5 Physic Magnetic-Altair Flux

ALTAIR FLUX 2019
CH5 - MAGNETIC APPLICATION

© 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair Flux, v2019
CHAPTER 5 - MAGNETIC APPLICATION

5) Magnetic application
• Applications • Regions
• Boundary conditions • Volumes
• Materials • Faces
• Mechanical sets (Kinematics) • Lines and points
• Techniques • Sources
• Defining a mechanical set • Magnets
• Electric circuit • Solid conductors
• Components • Meshed and not meshed coils
• Building process • Exercises 5A, 5B, 5C, 5D, 5E, 5F
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MAGNETIC APPLICATION
Geometric Construction
Mesh Generation
• Applications
Physical Properties • Project features
• General command sequence
Solving Process
Results post-processing
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PHYSICS – MAGNETIC APPLICATION
Application
Boundary conditions
Materials Frame
Stator
air
Half of air gap
 stator air
Rotor
air
Mechanical set Rotor

Permanent
Half of air gap
 rotor air
Sliding
magnet
surface
Circuit
Regions
Massive magnetic circuit Laminated magnetic circuit
Sources definition
Check physics
Do not forget cuts when needed!
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! (See annex)
APPLICATIONS
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APPLICATIONS
• First step defining physics: choose the application
• Flux offer three different application in magnetic (all available in 2D and 3D)
• Magneto Static
• Steady State AC Magnetic
• Transient Magnetic
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APPLICATIONS
Flux Application Magnetic sources … Application example…
Magneto Stationary currents

Magnets Contactor (steady state)
Static (steady state)
Variables currents
Transient Magnetic IPM (transient analysis)
(variable state / steady state) Magnets
Magnets
Steady State AC Magnetic Sinusoidal currents
(steady state) ! forbidden!
Transformer
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APPLICATIONS
• Magneto static example
Hard material
(magnets)
Soft material
(magnetic)
Coil conductor
(DC current)
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APPLICATIONS
• Steady State AC Magnetic/ Transient magnetic
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APPLICATIONS
• Steady State AC Magnetic
Active
Passive conductors conductors
&
Soft magnetic
materials Soft magnetic
material (core)
An electric circuit is necessary to simulate the current !

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APPLICATIONS
• Transient magnetic
Active conductors
Hard magnetic
material (moving!)
Soft magnetic
material (cores)
The movement must be modelled!

! Kinematic simulation needed!
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BOUNDARY CONDITIONS
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BOUNDARY CONDITIONS
• Boundary conditions:
• On DOMAIN edges are obligatory
• Inside the DOMAIN are POSSIBLE
• Specially relevant when they are attached to the domain definition
• Periodicity planes
• Symmetry planes
• Infinite box
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BOUNDARY CONDITIONS – DOMAIN DEFINITION

• Infinite Box
• Already defined during geometry building. No further
information needed
• Periodicity planes
• Even = Cyclic: V(T+u) = V(u)
• Odd = Anticyclic: V(T+u) = -V(u)
• Symmetry planes
• Normal magnetic field / Tangential electric field
• Tangential magnetic field / Normal electric field
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MATERIALS
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MATERIALS
• A MATERIAL is a set of physical properties :
• B(H) characteristic: permeability ()
• J(E) characteristic: resistivity ()
• D(E) characteristic: permittivity ()
• Thermal characteristics: conductivity k(T),
specific heat Cp(T)
• Mass Density: Mass Density (V)
• Three different ways to create materials (in the Flux project)

• Import a material from a data bank: MATERI.DAT
• Create a material directly in the Flux project
• Create a material in the data bank: Material Manager
A modification of the material properties in material manager (respectively in the Flux

! project) does not modify a material in Flux
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MATERIALS
• Behavior laws
• Used to define the properties of the physical regions
Law of … Medium Equation Medium property
 
magnetic behavior Magnetic medium B=H : magnetic permeability [H/m]
 
dielectric behavior Dielectric medium D=E : electric permittivity [F/m]
 
electric behavior Electric conductive medium J = E : electric conductivity [-1.m-1]
Law of… Medium Medium property

k: thermal conductivity [H/m]
thermal behavior Thermal conductive medium
 Cp: specific heat [J/m3/K]
Law of… Medium Medium property

material behavior Mass density ρV: Mass density [kg/m3]
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IMPORT MATERIALS
• Import material
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MATERIALS – MAGNETIC PROPERTIES

