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June 2005
The information contained in this document is subject to change without notice. Ansoft makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Ansoft shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. 2005 Ansoft Corporation. All rights reserved. Ansoft Corporation 225 West Station Square Suite 200 Pittsburgh, PA 15219 USA Phone: 412-261-3200 Fax: 412-471-9427 Maxwell and Optimetrics are registered trademarks or trademarks of Ansoft Corporation. All other trademarks are the property of their respective owners. New editions of this manual will incorporate all material updated since the previous edition. The manual printing date, which indicates the manuals current edition, changes when a new edition is printed. Minor corrections and updates that are incorporated at reprint do not cause the date to change. Update packages may be issued between editions and contain additional and/or replacement pages to be merged into the manual by the user. Pages that are rearranged due to changes on a previous page are not considered to be revised. Edition 1 D a te June 2005 S o f t w ar e Ve r s io n Maxwell 11
Alternate methods or tips are listed in the left margin in blue italic text.
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Getting Help
Ansoft Technical Support
To contact Ansoft technical support staff in your geographical area, please log on to the Ansoft corporate website, http://www.ansoft.com, click the Contact button, and then click Support. You will find phone numbers and e-mail addresses for the technical support staff. Your Ansoft account manager may also be contacted in order to obtain this information. All Ansoft software files are ASCII text and can be sent conveniently by email. When reporting difficulties, it is extremely helpful to include specific information about what steps were taken or what stages the simulation reached. This allows more rapid and effective debugging.
Context-Sensitive Help
To access online help from the Maxwell user interface, do one of the following: To open a help topic about a specific Maxwell menu command, press Shift+F1, and then click the command or toolbar icon. To open a help topic about a specific Maxwell dialog box, open the dialog box, and then press F1.
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Table of Contents
1. Introduction
Setting Up Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 About the Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Create the Coil Terminals . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Create the Background (Region) . . . . . . . . . . . . . . . . . . . . 3-9 Finalize the Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Define the Nonlinear Material for the Two Armatures . . . 4-2 Assign Material Properties . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Post Process the Transient Results . . . . . . . . . . . . . . . . . 6-4 Close the Project and Exit Maxwell . . . . . . . . . . . . . . . . . . 6-8
Contents-2
Introduction
Maxwell 3D is an interactive software package that uses finite element analysis (FEA) to simulate (solve) electromagnetic field problems. Maxwell integrates with other Ansoft software packages to perform complex tasks while remaining simple to use. The following types of solutions are supported by Maxwell 3D: Electric 3D fields, which can be one of the following two categories: Electrostatic 3D fields caused by user-specified distribution of voltages and charges; additional computed quantities include torque, force, capacitances as indicated by the user. Electric 3D fields in conductors characterized by a spatial distribution of voltage, electric field and current density; additional quantity in this case is power loss. Magnetostatic linear and non-linear 3D fields caused by user-specified distribution of DC current density, permanent or externally applied magnetic fields; additional computed quantities include torque, force, inductances (self and mutual) as indicated by the user; Harmonic (sinusoidal variation in time) steady state magnetic fields with pulsation-induced eddy currents in massive (solid) conductors caused by a user specified distribution of AC currents (all with same frequency but with possibly different initial phase angles) or by externally applied magnetic fields; this is a full wave solution and includes electromagnetic wave radiation;
Introduction
1-1
See the online help about the specific parameter you want to vary to determine if it can be assigned a variable.
Transient (time domain) magnetic fields caused by permanent magnets, conductors and windings supplied by voltage and/or current sources with arbitrary variation as functions of time; rotational or translational motion effects can be included in the simulation. The application described in this getting started guide is an extension of TEAM Workshop Problem 24, which is a rotational actuator design. Results presented correspond to the simulation of a 3D electromagnetic time-transient problem with effects of large motion included in the simulation. Both the rotor and the stator are made of solid ferromagnetic steel, creating significant eddy current effects. A nonlinear B-H curve for the stator and rotor steel is considered. Estimated mechanical inertia of the rotor is included in the solution. The results of the simulation with different FEM code are presented in IEEE Transactions on Magnetics, Vol 38, No. 2, March 2002, pp 609-612. By following the steps in this guide, you will learn how to perform the following tasks: Draw a geometric model. Modify a models design parameters. Assign variables to a models design parameters. Specify solution settings for a design. Validate a designs setup. Run a Maxwell simulation. Plot the magnetic flux density vector. Run a parametric analysis.
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Introduction
Setting Up Designs
In Maxwell 11, you are no longer required to follow a specific order when setting up your Maxwell design. However, the following order is recommended, particularly for new Maxwell users: 1 Open Maxwell, and save a new project. 2 Draw the geometry of the model. 3 (Optional) If necessary, modify the model's design parameters. 4 Assign variables to design parameters. 5 Specify solution settings. 6 Run a Maxwell simulation. 7 Create post-processing plots. 8 Create a parametric analysis. 9 Create a field animation of the parametric analysis results.
