Flux & FluxMotor New Features 12.2

New Features
Flux 12.2 & FluxMotor

Flux Conference 2016, Barcelona, Spain
Simon Guicheteau – Application Engineer - EM Solutions

Patrick Lombard – Lead Application Specialist - EM Solutions
Fabrice Marion – Program Manager FluxMotor
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Flux 12.2 New Features

• 3D Modeler Enhancements
• Great tool for Electric Field Analysis

• Streamer criterion
• Transient Electric application
• More efficient and fast solving

• Partial storage
• Improving solving speed
• FluxMotor
2
Flux 12.2
3D Modeler enhancements
3D Modeler Enhancements
• Main target
• Robustness & speed to create and manipulate complex 3D geometries
• New simplification tools
• New features for easier geometry creation in Flux
5
Import and Simplification

New Import and Simplification Tools

• Facilitated 3D CAD import
• Interference detection and correction
• No assembly when collision, the user can then make
• Union
• Assembly and simplification of small volumes
• Translation of the object
• More tools to simplify and repair faces

• To allow cleaning more configurations (fillet, holes, slot …)
• A new function “Repair Face” (equivalent to a cover wire)
7

• During the import, possibility to separate solids
2 different objects
• Improvement in the meshing of tangencies

• Limit the insertion of nodes in theses zones
8
• Keep the colors contained in the CAD files during the import
• Allows identifying easier different parts of the geometry
• Enable fast physics definition
• Improvement of the “Separate volume” functionality

• Allows separating only one volume
• Fast and robust “Complete Infinite Box” command
9
3D Example of Complex Geometry - Demo

• Import CAD geometry with colors
• Detect interferences and collisions
• Simplify details, shapes, details, writings
• Export to 2D
10
New Features for Easier Geometry Creation

• Improvement of 3D geometry construction starting from a 2D Flux project inside a sketch
• Add an export function in 3D Modeler to export a 2D CAD file of a cut plane
• Extrusion along any path

• Useful to build complex meshed windings
11
New Possibilities for Extrusion of Faces

New Possibilities for Extrusion of Faces

Extrusion along a path defined by points
Extrusion along a parameterized path
13
Extrusion along a Path Defined by Points

Open Excel (or any other text editor)
Select an area
Paste it directly in Flux
14
Extrusion along a Parameterized Path

Example to build meshed coils with parametric number of turns
N_TURN=15 N_TURN=10 N_TURN=5
15
Extrusion along a Parameterized Path
16
Other Examples of Extrusions

• Wounded torus • Elliptic conductor
17
Streamer Criterion
Streamer Criterion: Benefits
Evaluate breakdown voltage

to improve the design of
electrical equipment
Reduce your oversizing of

electrical equipment to 10%
(usually 20% based on
internal expertise and
testing)
19
Streamer Criterion: Approach

The streamer criterion is already well-known as a
good design criterion (cf. references)
Our approach
• Implement an automated postprocessing tool of
the streamer criterion
W.S. Zaengl, K. Petcharaks, “Application of Streamer breakdown
criterion for inhomogeneous fields in dry air and SF6”,
• Allow user’s model to be defined easily to go further Swiss Federal Institute of Technology (Zürich), 1991
A. Pedersen, T. Christen, A. Blaszczyk, H. Boehme,

“Streamer inception and propagation models for designing air
insulated power devices”, Proceedings IEEE Conference on
electrical insulation and dielectric phenomena, 2009
20
Streamer Criterion: Results

• Save time doing experiments and testing
• Great ROI compared to manual methods
• Reduce costs and oversizing
• Go further and find you own user formula
Schneider Electric reduced its oversizing to 10%

using this criterion with their own formula
21
Breakdown Mechanism in Gas

• A breakdown can happen in a dielectric domain if a difference of
potential above the breakdown voltage is applied,
• Streamer discharge:
• Accelerated electrons strike air molecules
• They knock other electrons off them, ionizing them
• The freed electrons go on to strike more molecules in a chain reaction
• Engineering approach
• Using the electric field to estimate a criterion for streamer breakdown
• Available in 2D plane & axisymmetric and 3D Electro-Static
22
Streamer Criterion: Model