• Soft magnetic material
• Type of magnetic property B(H) B
B
• Linear isotropic or anisotropic B [T]
• Linear isotropic or anisotropic complex
• Isotropic analytic saturation (2 coeff.)
• Isotropic analytic saturation (3 coeff.)
• Isotropic or anisotropic scalar spline HH
• Isotropic parabola + straight line
• User magnetic properties H [A/m]
• Type of magnetic property B(H, T)
• Linear isotropic * expo. function of T
• Isotropic analytic saturation (2 coeff.) * expo. function of T
• Isotropic analytic saturation (3 coeff.) * expo. function of T
• Linear isotropic tabulated function of T
• Isotropic analytic saturation (2 coeff.) * tabulated function of T
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• B(H) curve stored in a type entity:
2D curve (Material)
• The user must create the B(H) curve by the command:

New 2D curve (Material) B(H)
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• Hard magnetic material (magnets) B
• Type of magnetic property B(H) B [T]
• Linear magnet described by the Br module

Straight line of Br
• Linear magnet described by Cartesian vector Br slope 0 r
• Linear magnet described by cylindrical vector Br H
• Linear magnet described by spherical vector Br
H [A/m]
• Nonlinear magnet described by Hc and Br module
• Nonlinear magnet described by Hc and Br module + knee Hc
adjustment
  
• Nonlinear magnet described by a spline B =  H + Br
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MATERIALS – ELECTRICAL PROPERTIES

• Electrical property
• Type of electrical property J(E)

• Insulator
• Isotropic or anisotropic resistivity
• Isotropic superconductivity (power law)
• User resistivity
• Type of electrical property J(E, T)

• Isotropic or anisotropic resistivity,
linear function of T
• Isotropic or anisotropic resistivity,
exponential function of T
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MATERIALS – VOLUME MASS

• It is possible to define a material density in order to evaluate its mass.
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MECHANICAL SET
(KINEMATICS)
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MECHANICAL SET - KINEMATICS

• Kinematics necessary to model motors, electro-valves, actuators…
• Mechanical set options allows the simulation of moving parts
• Under different moving conditions
• Imposed speed
• Under the influence of mechanical forces (springs, friction, gravity)
• Simulating linear or rotating movements
• Etc.
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• Type of motion:
• translation along a main axis (X, Y or Z axis)
• rotation around a main axis (X, Y or Z axis)
• free movement (positions defined by the user)
• Kinematics model:
• Multi static (steady state applications):
equivalent to a parametric study (without full re-meshing)
• Imposed speed (transient state applications):
the moving part is driven at an imposed speed
• Coupled load (Transient Magnetic application):
the moving part is coupled with an external load
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• Typical example
Mechanical
Finite element domain
coupling
Coupled
Fixed Mobile load /
part part Imposed
speed
Sliding line/ Compressible

surface air area
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TECHNIQUES
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MECHANICAL SET – KINEMATICS TECHNIQUES
• Type of motion:
• Rotation around an axis Translation Rotation
• Translation along an axis
• Technique used: Sliding
• Sliding
• Re-meshing
• Mechanical set:
Re-meshing
• Fixed
• Moving
• Compressible* Fixed mechanical set
Moving mechanical set
Compressible mechanical set

Compressible type – An air area in
* which the moving part is in motion
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MECHANICAL SET – RE-MESHING TECHNIQUE

• Re-meshing technique: principle
• Separation at the dissociation surface
• of geometric objects Dissociation
(points, lines, faces) surfaces
• of mesh objects
(nodes, line elements,
Moving part
surface elements)
• and re-meshing the Compressible
compressible air area air area
independently of moving
and fixed parts
Fixed part
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MECHANICAL SET – SLIDING MOTION TECHNIQUE

• Sliding motion technique: principle Moving part Fixed part
• Separation at the sliding surface
• of geometric objects
(points, lines, faces)
• of mesh objects
(nodes, line elements, surface elements)
• no re-meshing Sliding
surface
• Slide cylinder used in machine simulation!
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MECHANICAL SET – SLIDING MOTION TECHNIQUE

• Sliding motion: Example in 3D
rear-view mirror motor: rotation with sliding surface
Frame
Stator
air
Half of air gap
 stator air
Rotor
air
Half of air gap