Introduction
1-3
The outer part consists of a ferromagnetic nonlinear armature carrying two coils. The inner part is composed of the same nonlinear material and can rotate around an axis. The inner and outer parts of the device are co-axial. The field distribution is expected to cause the flux density to a concentrate in the two steel armatures in the regions where the distance between them is minimal. The expected edge effect will then further increase the field concentration. The torque acting on the inner armature and the flunk linkage of the two coils will also be computed in this example.
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Introduction
In this chapter you will complete the following tasks: Open and save a new project. Insert a new Maxwell design into the project. Select a solution type for the project. Set the drawing units for the design.
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If you have already completed the magnetostatic example in the Getting Started with Maxwell: Designing a Rotational Actuator guide, you can open the existing Rotational_actuator project rather than creating a new one.
1 Double-click the Maxwell 11 icon on your desktop to launch Maxwell. 2 Click Project>Insert Maxwell Design .
The new design is listed in the project tree and is named MaxwellModeln by default. The 3D Modeler window appears to the right of the Project Manager. 3 Click File>Save As. The Save As window appears. The current design has the default name 4 Locate and select the folder in which you want to save the project MaxwellModel1 listed in 5 Type Rotational_actuator in the File name box, and click Save. the Project Manager window. You can change it by right-clicking it, selecting Rename command, and entering a new name for it. You can add additional designs to the project by repeating step 2 above, or by clicking the corresponding icon on the toolbar. For the current simulation task, we do not need to create additional designs.
2-2
The project is saved in the specified folder under the name Rotational_actuator.mxwl.
The current design has the default name MaxwellModel1 listed in the Project Manager window. You can change it by right-clicking it, selecting Rename, and entering a new name. You can add additional designs to the project by repeating step 2 above or by clicking the corresponding icon on the toolbar. For this simulation example, we do not need to create additional designs.
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2-4
In this chapter you will complete the following tasks: Create the outer armature of the actuator by subtracting and uniting objects. Create the inner armature of the actuator. Create the coils. Create the coil terminals. Create the background object.
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6 Change the Name field value (currently Cylinder1) to Outer_arm. 7 To change the color of the cylinder to red:
3-2 Creating the Geometry Model
A Linear step sweep type enables you to specify a linear range of values with a constant step size.
Use the Tab key to navigate between value fields (from X to Y to Z and from dX to dY to dZ).
a. Scroll down to the Color property, and click the Edit button. The Color palette window appears. b. Select one of the red shades from the Basic colors group, and click OK to return to the main Properties window. 8 To set the transparency to 0.6, click the button for the Transparent property, and enter 0.6 in the box, and click OK to close the Set Transparency dialog box and return to the main Properties window. 9 Click OK to close the Properties window. 10 In the history tree window, double-click the CreateCylinder field. The Properties window appears, with the Command tab displayed. 11 In this window, you can visualize the geometric data and edit it. Click OK when you are done making any desired edits. Repeat the procedure above to create another cylinder (named Cylinder_tool) with the same center and height as Outer_arm but with a radius of 83.1 mm. Next, subtract Cylinder_tool from Outer_arm. To subtract the second cylinder from the first: 1 Select both cylinders by clicking their names in the history tree (hold the Ctrl key down when selecting the second one). 2 Click 3D Modeler>Boolean>Subtract. 3 If necessary, move the Outer_arm object into the Blank Parts column and the Cylinder_tool object into the Tool Parts column, by selecting each object and using the arrows to move it. 4 Click OK. Add the two magnetic poles to the outer armature. First create a box, then move the box into the correct position, and use the Mirror command to create a duplicate of the box. Unite the three model objects, and subtract the a cylinder to arrive at the final shape. To create a box: 1 Select Box from the Draw menu. 2 Enter the box position (-13.0, 0, 0) in the X, Y, and Z fields at the bottom of the screen, and then press Enter. 3 Enter the box size (27.8, -40, 25.4) in the dX, dY, dZ fields, and then press Enter. The Properties window appears. 4 Click OK.
3-3
View the design variations that will be solved in table format under the Table tab. This enables you to visualize the design variations that will be solved and manually adjust sweep points if necessary.
For more information about the other options in the Setup Sweep Analysis dialog box, see the online help.