• Integration of f(E) along field lines
• K = ionization coefficient
• αeff = effective ionization
• The formula depends on module of E

• Air and SF6 standard models are available
• Get your own formula for your gas with online tool
• A threshold is defined for K when the streamer appears
23
Streamer Criterion: Model

• 2 modes for the integration
• Classical integration
• Stops when Ki is negative during the integration (E<2.6 kV/mm for the air)
• Other method
• Checks the possible breakdown on both sides and ignore terms where Ki is negative
Integration on the Orange Electrode 1 Electrode 2

region only for method 1 Electric field
Integration on
Orange and Green
separately for method 2
Electric field Integration area
corresponding to
K=0 Electrode gap
24
Streamer Criterion: Path Definition

• The path can follow E field lines or any quantity
• Specific Euler-Cauchy method to increase the accuracy of the direction
• Constant or adaptive step according to the mesh dimension
• You can create spatial paths using a Fieldline macro
• Global computation
• To find the streamer inception voltage value and the most critical starting point
• On a faces, lines, regions…
• Punctual computation
• To find voltage values instantaneously
• By graphical selection, existing points, or coordinates
• Can be along E field lines or along a specific user path
25
Streamer Criterion: Results

• Display
• All the lines with breakdown are displayed in black
• The first breakdown is in red and the visual entity
contains the information
• It is possible to obtain directly streamer inception
voltages values on other field lines (right click)
26
Streamer Criterion: Additional Results

• Creation of results
• Spatial path of the electric arc
• Mod(E) and α curves along the critical field line
• Result entity containing all the creation information and
results
27
How Does It Works ?

• Demo on a simple 3D insulator
• Global computation
• Punctual computation
• Using spatial path
• Results analysis
28
How Schneider Electric reduced oversizing to 10 %
François Gentils,
Dielectric Domain Leader
Schneider Electric (Varces, France)
Description of the Tests
Industrial use of the streamer compared to internal manual computations
Schneider Electric has an internal formula used with the tool to improve the design
and reduce oversizing
30
Line Paths Definition between Bars

Barre_barre
• Complex 3D geometry 100,500,1000,3000 points
• Straight paths between 2 phases
31
View of Surface Mesh

• Good mesh but not very thin
170 kV with Flux, straight path
174 kV with Flux, with auto-path

in streamer tool
32
Case 1: Global Computation

• Bar/bar field line
• Dielectric plastic barriers are used
but the E field <2.6kV/mm before the barrier
Criteria can be used for inception voltage estimation
But it is wrong for the breakdown voltage
Flux: 118 kV with Flux streamer tool 125kV with the path
obtained with field line macro
Difference due to small change of the path
33
Case 2: Global Computation Alt2
• Bar/Ground field line
Alt1
• Streamer inception voltage is applicable

(strong decrease from 5,4kV/mm to 1,6kV/mm in
air before barrier
• Estimated streamer inception voltage is 84,6 kV
34
Case 3: Punctual Computations

• Cable box with unshielded cables
str9
str8
Streamer inception voltage STR8 = 40,87 kV

Streamer inception voltage STR9 = 51,1 kV
(this part has to be used with a silicone sleeve around it to pass the performance)
35
Case 4: Example of Path Definition
With automatic path With path from the macro

Not realistic, Wrong path Correct path
Inception voltage > 200kV Inception voltage = 169 kV
36
How to improve
• Ideas for future versions

• Speed up global computations by selecting critical starting areas
• Automate some usual paths

• Straight lines perpendicular to the surface (can be enough to analyze first mm)
• Shortest distance between conductors
• Create a “Streamer inception voltage” sensor to allow parametric studies and

optimization
• Reduce computation time
37
Streamer Criterion: Conclusions

• Schneider’s benefit: good estimation of the streamer voltage and great ROI
Reduction of oversizing to 10%
• The streamer criterion depends on:

• Mesh of the starting zone for the first mm
• Path definition
• Formula which can be customized
• Not a perfect breakdown voltage evaluation !
• To be used as a powerful postprocessing tool to analyze gas breakdown probability
38
Electric Transient Application

An Increasing Need for Transient Phenomena Study
• New high voltage equipment

• FACTS, HVDC and other power converters can generate
fast transient and more stress on these devices
• More control and fast switching on the network
• Need to represent these phenomena

• Surges, spikes or lightning strikes
• Polarity reversals
• In 2D plane, 2D axi and 3D
40
• Provide the electric simulation with any transient input

• Possibility to simulate lightning strike, polarity reversal, etc.
• Industrial Applications
• HVDC devices (offshore cables for instance)
• Any electrical device with large variations in transient
• Benefits
• Improvement of Steady State AC Electric
• Using your own input voltage shape
• Detect sharp increase of E causing electric stress
• Take into account non linear materials
41
Electric Transient user’s case
Gérard Beranger,
Consulting Manager / DTD
General Cable (Montereau, France)

• Lighting test on cables junction
Cond
Cable
• Source: HV
• up to ~400kV in less than 1ms (line) εr=3
Ground
(line)
εr=2,5
43
Postprocessing
• Analyze electric field versus time
• Check E maximum values to ensure

dielectric strength in each material
44
Partial Storage
Partial Storage
Goal : to limit the size of Flux files on the disk
How:
do not store all information but only the relevant one
save in binary format
What are the relevant information?

All circuit physical quantities (V,I, …)
All mechanical data (torque, speed, …)
All I/O parameters
All sensors
When :
when defining the solving scenario
when post-processing and modifying the solving scenario (before saving again)
46
Partial Storage: Interface

Driven from the solving scenario
New tab
select the mode
47
Partial Storage: Short-Circuit Example

IPM motor
Run parametric analysis
position is one parameter (801 values)
speed is another parameter (12 values)
Circuit
Resistance is defined with formula

off at the beginning
on after a while
48
Partial Storage: Short-Circuit example

From 3D curve extract (with ExtractFrom3DCurve
macro)
Imax versus speed
Irms versus speed
Torque max versus speed
Size
Case
(in Mb)
Without partial storage 2700
With partial storage 144
49
Partial Storage: IM Motor

Goal : compute torque versus speed (in TM) for one speed
Long transient, only the ending part is relevant
Solve for 0,2s and store only from 0,1s to 0,2s
Current versus time
Case Size (in Mb)
Without partial storage 292,8
With partial storage 188,2
50
Partial Storage: IM Motor
51
Partial Storage: IM Example
52
Partial Storage IM Example

2 parameters
time (441 steps)
speed (12 values)
Case Size (in Mb)
Without partial 2770

storage
With partial storage 293
Note : partial storage can be applied after

post-processing to minimize size of Flux
project on disk
53
Improving Solving Speed

Improving Speed
Improvement with sliding cylinder in 3D
Improvement in default options (for 3D transient and non linear)
Example on a specific project Geometries

Application Flux 12.0 Flux 12.2
3D axial motor
2D Motor fed by
259 s 235 s
current voltage
3D actuator 39 s 32 s
3D radial motor 51,7 min 30,4 min
3D rear view mirror

73 s 28 s
motor
55
Miscellaneous
Autoadaptive Mesh
• Extension of existing feature in magnetostatic
• With periodicity
• With non meshed coils
• With mechanical set
• With airgap region
• Possibility to define options

• More (1) or less (0) error accepted
• Max number of iterations
• Possibility to exclude a region (no mesh refinement
on this region)
57
Step 1 © 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Starting
Autoadaptive Mesh
Step 2
Step 4
Step 3
58
Flux Coupled to OptiStruct for Vibro-acoustics Analysis

More info
during
workshop
Magnetic forces Displacements Noise
Magnetic Vibration Acoustic
59
New Management of Error Messages

• Goal :
• Better difference between warning (orange) and
error (red)
• FORTRAN part not appearing first
• Message is easier to understand
• New method has been implemented
• Will be applied to more type of error messages
• Possibility to directly see the different error

messages
60
Flux 12.2
And also …
Continue distributed computations
Faster computation of values on cutting planes
Optimization using HyperStudy coupled to Flux

