Altair Flux - V2019 Ch14 - Iron Losses

ALTAIR FLUX - V2019
CH14 - IRON LOSSES

© 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair Flux, v2019
CHAPTER 14 - IRON LOSSES

14) Iron Losses
• Bertotti’s method
• Loss Surface method (LS method)
• Comparison between both method
• Demo case
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Altair Flux, v2019
IRON LOSSES COMPUTATION: INTRODUCTION

• Iron losses estimation
• Computation is done with classical materials
• Iron losses is estimated « a posteriori » (after computation)
• Iron losses is still a topic for research
• 2 methods are available in Flux:

• Bertotti’s method
• Loss Surface method (LS method)
• Content:
• Description of each method (principle, how to use, main results)
• Comparison between both method
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Altair Flux, v2019
BERTOTTI’S METHOD
• Main hypothesis:
• For lamination
• Based on the principle of separation of losses versus the origin
• Hysteresis losses Loss (W/kg) at 50 Hz
• Eddy current losses 14.0
• Excess losses 12.0
10.0
Measured Loss (W/kg)
8.0
Bertotti (W/kg)
6.0
4.0
2.0
• Available in AC and in transient 0.0

0.0 0.5 1.0 1.5 2.0
• For each type of losses there are specific formula for estimating the values
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Altair Flux, v2019
BERTOTTI IRON LOSSES EQUATIONS

• In Steady state:
α1 α2 α3
dPTOT = k1 ∙ Bmax ∙ f + k 2 ∙ Bmax ∙ f + k 3 ∙ Bmax ∙ f
• In transient magnetic:
α2 α3
dPTOT t = k1 ∙ Bmax α1 ∙ f + k 2 ∙ dBൗdt + k 3 ∙ dBൗdt
(by default, exponents are α1 = 2, α2 = 2, α3 = 3/2 )
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Altair Flux, v2019
BERTOTTI’S FORMULA
α1 α2 α3
dPTOT = k1 ∙ Bmax ∙ f + k 2 ∙ Bmax ∙ f + k 3 ∙ Bmax ∙ f ∙ k4
With coefficients that user must fill in :

coefficients can be extracted from iron
k1 : coefficient of losses by hysteresis in W/T²/s/m3 losses versus frequency and flux density
k2 : coefficient of classical Eddy current losses
k3 : coefficient of supplementary losses or in excess
k4 : stacking factor (about 1) (usefull to calculate the total volume)
α1 : exponent of losses by hysteresis Specific Excel file
α2 : exponent of classical Eddy current losses …\flux\Flux\DocExamples\Tools\
BertottiLossesCoefficients
α3 : exponent of supplementary losses
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Altair Flux, v2019
BERTOTTI’S COEFFICIENT
• From manufacturer data, Bertotti’s coefficient can be deduced:
• Need of losses versus flux density for different frequencies
• Need of mass density, resistivity, thickness of lamination
• There is an Excel file with a procedure allowing to extract more easily, k1 , k2 and k3
and exponent coefficients:
• Enter losses versus flux density at given frequency
• Enter mass density, resistivity, thickness of lamination
• Using Excel optimiser to find out k1 , k2 …
• Available at (for standard installation):
…\flux\Flux\DocExamples\Tools\BertottiLossesCoefficients
• Typical values
• Fev1000-65HA , 50 Hz
• K1 = 227,7, K2 = 56,4 , K3 = 52,3 , α1 = 2,258, α2 = 1,135, α3 = 0,964
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Altair Flux, v2019
BERTOTTI’S COEFFICIENT: EXCEL FILE
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Altair Flux, v2019
BERTOTTI’S LOSSES: RESULTS

• Results can be displayed in various formats:
• Average value on region for each time step (note: only average value over a time period is
meaningfull)
• Display power density (average value over a time period) in color shade
• The 3 types of losses are available (as 3 components)
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Altair Flux, v2019
BERTOTTI’S LOSSES ACCURACY

• Expected accuracy: average
• Lack of accuracy due to:

• Rotating losses not taken into account
• Rough model
• Only one frequency at a time (if you look around the airgap, higher frequency are present)
• Note: it is recommended to use this feature in qualitative modes rather than quantitative
• In this model b iron losses is increased by 20% compare to model a
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Altair Flux, v2019
BERTOTTI’S LOSSES WITH ALTAIR FLUX 2019

• Some improvements have been done with new iron losses model, especially for the
computation time
• Limitation:
• To apply this new method, there is nothing to do, the iron losses will be
computed faster if there are some laminated magnetic non-conducting
regions in the project.
• The computation time and the size of the Flux project may be impacted.
• Results
• To apply this new method, there is nothing to do, the iron losses will be
computed faster if there are some laminated magnetic non-conducting
regions in the project.
• The computation time and the size of the Flux project may be impacted.
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Altair Flux, v2019
LS MODEL
• Main assumption:
• Based on specific measurements for each grade

• Measurement includes variation versus B but also versus dB/dt
• Model based on static hyteresis and dynamic hysteresis

• Developped by G2ELAB research team
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Altair Flux, v2019
LS MODEL
• Available materials
• Name: in M600-50A
• 600 means 6W/kg of losses for 1.5T at 50Hz
• 50 means 0.5 mm of thickness
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Altair Flux, v2019
LS MODEL: RESULTS
• Results can be displayed in various format:
• Average value on region for each time step (note: only average value over a time period is meaningly)
• Display power density (average value over a time period) in color shade
• Compute B(H) on local points
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Altair Flux, v2019
LS MODEL ACCURACY
• Expected accuracy: good
• Better accuracy due to:
• Dedicated input data
• Better model
• Way of using it
• As you may not have your grade, you can look at the 2 grades which have just less and just more
losses than yours: then you can do an average to get your estimated value
• For instance for M500-50A, compute M400-50A and M600-50A