To move the box into position: 1 Select the box object previously created (for example, click the respective name in the history tree window). 2 Select Edit>Arrange>Move. 3 Enter (0, 0, 0) in the (X, Y, Z) fields as the origin of the move vector, and press Enter. 4 Enter (0, -45, 0) in the (dX, dY, dZ) fields as the target point of the move vector, and press Enter. To create a duplicate of the box using mirroring: 1 Select the box previously created. 2 Select Edit>Duplicate>Mirror. 3 Enter (0, 0, 0) in the (X, Y, Z) fields as coordinates for the anchor point on the mirror plane and press Enter. 4 Enter (0, 1, 0) in the (dX, dY, dZ) fields as coordinates of target point of the vector normal to the mirror plane and press Enter. To unite the three objects in the model: 1 Select the three objects in the model from the history tree window (select Outer_arm first, then hold down the Ctrl key and select the boxes). 2 Select 3D Modeler>Boolean>Unite. Because the first selected object was Outer_arm, the final object name assigned by default is Outer_arm. The name of the objects can be easily changed if desired in the Properties window with the Attribute tab selected. To provide the final shape for the magnetic pole faces: 1 Create a cylinder with the center at (0, 0,0), a radius of 53.75, and a height of 25.4. 2 Select the Outer_arm object, then hold down the Ctrl key and select the cylinder. 3 Select 3D Modeler>Boolean>Subtract. The Subtract dialog box appears. 4 Make sure the Outer_arm object is in the Blank Parts column and the Cylinder1 object is in the Tool Parts column. 5 Click OK.
3-4
To automatically expand the project tree when an item is added to the project: Click Tools>Options> General Options. Under Project Options, select Expand Project Tree on Insert.
Creating the Geometry Model 3-5
3 Enter (0, 0, 0) in the (X, Y, Z) fields as coordinates for the anchor point
on the mirror plane, and press Enter. 4 Enter (0, 1, 0) in the (dX, dY, dZ) fields as coordinates of target point of the vector normal to the mirror plane, and press Enter. To unite the inner armature object with the two boxes: 1 Select the three objects in the model from the history tree window (select Inner_arm first, then hold down the Ctrl key and select the two boxes). 2 Select 3D Modeler>Boolean>Unite from the menu bar. Because the first selected object was Inner_arm, the final object name assigned by default is Inner_arm. The name of the objects can be easily changed in the Properties window on the Attribute tab. To provide the final shape for the magnetic pole faces: 1 Create a cylinder with the center at (0, 0,0), a radius of 51.05, and a height of 25.4. 2 Select the Inner_arm object, and then hold down the Ctrl key, and select the new Cylinder2 object. 3 Select 3D Modeler>Boolean>Intersect.
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3-8
17 mm. 2 Select the cylinder and the coil, and perform a Boolean intersection.
4 Specify (0, 1, 0) in the (dX, dY, dZ) fields as coordinates of target point
of the vector normal to the mirror plane, and press Enter.
3-9
3-10
In this chapter you will complete the following tasks: Define material properties. Assign excitations. Set up the mesh operations.
4-2
9 Click OK when done entering the H and B values. 10 Click Validate, and then click OK to exit the Edit operation. 11 Click OK once more to validate the definition and close the Select Definitions window.
Assign Excitations
Currents need to be defined and assigned as excitations for the two coil terminals. To define the currents: 1 Select each terminal (one at a time) by clicking it in the history tree window. 2 Right-click, and select Assign Excitation>Coil Terminal from the shortcut menu. 3 Enter 350 A in the Number of Conductors box. 4 Optionally, you can swap direction. 5 Click OK to validate the excitation and close the window. 6 Repeat steps 1-6 for the second terminal, making sure that the two terminal coils are connected in series. By default, all faces of the region box (background) are assigned with magnetic flux tangent boundary conditions. Therefore, no additional boundary conditions are required for this example problem. To add a winding: 1 Right-click in the model window, and select Assign Excitation>Add Winding. The Winding Definition window appears. 2 Enter a name in the Name box (or accept the default, such as Winding1). 3 Set the Type to External, and select the Stranded radio button. 4 Leave the Initial Current set at the default value of 0 (zero).
Note
In this application we are using an external circuit to supply the excitation to the coil. For this example, we also could have used a voltage type of excitation.
5 Click OK.
To add a terminal for the winding: 1 Right-click the Winding1 name in the project tree, and then select Add terminals. 2 Select the two previously defined terminals by clicking on their names (while holding down the Shift key). 3 Click OK. In the project tree, the two terminals are moved beneath Winding1.
4-4 Defining Material Properties, Excitations, and
The region box (background) will have by default all faces assigned with magnetic flux tangent boundary conditions. Thus for this problem no additional boundary conditions are needed.
To set up the external circuit: 1 From the Windows taskbar, click Start>Ansoft>Maxwell>Maxwell Circuit Editor. The Maxwell Circuit Editor opens. 2 Click Project>Insert Maxwell Circuit Design.