Rotor  rotor air
Permanent
Sliding
magnet
surface
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DEFINING A MECHANICAL SET
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MECHANICAL SET – ROTATION DEFINITION
Type of mechanical set

 Rotation around one axis
 Translation along one axis
 Compressible
 Fixed
Rotation axis
• Rotation around one axis …
 parallel to OX
 parallel to OY
 parallel to OZ
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MECHANICAL SET – TRANSLATION DEFINITION
Type of mechanical set

 Rotation around one axis
 Translation along one axis
 Compressible
 Fixed
Translation axis
 Translation along Ox
• Translation along Oy
• Translation along Oz
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MECHANICAL SET – DEFINITION

Valid for both translation and rotation with minor variations
Type of kinematics
 Imposed speed
 Coupled load
 Multi static
• Velocity
• Position at t = 0 s
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Valid for both translation and rotation with minor variations
Type of kinematics
 Imposed speed
 Coupled load
 Multi static
 Velocity at t = 0 s
 Position at t = 0 s
 Type of load
 Inertia, friction and spring
(= predefined formula)
 Inertia and resistive torque
(= user formula)
• Specific characteristics
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Coupled load (translation kinematics)
• Same inputs for rotation
• Linear magnitudes are transformed into
angular ones
Load type
Friction variables
Spring variables
! Internal and external variables are added in order to obtain their global values
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MECHANICAL SET – DEFINING THE FREE MOTION

• The motion called « free »:
• The motion is defined by a list of positions
• The kinematic model is the multi static model
• Operation
Phase Description
1 Creation of a mechanical set
of the free motion type
(The positions taken by the mobile part are not entered by the user at the moment of
creation)
2 Creation of a scenario (piloting of the solving process)
 definition of the list of different positions of the mobile part
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ELECTRIC CIRCUIT
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ELECTRIC CIRCUIT - GENERAL CONCEPTS

• Used to solve simultaneously
• Maxwell equations (FEM model)
• Circuit equations
• For magnetic applications
• AC steady state
• Transient
• Required in plenty of applications
• Electrical machines
• Transformers
• Sensors
• Actuators…
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ELECTRIC CIRCUIT – GENERAL CONCEPTS

• Performing a study with field – circuit coupling
• Describe the circuit - circuit editor
• Accessible from physics menu
• Define link between FEM and electrical circuit

• See “Sources” section
Circuit saved in the working directory in a *.xcir file which can be used in
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other Flux projects
CIRCUIT COMPONENTS
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ELECTRIC CIRCUIT – CIRCUIT COMPONENTS

• List of components
Passive components
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Sources
AC Steady Transient
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Coupling components
• Coupled with FE simulation (see section “Sources”)

• Two different types
• Coil conductors: Coils in transformers, motors, etc.
• Almost uniform current density in the wires cross sections
• Skin depth greater than cross sections
• Their resistance can be either provided or calculated by Flux
• Solid conductor: bars, iron plates, etc.
• Variable current density in the cross section
• Skin depth smaller than conductors cross section
They must be linked to a source of the

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! Finite Element magnetic model!
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Switches (only transient application)

• Controlled by user’s command ( by function or square
signal)
R(t) T
Roff
Ron
0 Ton Toff t
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Diodes (only transient application)

• “Electronic switch”: Electric properties depends on
voltage polarization
• Three physical models available
ID
Slope line
1/RS
- IS V F0 UD
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Rotating machine components: Brush-segment

• Describes the contact between the commutator and the
brushes in a brush DC machine
bru + bar
bru - bar
1
G =
R on
1
R off
O
−  pos −  pos + 360 
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Rotating machine components: Squirrel cage

• Describes squirrel cage for induction machines
• One resistance and one inductance between either end
of each of the conductors to simulate end rings
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Ground
• Compulsory in every circuit
• It must be possible to trace a path from any component through
the ground
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BUILDING THE CIRCUIT
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ELECTRIC CIRCUIT – BUILDING PROCESS I

• Orientation of the components
Hot point
• Sign convection: The square marks the “hot point”
• Current entering the square is positive
• Voltage is measured as U=Vhot_point -Vcold_point
U
• Connecting the circuit
• A ground is always required
• The circuit must be connected (no independent branches)
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ELECTRIC CIRCUIT – BUILDING PROCESS

• Symmetries and periodicities
• From a FE point of view the device can be fully or partially described

• How to describe the electrical circuit in such conditions ?
• Which for components (resistances, voltages, etc)?
! Device real values must be used !
• Voltage/current must not be imposed twice !