15
Altair Flux, v2019
COMPARISON BETWEEN BOTH METHODS
Topic Bertotti’s model LS model
Input data From manufacturer 11 grades in Flux
Only one frequency taken

into account, Some time less accurate for
Main limitations high saturation and high
Rotating losses not taken frequency
into account
Expected accuracy average good
Input coefficient from Possibility to display local

Specific points
specific Excel file B(H) curves
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Altair Flux, v2019
CONCLUSION ON IRON LOSSES

• This is still a research domain
• Note: it is recommended to use this feature in qualitative mode rather than quantitative mode
• In this model b iron losses is increased by 20% compare to model a
• LS model is more precise but less material properties are available
• With LS model it is better to use the latest material characterised: M27035A, M33035A and
M80065A
• Work under progress in order to be able to create LS model from measurement provided by
the user (target for Flux in 2019)
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Altair Flux, v2019
ANNEX: DESCRIPTION OF THE METHOD FOR INCLUDING

MEASUREMENTS
Goal: add possibility to create new LS model from measurement
Note: already available in beta mode in current version Flux 2019
Need to use a dedicated Compose application
Example of text file for B(H) curves vs frequency
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Altair Flux, v2019
CREATING NEW LS MODEL FROM MEASUREMENT

Global worflow
Make measurement
B(H) curves vs
frequency
Use Compose to
create LS model and
B(H) curve
Import model in Flux

And use it
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Altair Flux, v2019
USING COMPOSE TO GENERATE NEW LS MODEL

Global workflow in Compose
Panel 1
Static identification
Next/previous
Panel 2
Dynamic identification
Next/previous
Panel 3
Overall verification
Next/previous
Panel 4
Model generation
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Altair Flux, v2019
LS MODEL: MOTOR LOSSES EXAMPLE 1
Comparison of
measured and
model cycles
Anthony Frias, Afef Kedous-Lebouc, Christian Chillet, Laurent Albert, Lionel Calegari,
21 « Improvement and Validation of an Irn Loss Model for Synchronous Machine », ICEM 2012
Altair Flux, v2019
LS MODEL: MOTOR LOSSES EXAMPLE 2

Induction motor
2 poles
5,5 kW, 400
Vlban Marino
Alban Marino, Afef Kedous-Lebouc, Bruno Cornut, Philippe Manfe,

22 « Iron loss prediction in an induction motor», SMM 2008
DEMO CASES
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Altair Flux, v2019
HOW TO RUN AN EXAMPLE IN THE CASE OF IRON LOSS

Open Flux Supervisor
context
Select Application
Flux 2D Skew Flux 3D PEEC
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Altair Flux, v2019
HOW TO RUN AN EXAMPLE IN THE CASE OF IRON LOSS

Demo case
• Open Flux Supervisor > Select application Flux 2D
• In the context choose open example
• In the example tree, select Technical tutorials
• Select an example Brushless IPM motor (embedded magnet)
• Select Motor performances at constant speed
• Build geometry and mesh: double click on geometry and meshing

• Physics: double click on physics
• Solving: double click on solving
• Postprocessing: double click on Postprocessing
• A new folder will be created in the current working directory
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Altair Flux, v2019
QUESTIONS & ANSWERS
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ALTAIR FLUX - V2019

CH14 - IRON LOSSES

CHAPTER 14 - IRON LOSSES

IRON LOSSES COMPUTATION: INTRODUCTION

• 2 methods are available in Flux:

• Available in AC and in transient 0.0

BERTOTTI IRON LOSSES EQUATIONS

(by default, exponents are α1 = 2, α2 = 2, α3 = 3/2 )

With coefficients that user must fill in :

BERTOTTI’S COEFFICIENT: EXCEL FILE

BERTOTTI’S LOSSES: RESULTS

• The 3 types of losses are available (as 3 components)

BERTOTTI’S LOSSES ACCURACY

• Lack of accuracy due to:

BERTOTTI’S LOSSES WITH ALTAIR FLUX 2019

• Based on specific measurements for each grade

• Model based on static hyteresis and dynamic hysteresis

• Better accuracy due to:

• Dedicated input data

• For instance for M500-50A, compute M400-50A and M600-50A

COMPARISON BETWEEN BOTH METHODS

Topic Bertotti’s model LS model

Input data From manufacturer 11 grades in Flux

Only one frequency taken

Expected accuracy average good

Input coefficient from Possibility to display local

CONCLUSION ON IRON LOSSES

• LS model is more precise but less material properties are available

ANNEX: DESCRIPTION OF THE METHOD FOR INCLUDING

Note: already available in beta mode in current version Flux 2019

Need to use a dedicated Compose application

Example of text file for B(H) curves vs frequency

CREATING NEW LS MODEL FROM MEASUREMENT

Import model in Flux

USING COMPOSE TO GENERATE NEW LS MODEL

LS MODEL: MOTOR LOSSES EXAMPLE 1

LS MODEL: MOTOR LOSSES EXAMPLE 2

Alban Marino, Afef Kedous-Lebouc, Bruno Cornut, Philippe Manfe,

HOW TO RUN AN EXAMPLE IN THE CASE OF IRON LOSS

Flux 2D Skew Flux 3D PEEC

HOW TO RUN AN EXAMPLE IN THE CASE OF IRON LOSS

• Build geometry and mesh: double click on geometry and meshing

• A new folder will be created in the current working directory

QUESTIONS & ANSWERS

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