3 Select the Components tab in the project tree window. 4 Add the circuit elements:
a. Place the winding element on the sheet: In the project tree, under Maxwell Circuit Elements/Dedicated Elements, select the Winding element, and drag it onto the sheet at the desired location. Rightclick, and select Finish to place the component. To view the properties, click the component in the schematic window. In Properties window, change the DeviceName to Winding1, the same name you used when defining the winding in the Maxwell design. Click Draw>Rotate to position the winding vertically.
Note
In the schematic sheet, all the windings must use the same names that were defined for them in Maxwell in the previous section. b. Place a resistor on the sheet: In the project tree, under Passive Elements, select Resistor, and drag the resistor onto the sheet. Rightclick, and choose Finish to place it where desired. Double-click the symbol of the resistor, and change the value of the resistor, R, to
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3.09 Ohms. Click OK when done. c. Place a voltage pulse: In the project tree, under Sources select a VPulse element (Pulse Voltage Source), drag it to the sheet, and then right-click and select Finish to place it onto the sheet. Doubleclick the source element symbol on the sheet, and then specify the characteristics of the source as follows: V1 (Initial voltage) = 0 V2 (Peak voltage) = 5.97 Tr (Rise time) = 0.001 Tf (Fall time) = 0.001 Pw (Pulse width) = 1 Period =1 Leave the other fields set to the default values, and click OK.
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The Set Eddy Effect dialog box appears. 2 Select the check boxes for the Inner_arm and Outer_arm objects.
3 Click OK.
4-10
In this chapter you will complete the following tasks: Set up the analysis. Run and solve the analysis.
5-1
5-2
In this chapter you will complete the following tasks: Plot the magnetic flux density vector. Close the project and exit Maxwell.
6-1
As requested, Maxwell has modified the T-junction geometry so that the value of offset is 0.09 inches, or the optimal variable value. You can select a different value of offset in the table, and then click Apply to modify the T-junction geometry to that offset value. When you are done, click Revert to return the geometry to the optimal value.
6-2
To plot the current density distribution on the same XP plane of CS1: 1 Select the plane, right-click in the 3D modeler window, and select Fields/J/Mag_J. 2 Specify the volume as Outer_arm. 3 Click Done to plot. Notice the partial penetration of the field in the stator of the device; the transient distribution of the current density shows significant skin effects.
Varying global quantities as a function of time is a very important output from the transient analysis. Examples of such quantities of interest include currents and voltages, power loss, torque/force, flux linkage of windings, and induced voltages.
6-3
To create those plots: 1 Right-click Results in the project tree, and select Create Report. 2 Leave the Report Type set to Transient and the Display Type to Rectangular Plot. 3 Click OK. 4 From the Solution pull-down list, select Winding1. 5 From the Category pull-down list, select Current. 6 Click the Add Trace button. 7 Click Done to display the plot. To create a plot of the torque as a function of time: 1 Right-click Results in the project tree, and select Create Report. 2 Leave the Report Type set to Transient and the Display Type to Rectangular Plot. 3 Click OK. The Traces dialog box appears. 4 From the Solution pull-down list, select Torque1. 5 From the Category list, select Torque. 6 Click the Add Trace button. 7 Click Done to display the plot.
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To close the plot (it will still be available to view later): Click the X in the upper right corner of the plot window.
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6-6
In this chapter you will complete the following tasks: Include large motion in the simulation. Post process the transient results.
7-1
Add Motion
Before adding motion, save the without motion design and create a copy: 1 Save the transient without motion design. 2 Right-click the name of the design in the project tree, and select Copy. 3 To paste it into the same project folder, right-click the name of the project in the project tree, and select Paste. 4 Double click the name of the copy to make it the active design.
You can also use the Design Properties command to add new variables.
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4 Specify Rotate as the Motion Type. 5 Click the Mechanical tab. 6 Enter 0.0024 Kg m2 as Moment of Inertia and 0.015 N m sec / rad as
the Damping.
7 Click OK.
To apply the appropriate mesh operation to the band object: 1 Select the band object. 2 Apply a mesh operation requesting the maximum mesh size of 20 mm for the respective elements. 3 To initialize the problem, right-click Setup1 in the project tree, and select Revert to Initial Mesh. Now you are ready to start the analysis with the effect of large motion included.
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7-5
Follow the same steps to plot the current, torque, and power loss vs. time (selecting a different Category for each plot). The resulting plots are shown below.
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7-7
7-8
In this chapter you will learn how to complete the following tasks: Recognize desktop windows. Use mouse buttons. Set up a matrix.
A.Desktop Windows
Project Manager Window Menu Bar Tool Bar
Message Window
Progress Window
tions or excitations, performing field plots on previously selected geometries, or exiting the zoom mode or dram mode, to name a few examples).
C.Geometry
27.8 102.1 209.0
Coils