• This is specially important in triphasic circuits when usually three coherent sources are used
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ELECTRIC CIRCUIT – DEFINING SYMMETRIES/ PERIODICITIES

• Management of flux coefficient due to symmetry/periodicity
• You have the option to define the coefficient management at the application level
• Automatic coefficient
• Imposed coefficient (Number)
• Imposed coefficient (Fraction)
• If imposed coefficient equal to 1, the circuit has to be described for the represented part (for instance
one quarter of voltage for one quarter of device)
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REGIONS
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REGIONS
• A region is…
• … a set of geometric entities of the same type
(points, lines, faces or volumes) …
• … having the same physical properties
• Examples of use
Region (2D) Region (3D) Use for the description of … Example
Face Volume • parts of any shape
• planar parts of small thickness

Line Face • current sheet air gap, magnetic sheets
• specific boundary conditions
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REGIONS
• Volume (3D) /Face (2D) region for magnetic applications
A region … Enables the modeling of a … This region type represents a coil :
Air or vacuum
Air or vacuum
(permeability r=1)
• consisted of turns (no. of turns)
Magnetic (non Magnetic (permeability r)
• supplied by a source current Js
conducting) non conducting medium
I
conductor with source non magnetic
Of coil conductor type
(permeability r=1) medium
This region type could be :
A region … Enables the modeling of a …
Magnetic (permeability r) • passive (conductor supplied indirectly “by induction”)

Of solid conductor type
conducting (resistivity ) medium
• active (conductor supplied directly by an external
source or indirectly as previously)
Specific Steady State AC Magnetic (3D) …
region of solid conductor type described by surface impedance
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VOLUME REGION
• Type of volume region
• Air or vacuum region

• Magnetic non conducting region
• Coil conductor region
• Solid conductor region (Transient, Steady State AC)
• Region with current density (Transient)
• Laminated non conducting region
• Inactive region
• Solid conductor region described by surface
impedance (Steady State AC )
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FACE REGION (2D)

• Type of face region
• Air or vacuum region

• Solid conductor region
• Region with current density
• Laminated magnetic non conducting region
• Inactive region
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LAMINATED REGIONS
• 2D/3D Magneto Static & Transient Magnetic:
• Region of type Laminated magnetic non conducting region
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LAMINATED REGIONS
• In electrotechnics field, it is crucial to reduce losses to improve the efficiency of the
electric devices like electrical transformers
• Specially losses generated by eddy currents
Massive magnetic circuit Laminated magnetic circuit
Accurate and fast simulation of

cores made of laminations
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FACE REGION (3D)

• Air gap region
• Boundary condition:
tangential magnetic field / normal electric field
normal magnetic field / tangential electric field
• Inactive region
(Steady State AC Magnetic)
• Thin conducting region (hyperbolic current
density through the thickness)
• Surface impedance region
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LINE REGION (2D)

• Type of line region
• Air gap region
• Solid conductor region
• Region with current density
tangential magnetic field / normal electric field
normal magnetic field / tangential electric field
imposed magnetic flux
• Inactive region
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REGIONS – ASSIGN REGIONS

• Assign regions to geometric entities
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SOURCES
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SOURCES
• Source
• Information on the PHYSICS of the problem that makes that its solution is not zero
• They need additional information generally not provided during regions definition
• Magnetic sources: Regions

• Permanent magnets (type of magnetic non conducting region)
• Solid conductor region (transient state and Steady State AC)
• Magnetic sources: Non meshed sources (not linked to a region)

• Non meshed coil
• Non-meshed magnetic field source
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PERMANENT MAGNETS REGIONS
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PERMANENT MAGNET REGIONS

• Regions containing hard magnetic materials must be oriented
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SOLID CONDUCTOR REGIONS
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SOLID CONDUCTOR
• Source used for
• bars, iron plates, …
• Value of skin depth comparable to or smaller than the dimensions of conductor cross section
• Current density not uniform (depending on Eddy currents)
• Region type:
• Active: Region directly supplied by a circuit (it needs a circuit component)
• Passive: Currents maybe exists caused by inductive effects
• Defined by:
• On circuit side by component:
• Solid conductor
• Information about symmetry/periodicity connections
• On finite element side by region:

• A region of solid conductor time
• An orientation must be added
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SOLID CONDUCTOR IN 2D/SKEW

• In FE side:
• Features and orientation
are defined during region
definition
• For active excitation: solid
conductor needed in circuit
side
• For passive excitation: no
circuit side required
• In circuit side:
• Solid conductor is defined
• About orientation
• Circuit: current entering the
square is positive
• FE side: current flowing
through +Z is positive
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SOLID CONDUCTOR IN 3D
• Define solid conductor and circuit
• Including serial/parallel connections for
symmetrical/periodical parts
• In FE side:
1. Only the material is chosen during region
definition
2. For each solid conductor in the circuit side:
• Select a solid conductor region
• Assign input and output terminals (surfaces)
3. Notice: A solid conductor region do not need a
linked solid conductor in the circuit side!
Each solid conductor circuit component must be linked to a

! solid conductor region!
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COIL CONDUCTOR REGIONS
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COIL CONDUCTOR REGION

• Source used for
• Wires, coils, cables…
• Value of skin depth greater than the dimensions of the conductor cross section
• Almost uniformity of current density in the cross section
• Defined by
• On circuit side by component
• Stranded coil conductor (with associated resistance)
• On finite element side by region:

• Number of turns
• Orientation (positive or negative)
• Symmetry/periodicity connections
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COIL CONDUCTOR REGION IN 2D/SKEW

• In FE side:
• Features and orientation are
defined during region definition
• Connections for the
periodical/symmetrical defined
• It must be linked with a stranded
coil conductor (circuit side)
• Define stranded coil conductor
• Belonging to a circuit
• With imposed current
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COIL CONDUCTOR REGION IN 3D

• Define circuit or impose current
• In FE side:
1. Define region: As in 2D but without
orientation information
2. For each coil conductor region in FE
side
• Orient wires of coil conductor region
• Select input/output surfaces
• Select current orientation (by line)
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COIL CONDUCTOR REGION IN 3D -ORIENTATION

• Terminals can be external or internal
• Open coil: External terminals • Closed coil: Internal terminal
Orientation
line Terminal
Entering Exiting
face face
Entering face defines the current positive A line is selected to define current
direction orientation
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NON-MESHED COILS
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NON-MESHED COILS
• A non-meshed coil is:
• Geometric entity that is superposed onto the mesh and which is independent.
• Used for
• Wires, coils, cables… Same use than coil conductor region
• Only available in 3D
• Defined by
• On circuit side by component
• Stranded coil conductor (with associated resistance)
• On FE side by specific object non-meshed coil with:

• Geometric and orientation
• Electric information (fill factor, number of turns, resistivity…)
• Symmetry/periodicity connections
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NON-MESHED COILS – DEFINITION (3D)


• Define circuit or impose current
• In FE side:
• New non-meshed coil

• Define geometry (including
mechanical set)
• Define electric features (including
link with stranded coil conductor)
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NON-MESHED COILS – GEOMETRY DEFINITION

• Non-meshed coil
Composed coils
Basic coils Circular Rectangular
with closed path
Along Oy
Along Ox
Radius Fillet radius P3 (x3, y3, z3)

Definition z
y Center z
y Center
x
P1 (x1, y1, z1)
(mean fiber) x
z
y
Section: x P2 (x2, y2, z2)
Line
with open path
P3 (x3, y3, z3)
Section:
P1 (x1, y1, z1)
Rectangle R2
z
y
x P2 (x2, y2, z2)
Section:
Disc
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NON-MESHED COILS VS COIL CONDUCTOR REGION

• Non-meshed coil
Non-meshed coils Conductor coil region
Easiness of use
Independence from
mesh
Computation time
Accuracy
Losses and force
calculus
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CHECK PHYSICS
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PREPROCESSING - ACTIONS
• Last steps in physics definition
! Do not forget to check your geometry!