(Beta version)
More info
during
workshop
61
Visiting FAQ and Macros

• Thank you for visiting our FAQ! (4039 visits last year)
• Top 5 on the last year
• 182 views : In 3D project with symmetry, how is managed the non meshed coils ?
• 141 views : Is it correct to use three current sources in star connections ?
• 130 views : Is the Bertotti model adapted to compute iron losses for the rotor permanent magnet machine and
synchronous reluctance machine ?
• 77 views : Why Flux 12.1 is giving a different result on iron losses computed with Bertotti method than in previous
version ?
• 75 views : How to create a PWM supply ?
• Thank you for visiting our latest macros (686 visits last year)
• Top 5 on the last year
• 47 views : RunEfficiencyMapWithBertotti
• 41 views : Turn_TM_2D_to_TM_Skewed
• 39 views : RunDemagnetization2D
• 28 views : RunEfficiencyMapWithLdLqData
• 23 views : RunDemagnetization3D
62
New Demo Cases

• 2D
• Synchronous motor
• DCM motor (4 poles)
• SRM high speed
• PWM on SPM motor
• Helmholtz coil
• 3D
• Thermal analysis on radial motor
• Skewed motor in 3D
• High speed motor with ring stator
• Helmholtz coil (with non meshed coil
• New documentation available explaining how to create each case
63
FluxMotor
A new approach to an effective and quick electric motor design
Fabrice Marion, FluxMotor Program Manager

Our Vision
To radically change the way

organizations design products
and make decisions
65
What is FluxMotor ?
FluxMotor to predesign motors
Specification Production
Prototyping
Pre-design Design
67
Address a broad range of users
Design
• Electric motor designer, Manufacturers, &
… users of FEM software Manufacture
• Integrators, OEM, …
Demonstrate Evaluate
• Sales staff, suppliers, training staff &
&
sell Integrate
68
Architecture & functions needed

Assembling Computing Results
REPORT
DESIGN TEST
Motor Factory
Catalog Part
Building Blocks
Materials
Manager Manager
Compare Part Source
& choose Factory Data
69
The Motor Factory to design & test

Designing electric motors

• A new machine project within minutes
• Build the machine step by step
• Never start from a blank page!
71
User-oriented winding tool

• 4 winding modes
• Automatic, Easy, Advanced and Expert
• Settings adapted to the task
• An automatic diagnostic is issued

• With quality criteria of the winding
• To adjust the winding parameters
• An automatic winding report

• Main information to build the winding
72
Building blocks available

A comprehensive and scalable material database
• A large selection of typical materials
• Users can manage their own materials
• Easy way to define B(H) curve

or iron losses parameters
74
Effective machines parts management
• Libraries are provided with standard parts
• A large number of slots or magnets available
• All the topologies are parameterized
• Customization of parts is possible
75
Results and analyses

Testing and evaluating electric motors
• Standard and relevant test portfolio available
• Predefined tests ready to be performed
• Relevant input parameters to control the test

conditions
• Processes based on optimization technology
• Results are automatically illustrated
77
Process of computation – Back-emf - principle
• A few measurement points of the coupling flux are

checked with FE
• A FFT allows to compute the useful harmonics
• The coupling flux versus angular position is rebuilt
• The back - emf versus time is then deduced
dΦ dΦ dθ dΦ
E= = × = Ω×
dt dθ dt dθ
78
Process of computation – DQ-axis coupling flux - principle
• Combinations values of Id and Iq are considered
• Characterisation of coupling flux – Maps (Id, Iq)
• Response surfaces are computed to prepare optimization
Te = m × p × (Φ d × I q − Φ q × I d )
79
The latest software technologies available today

• Kernel based on optimization enabled technology
• Powerful architecture “Java Light Co-Development”
• “Flux” as Finite Element solver inside!

• Topologies of machines are perfectly respected
• Saturation of materials are taken into account
• Analytical computations are also used!

