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Stopper/Blocker
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Introduction
Linear plunger/actuator is use for many applications such as voice coil,
electromagnetic relays, electromagnetic valves etc.
The actuator has a blocker/stopper that restricts the linear motion of the
plunger. It consists of coil, magnetic core, spring and moving magnetic
plunger/armature.
The plunger is guided by the nonmagnetic guider.
Magnetic core and plunger are modeled with both linear and nonlinear BH
Curves separately.
The transient current is passed through the coil to actuate the plunger and
the dynamics is modeled.
The electromagnetic force on the plunger is computed and coupled with the
dynamic equation of motion.
The equation of motion of the plunger and the spring and damping attached
to its bottom are modeled using the Global ODEs and DAEs.
The Events interface is used to model the contact and release of plunger.
The model is parameterized so that the model can be simulated for variation
of one or many of these parameters using parametric sweep study.
Construction: A 3D View
Stopper/Blocke
r
Magnetic core
Multi-turn coil
Air region
Guider
Plunger/armature
Plunger motion direction
Air region
(white)
Guider
Plunger/armature
Plunger motion
direction
r=0
Figure: 2D axi-symmetry geometry depicting various parts of the linear plunger
Modeling Approach
Geometry dimension: 2D-axisymmetry
Geometry finalized: using Form Assembly
Physics used:
1. Magnetic Fields
2. Moving Mesh
3. Global ODEs and DAEs
4. Coefficient Form Boundary PDE
5. Events
Study type: Time Dependent
Results:
Electromagnetic force on the plunger vs time
Dynamic position of the plunger vs time
Dynamic velocity of the plunger vs time
Model Parameters
Model Variables
The Magnetic Core and Plunger are modeled using separate Amperes Law
nodes. A linear relationship between B and H is defined using Magnetic
Permeability.
The relative permeability for linear material are: mur_plunger = 4000, and
mur_core = 1200.
Above figures show the setup for plunger and similar settings are applied for
Magnetic Core as well.
The coil is defined using a Multi-Turn Coil feature. The current in the
coil is defined using a rectangular waveform defined in the variables
tab. The number of turns, coil conductivity and coil cross-sections are
defined as shown in the above figure.
Force
Calculation
Eventsinterface to model the instance when the plunger is in contact with the
stopper/blocker or is released when the coil is turned of
TheEventsinterface, which is available within theMathematics > ODE and
DAEinterfaces branch
The Discrete states interface is used to model the state of the plunger. The two
states are when the plunger is in contact with the blocker and when the
plunger is not in contact. The PlungerState variable is defined for this purpose.
This variable is further used in Global ODEs and DAEsinterface to appropriately
model the plunger in contact or of contact.
The above
separate
dv equation can be rewritten into two Where,
M
D
.
v
k
.
p
F
(
p
,
v
,
t
)
0
z
p = z-position
equations
dt as
dp
v 0
dt
v = velocity
M = mass
D = damping coefficient
k = stifness
Fz = electromagnetic force
The PDE solved along the boundaries and the Dirichlet boundary
conditions applied are shown in the figures below
Fixed boundary
Since there is a blocker in the actuator the mesh between the plunger
and the blocker is contracted to almost zero volume. To avoid this the
height of the contracted mesh is fixed to a finite value (0.5 mm).
On the side boundaries of the contracting and expanding air region, the
prescribed displacement in z direction is assigned a new variable ZHelp.
This variable is solved using Coefficient Form Boundary PDE interface.
The following blogposts describe in detail this method:
https://www.comsol.com/blogs/model-translational-motion-with-the-deformed-mes
h-interfaces/
https://www.comsol.com/blogs/deformed-mesh-interfaces-rotations-and-linear-tran
slations/
Meshing
This figure shows the meshing around the plunger, showing the portion where the
contraction of the structured mesh is occurring in the air region.
Solver Configuration
Use BDF 2nd order solver with Event tolerance set to 0.001.
Use a Fully Coupled solver with setting as shown in the above picture (right).
The solver settings for this example is similar to the suggestion in the following
Knowledge Based Entry:
https://www.comsol.com/support/knowledgebase/1127/
Changing Discretization
1
2
In Contact
Figure: The velocity profile of the plunger w.r.t time as the current
varies in the coil
Core
Coil
Plunger/Armature
NOTE: You need to click on Slide Show mode to visualize the animation.