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EXERCISE 5A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

File Name and Location
…\STUDENT-EXERCISE\2D\A_Translation_motion\4A_GeoMesh.FLU
Or restart from the file 4A_GeoMesh.FLU you saved in chapter 4
Objectives - Physics of the geometry

• Define a Magnetic physic
• Create a symmetry
• Create mechanical sets
• Create a material
• Create a source for electrical component
• Create and assign line regions
• Create and assign face regions
• Check the physic
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• Objectives - Physics of the geometry … continue
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STEPS 14-24
Step 14
a) Open the project: 4A_GeoMesh.FLU
b) Application
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STEPS 14-24
Step 15: Symmetry
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STEPS 14-24
Step 16: Create mechanical sets: stator and rotor
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STEPS 14-24
Step 17: Create materials
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STEPS 14-24
Step 18: Create a source (electric component and coil)
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STEPS 14-24
1
Step 19: Create line region
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STEPS 14-24
1 1
Step 20: Create face regions
2 2
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STEPS 14-24
Step 20: Create face regions 1
1
2
2
3 3
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STEPS 14-24
Step 20: Create face regions
1
2
3
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STEPS 14-24
Step 21: Assign line region
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STEPS 14-24
Step 22: Assign face regions
Note: The number of the selected faces may
differ from that in the pictures
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STEPS 14-24
Step 22: Assign face regions
Note: The number of the selected faces may
differ from that in the pictures
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STEPS 14-24
Step 23: Check physics
Step 24: Save project as: 5A_Physics.FLU

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EXERCISE 5B: EMBEDDED MAGNETS MOTOR PHYSICS CREATION

STEPS 9-15
…\STUDENT-EXERCISE\2D\B_2D_machines\4B_GeoMesh.FLU
Or restart from the file 4B_GeoMesh.FLU you saved in chapter 4

• Create ad Import a material
• Create face regions
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STEPS 9-15
• Objectives - Physics of the geometry … continue
• Motor Prius 2 (for hybrid electrical vehicule)
• Ratings
• Max bus voltage : 500 V
• Peak torque : 400 Nm
• Max speed : 6000 rpm
• Peak power rating : 50 kW at 1200-1500 rpm
• Motor characteristics
• 48 stator slots
• 3 phases wye connected
• 8 poles
• NdFeB magnet
• Lamination type M270-35A
• Outer diameter: 242 mm
• Stack length : 75 mm
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STEPS 9-15
Step 9
a) Open the project: 4B_GeoMesh.FLU
b) Application
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Altair Flux, v2019

STEPS 9-15
Step 10: Import and create material
104
Altair Flux, v2019

STEPS 9-15 1
105
Altair Flux, v2019

STEPS 9-15
Step 12: Face regions
a) Stator and rotor
106
Altair Flux, v2019

STEPS 9-15
a) Air gap region: the same principale, you select the regions and you edit array
107
Altair Flux, v2019

STEPS 9-15
a) Air gap region: the same principale, you select the regions and you edit array
108
Altair Flux, v2019

STEPS 9-15
b) Magnets, you select the regions and you edit array
109
Altair Flux, v2019

STEPS 9-15
c) Magnets, orientation of volume regions
110
Altair Flux, v2019

STEPS 9-15
Step 15: Save project: 5B_Physics.FLU
111
Altair Flux, v2019
EXERCISE 5C: EMBEDDED MAGNETS MOTOR WITH SKEW

STEPS 9-14
…\STUDENT-EXERCISE\Skew\4C_GeoMesh.FLU
Or restart from the file 4C_GeoMesh.FLU you saved in chapter 4

• Create face regions
112
Altair Flux, v2019

STEPS 9-14
Objectives - Physics of the geometry … continue
• Ratings
• Peak power rating: 50 kW at 1200-1500 rpm
• 48 stator slots
• 8 poles
• NdFeB magnet
113
Altair Flux, v2019

STEPS 9-14
Step 9
a) Open the project: 4B_GeoMesh.FLU
b) Application
114
Altair Flux, v2019

STEPS 9-14
115
Altair Flux, v2019

STEPS 9-14
1 2
116
Altair Flux, v2019

STEPS 9-14
a) Stator and rotor
117
Altair Flux, v2019

STEPS 9-14
b) Air gap region: the same principale, you select the regions and you edit array
118
Altair Flux, v2019

STEPS 9-14
c) Magnets, you select the regions and you edit array
119
Altair Flux, v2019

STEPS 9-14
d) Magnets, orientation of volume regions
120
Altair Flux, v2019

STEPS 9-14
Step 14: Save project: 5C_Physics.FLU

121
Altair Flux, v2019
EXERCISE 5D: SENSOR WHEEL PHYSICS CREATION

STEPS 23-30
…\STUDENT-EXERCISE\3D\D_Modeler_context\4D_GeoMesh.FLU
Or restart from the file 4D_GeoMesh.FLU you saved in chapter 4
WHEEL