• To get quick response when sufficient
• To give input parameters to Flux
• Analytical + FE computations
• Highest ratio between quick computations and
accuracy of results
80
Complementarity with FE Flux

• Easy flux project export
• To perform advanced studies like eccentricity, vibro-accoustic, thermal, drive and control,…
• At any time, the Flux model ready to be used

• Full parameterized
• All the physical properties embedded
• Ready to be solved in Flux Environment
Stand-alone software
Geometry Mesh Physics Solve Analysis
81
Powerful and easy project management
• To enhance project management
• To access quickly to past studies
• To manage full range of products
• For quick performances comparison
• An embedded comparator is available
82
Product highlights
• Dedicated to electric rotating motor pre-design
• Rapidity of design
• An user-oriented winding tool
• Automated tests and reports

• Fast without compromise on accuracy
• Open material database

• Effective machine parts management
• Slots & magnet shapes with possible customizations
• An innovative way to manage projects with catalogs
83
As a conclusion… Benefits
• High productivity gain
• A broad range of users
• Fulfill all the design tasks
• No compromise on accuracy
• Connection for advanced study
84
Next meeting with FluxMotor
Workshop
New Solution for Electric Motor Design
85
Conclusion
Conclusion
• Released end of November
• Go faster from the geometry to the results !

• Modeler enhancements
• Speed ups
• New electric challenges to be simulated

• Streamer criterion and electric transient
• Compatible with HyperWorks Units licensing system
• FluxMotor is coming ! (RC2 available soon)
87
Thank you for your Attention !

Flux &amp; FluxMotor New Features 12.2

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New Features

Flux 12.2 & FluxMotor

Simon Guicheteau – Application Engineer - EM Solutions

Flux 12.2 New Features

• Great tool for Electric Field Analysis

• More efficient and fast solving

• New simplification tools

• New features for easier geometry creation in Flux

Import and Simplification

New Import and Simplification Tools

• More tools to simplify and repair faces

New Import and Simplification Tools

• Improvement in the meshing of tangencies

New Import and Simplification Tools

• Improvement of the “Separate volume” functionality

• Fast and robust “Complete Infinite Box” command

3D Example of Complex Geometry - Demo

• Detect interferences and collisions

• Simplify details, shapes, details, writings

New Features for Easier Geometry Creation

• Add an export function in 3D Modeler to export a 2D CAD file of a cut plane

• Extrusion along any path

New Possibilities for Extrusion of Faces

New Possibilities for Extrusion of Faces

Extrusion along a Path Defined by Points

Extrusion along a Parameterized Path

N_TURN=15 N_TURN=10 N_TURN=5

Extrusion along a Parameterized Path

Other Examples of Extrusions

Streamer Criterion: Benefits

Evaluate breakdown voltage

Reduce your oversizing of

Streamer Criterion: Approach

A. Pedersen, T. Christen, A. Blaszczyk, H. Boehme,

Streamer Criterion: Results

• Reduce costs and oversizing

• Go further and find you own user formula

Schneider Electric reduced its oversizing to 10%

Breakdown Mechanism in Gas

Streamer Criterion: Model

• The formula depends on module of E

• A threshold is defined for K when the streamer appears

Streamer Criterion: Model

Integration on the Orange Electrode 1 Electrode 2

Streamer Criterion: Path Definition

Streamer Criterion: Results

Streamer Criterion: Additional Results

How Does It Works ?

How Schneider Electric reduced oversizing to 10 %

Description of the Tests

Industrial use of the streamer compared to internal manual computations

Line Paths Definition between Bars

• Straight paths between 2 phases

View of Surface Mesh

170 kV with Flux, straight path

174 kV with Flux, with auto-path

Case 1: Global Computation

Case 2: Global Computation Alt2

• Bar/Ground field line

• Streamer inception voltage is applicable

• Estimated streamer inception voltage is 84,6 kV

Case 3: Punctual Computations

Streamer inception voltage STR8 = 40,87 kV

Case 4: Example of Path Definition

Flux & FluxMotor New Features 12.2

Flux & FluxMotor New Features 12.2