SPIN SPIN Applicazioni

Applicazioni Magnetiche
Magnetiche Srl © www.spinmag.it
 Low-frequency electromagnetic
and thermal analysis for
electromechanical devices: an
overview of Altair suite

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux
2D/3D FEM-based low
frequency electromagnetic and
thermal simulation software

E, D, B, H
High frequency Low frequency
• Thermal applications
Maxwell equations
decoupling
• Electric applications

• Magnetic applications

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: preprocessing
• Easy handling of complex geometries

• Mesh import tool from Simlab/HyperMesh

Medium voltage disconnector

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: dielectric design
• Electrostatic application: Electric field distribution

 Electric ‘hot-spot’ detection

 Electric potential distribution
 Stray capacitance analysis
Electric field isovalue (cross-section plane)

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: dielectric design
• Electrostatic application: Breakdown voltage

Ionization inception condition provided

by a fully automated Streamer
Criterion, based on the background
electric field previously computed.

Gaseous medium model:

- Air
- SF6
- User-defined Weakest breakdown path

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux-Inspire: mechanical design
• Blow-off effect analysis: test on arcing horns

Blow-off force, due to current

spot constriction, has been
evaluated with Flux and
simulated using Inspire.

6 kA
6 kA
Displacement (left horn)
Global Lorentz force (left horn)

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: dielectric design
• Electrostatic application: Capacitance matrix

The capacitances computed in DC

condition (Electrostatic application) can be
imported in a Magnetic AC SS model, which
implements a finite element-circuit coupling.

Export
Electrostatic Steady State AC Magnetic

Choke filter frequency response

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: dielectric design
• Electrostatic application: Capacitance matrix

Impedance vs frequency

Resonances, capacitive behaviour

Mainly resistive-inductive effect

Choke filter frequency response

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: dielectric design
• Electric transient application

GND

Ideal profile (low

 Effects of lightning on large power frequency bound)
transformer, turn-to-turn overvoltages analysis
 Electric field distribution on cable joint

GND

Voltage distribution along a winding [pu]

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: Inductive power transfer
• Wireless charging: AC SS Magnetic application

Ferrite
plates

Coils

 Coupling coefficient versus coil position

 Saturation effects modeled
 Iron losses computation (Bertotti model)
 Finite element-circuit coupling

𝑘𝑘𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = 𝑀𝑀 𝐿𝐿𝑝𝑝 𝐿𝐿𝑠𝑠

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: Inductive power transfer
• Wireless charging: AC SS Magnetic application

Flux density arrows

Flux density isovalue (longitudinal cross-section plane)

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: Inductive power transfer
• Wireless charging: AC SS Magnetic application

Voltage
generator

Complex circuit topology analysis

Resonant frequency
and tuning with Flux-Activate link
(20 kHz)

Generator reactive/active power versus frequency

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: Eddy current brake
• Application: Transient Magnetic 3D

Non-meshed coil
(DC supply) Aluminum
disk
18000 rpm

Iron core Extrusive

mesh on disk

 Mechanical equation - finite element domain coupling

 Saturation effects modeled
 Non-meshed magnetic sources to speed-up simulation

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: Eddy current brake
• Application: Transient Magnetic 3D

18000 rpm

Current density
distribution (disk)

Flux density isovalue (core)

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: Eddy current brake
 Surface magnetic forces export to HyperMesh
for accurate mechanical analysis

Export  Static analysis

 Air gap variation

Magnetic
forces effect
Surface magnetic forces distribution (iron core, upper pole)

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: induction heating
Cosimulation available (‘Magneto-thermal
coupling’), to actualize the value of power
losses with time-varying temperature

Steady State AC Magnetic Transient thermal

0,5 m/s

Moving aluminum foil heating

(Application: ink drying)
Target power = 100 W
Thickness = 20 μm Hexahedral meshes on foil
Frequency = 100 kHz

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: induction heating

 Surface impedance formulation on coils (time

saving, proximity effect is taken into account)

Flux density on CutPlane (shown above) Eddy current distribution on foil

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: induction heating
 Lorentz/Laplace forces export to HyperMesh for
accurate mechanical analysis (Flux 2018 new feature)

Laplace force arrows (foil)

Export

 DC component of force
.NAS file  Harmonic force

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: induction heating
 Power density distribution export to AcuSolve
for detailed thermal analysis

Export

.NAS file  CFD solver

 Convective heat transfer
coefficient analysis
 Radiative exchanges
 Temperature distribution

Joule losses isovalue

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: thermal analysis
 Modeling capabilities

 Phase transition and lattice rearrangement can be

simulated by using non-linear thermal properties
 Anisotropic material
 Spatially-dependent parameters

Specific
heat

Iron-Carbon phase transition diagram Gaussian model (E=phase transition energy)

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: electric motor
• Fast model building with dedicated overlays
• FluxMotor tool for pre-design

Efficiency mapping

 Operating point computation

 Magnetic forces export for
vibro-acoustic analysis

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: electric motor
• Internal Permanent Magnet motor: vibroacoustic analysis

Fy
16th
harmonic

Fx

y
Forces on tooth
x

Surface magnetic
Magnetic Transient 2D application
forces export

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: electric motor
• Internal Permanent Magnet motor: vibroacoustic analysis

Mode 1 Mode 5
(425 Hz) (1091 Hz)

Mode 12 Mode 23
(2633 Hz) (4103 Hz)

Modal analysis results on stator

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux: electric motor
• Special application

Levitating rotor motor

Axial flux technology

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux-Hyperstudy: optimization
• Link to optimization tool

Objective function

.F2G file

 Design of experiment (DOE)

 Multi-objective optimization
 Advanced data mining and postprocessing
(correlation matrices, interaction effect plots)

SPIN Applicazioni Magnetiche www.spinmag.it

 Flux-Hyperstudy: optimization
• Electric motor bemf optimization

Back-electromotive
Objective: force optimization

Optimized Permanent
variable: magnet length

Harmonic distortion
reduction (-16%)
Other objective
function optimizable:
 Torque ripple
 Cogging torque
 Efficiency

SPIN Applicazioni Magnetiche www.spinmag.it

 Activate
• Electric drive simulation: 3PH - Surface
Permanent Magnet motor control

Signal-based model

PI controller

Reference speed
(imposed)

Power
converter

Electric
motor model

SPIN Applicazioni Magnetiche www.spinmag.it

 Activate
• Electric drive simulation: 3PH - Surface
Permanent Magnet motor control
Angular speed
Signal-based model

(reference)
PWM supply voltage

(actual)

d-q currents

SPIN Applicazioni Magnetiche www.spinmag.it

 Activate
• Electric drive simulation: 3PH - Internal
Permanent Magnet generator starting transient

Flux – Activate cosimulation

Flux-Activate
link block

PID controller

Mechanical
equation
Reference
voltage (step) Internal combustion
engine (prime mover)

SPIN Applicazioni Magnetiche www.spinmag.it

 Activate
• Electric drive simulation: 3PH - Internal
Permanent Magnet generator starting transient

Flux – Activate cosimulation

Angular speed

Phase voltages ICE torque

SPIN Applicazioni Magnetiche www.spinmag.it

SPIN Applicazioni Magnetiche www.spinmag.it