• Create materials
• Create coordinate system COIL 1
PROBE 1
•
MAGNET 1
Create mechanical sets
COIL 2
• Create coil conductors components MAGNET 2
PROBE 2
• Create volume regions

• Create post processing sensors
122
Altair Flux, v2019

STEPS 23-30
• Studied device
• a variable reluctance speed sensor
• Functionality
• The rotation of the target wheel near the tip of the sensor changes the magnetic flux, creating an analog
voltage signal that can be recovered in probes.
• The device consists of WHEEL
• one cogged wheel with three teeth

• two probes with a magnet and a coil around
COIL 1
PROBE 1
MAGNET 1
COIL 2
PROBE 2
MAGNET 2
123
Altair Flux, v2019

STEPS 23-30
Step 23
a) Open project: 4D_GeoMesh.FLU
b) Application
124
Altair Flux, v2019

STEPS 23-30
Step 24: Create material
125
Altair Flux, v2019

STEPS 23-30
Step 25: Create mechanical sets
a) Fixed
b) Compressible
126
Altair Flux, v2019

STEPS 23-30
Step 25: Create mechanical sets
c) Rotation
127
Altair Flux, v2019

STEPS 23-30
Step 26: Create coil conductors components
128
Altair Flux, v2019

STEPS 23-30
Step 27: Volume regions
a) Create volume region
129
Altair Flux, v2019

STEPS 23-30
• Following the steps explained in slide bellow, you create the other volume regions
130
Altair Flux, v2019

STEPS 23-30
b) Assign volume regions to regions
131
Altair Flux, v2019

STEPS 23-30
b) Assign volume regions to regions
• Do the same thing with the other volume regions except the volume region infinite according to this picture
132
Altair Flux, v2019

STEPS 23-30
c) Orient material for volume region
133
Altair Flux, v2019

STEPS 23-30
c) Orient material for volume region
134
Altair Flux, v2019

STEPS 23-30
d) Orient wires (coil orientation)
135
Altair Flux, v2019

STEPS 23-30
d) Orient wires (coil orientation)
136
Altair Flux, v2019

STEPS 23-30
Step 28: Create post processing sensors
137
Altair Flux, v2019

STEPS 23-30
Step 30: Save project as: 5D_Physics.FLU

138
Altair Flux, v2019
EXERCISE 5E: EMBEDDED MAGNETS MOTOR PHYSIC CREATION

STEPS 8-16
…\STUDENT-EXERCISE\3D\E_3D_machines\4E_GeomMesh.FLU
Or restart from the file 4E_GeoMesh.FLU you saved in chapter 4

• Create non meshed coils
• Create an electric circuit
139
Altair Flux, v2019

STEPS 8-16
• Ratings
• Peak power rating: 50 kW at 1200-1500 rpm
• 48 stator slots
• 8 poles
• NdFeB magnet
140
Altair Flux, v2019

STEPS 8-16
Step 8
a) Open project: 4E_GeomMesh.FLU
b) Application
141
Altair Flux, v2019

STEPS 8-16
Step 9: Create non meshed coils
a) Load macro: “CreateNonMeshedCoilForRadialMotor.PFM”
142
Altair Flux, v2019

STEPS 8-16
b) Run macro: “CreateNonMeshedCoilForRadialMotor.PFM”
143
Altair Flux, v2019

STEPS 8-16
c) Load macro: “DuplicateNonMeshedCoils.PFM” and create two coordinate systems
144
Altair Flux, v2019

STEPS 8-16
d) Create two coordinate systems
145
Altair Flux, v2019

STEPS 8-16
e) Run macro: “DuplicateNonMeshedCoils.PFM”
146
Altair Flux, v2019

STEPS 8-16
147
Altair Flux, v2019

STEPS 8-16
148
Altair Flux, v2019

STEPS 8-16
a) Stator and rotor
149
Altair Flux, v2019

STEPS 8-16
b) Air gap region: the same principale, you select the regions and you edit array
150
Altair Flux, v2019

STEPS 8-16
c) Magnets, you select the regions and you edit array
151
Altair Flux, v2019

