ance
(Ω
)
Frequency f (MHz)
Prototype FEA - Mnf. data FEA - PSMA data
Z @ 50kHz Z @500kHz
Prototype 187 Ω 1075 Ω
Mnf. data 193 Ω 1417 Ω
PSMA data 192 Ω 999 Ω
Δ Mnf. Data 3.2 % 32 %
Δ PSMA data 2.6 % 7 %
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
FEA vs. Experimental - Flux propagation
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Post ProcessingExperimental
validation
Simulation Process Flow
In the next step flux distribution measurement are contrasted with simulation.
The flux density ratio frequency characteristics are normalised by main flux density for each frequency
Magnetic flux density ratio(𝑓) =𝐵𝐴(𝑓)
𝐵𝐸(𝑓)
where:
BA(f ) –flux density in section A
BE(f )– flux density in the entire area of the core
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
0 200 400 600 800 1000 1200 1400 1600
Mag
net
ic f
lux
den
sity
rat
io
Frequency (kHz)Section A Section B
*M. Kącki, M.S. Ryłko, J.G Hayes, C.R. Sullivan, E. Herbert, “Magnetic core dimensional effects - flux propagation in ferrites,” PSMA Workshop during IEEE Applied Power Electronics Conference, 2018
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
FEA vs. Experimental - Flux propagation
20
Post ProcessingExperimental
validation
Simulation Process Flow
f = 500 kHzf = 500 kHz
Flux distribution based on FEA simulation, material characteristic form ferrite manufacturers datasheet
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
0 200 400 600 800 1000 1200 1400 1600
Mag
net
ic f
lux
den
sity
rat
io
Frequency (kHz)Section A Section B Section A - FEA Section B - FEA
*M. Kącki, M.S. Ryłko, J.G Hayes, C.R. Sullivan, E. Herbert, “Magnetic core dimensional effects - flux propagation in ferrites,” PSMA Workshop during IEEE Applied Power Electronics Conference, 2018
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
FEA vs. Experimental - Flux propagation
21
Post ProcessingExperimental
validation
Simulation Process Flow
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
0 200 400 600 800 1000 1200 1400 1600
Mag
net
ic f
lux
den
sity
rat
io
Frequency (kHz)Section A Section B Section A - FEA Section B - FEA
f = 500 kHzf = 500 kHz
Flux distribution based on FEA simulation,material characteristic from PSMA-SMA special project
*M. Kącki, M.S. Ryłko, J.G Hayes, C.R. Sullivan, E. Herbert, “Magnetic core dimensional effects - flux propagation in ferrites,” PSMA Workshop during IEEE Applied Power Electronics Conference, 2018
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
Summary
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> Ansys software with its specialized packages allows for solving multi physical problems
> Number of dedicated solutions addresses individual areas of the interest
> Use of Ansys is simplified and intuitive, the interfaces are improved and user friendly
> The use of the FEA solvers and its interfacing is not a barrier for practicing engineers
> FEA solvers results quality depends on the input data quality
> FEA solvers aid design process and visualize component operation allowing for advance prediction of
potential design failures
MESCOPSMA Workshop 16.06.2020T. Kądziołka, M. Rylko, M. Kacki
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