STEPS 8-16
d) Magnets, orientation of volume regions
152
Altair Flux, v2019

STEPS 8-16
Step 13: Electric circuit
a) Creation of electric circuit: select the components (Resistors and Coil conductors) and link them with the pen
b) Leave the circuit context
Use the pen to link
Leave the circuit context Select components the components
153
Altair Flux, v2019

STEPS 8-16
c) Edit array for Resistors and Coil conductors
Resistors
Coil conductors
154
Altair Flux, v2019

STEPS 8-16
d) Delete of electric circuit component
155
Altair Flux, v2019

STEPS 8-16
a) Coils
156
Altair Flux, v2019

STEPS 8-16
Step 16: Save project as: 4E_Physics.FLU

157
Altair Flux, v2019
EXERCISE 5F: AXIAL FLUX MOTOR GEOMETRY PHYSICS

STEPS 15-20
old
…\STUDENT-EXERCISE\Import\4F_GeoMesh.FLU
Or restart from the file 4F_GeoMesh.FLU you saved in chapter 4
Objectives - Flux 3D Project physics

158
Altair Flux, v2019

STEPS 15-20
old
Objectives - Flux 3D Project physics … continue
• External diameter: 100 mm

• Length: 38.5 mm
• Power rating: 1 kW
• Operating speed: 1000 rpm
• Rated torque: 1.1 N.m
159
Altair Flux, v2019

STEPS 15-20
new
File Name and Location Characteristics
…\STUDENT- • External diameter: 100 mm
EXERCISE\Import\4F_GeoMesh.FLU • Length: 38.5 mm
Or restart from the file 4F_GeoMesh.FLU you • Power rating: 1 kW
saved in chapter 4
• Operating speed: 1000 rpm
• Rated torque: 1.1 N.m
Objectives - Flux 3D Project physics
160
Altair Flux, v2019

STEPS 15-20
Step 15
a) Open project: 4F_GeoMesh.FLU
b) Application
161
Altair Flux, v2019

STEPS 15-20
1 2 3
162
Altair Flux, v2019

STEPS 15-20
2 3
163
Altair Flux, v2019

STEPS 15-20
164
Altair Flux, v2019

STEPS 15-20
b) Create volume region
• Following the steps explained in slide bellow, you create the other volume regions
Region name Type Material Mechanical set
Stator Magnetic non conducting region Iron Stator
Rotor Magnetic non-conducting region Iron Rotor
Stator_air Air or vaccum region // Stator
Rotor_air Air or vaccum region // Rotor

Magnet_plus Magnetic non-conducting region Magnet_plus Rotor
Magnet_minus Magnetic non-conducting region Magnet_minus Rotor
165
Altair Flux, v2019

STEPS 15-20
c) Assign volume regions to regions
166
Altair Flux, v2019

STEPS 15-20
Yellow color means the select volume
d) Assign volume regions to regions
167
Altair Flux, v2019

STEPS 15-20
e) Magnets, orientation of volume regions
168
Altair Flux, v2019

STEPS 15-20
f) Change color of volume regions
Select volume region: ctrl+mouse
169
Altair Flux, v2019

STEPS 15-20
Step 20: Save project as: 5F_Physics.FLU

170
ANNEX
CONNECTIVITY PROBLEMS
171
Altair Flux, v2019
ANNEX - CONNECTIVITY PROBLEMS (3D)

• What is a connectivity problem?
• The coupling between the different potentials (formulations) sometimes forbidden since the
hypotheses allowing this coupling are no longer valid
• This problem occurs with non-simply connected objects
• There are two types of connectivity problems
• Magnetic connectivity problem

• In case of a closed magnetic circuit
• Electric connectivity problem

• In case of a closed electric loop
172
Altair Flux, v2019

• Notion of connected space:
• A geometrical object is called “connected” if it consists of
a simple object (i.e. object as being an object that's all one piece)
Connected space Non-connected space

(one object) (two objects)
• Notion of simply connected space:

• A geometrical object is called “simply connected” if it consists of
one piece and doesn't have any circle-shaped "holes" or "handles".
Simply connected Non-simply connected

space space
173
Altair Flux, v2019

• What is a cut?
• A cut permits to transform a non-simply connected object in a simply connected one
Introduction Do not introduce a third cut, the

of a cut Introduction object would become non-
of 2 cuts connected
174
Altair Flux, v2019

• Magnetic connectivity problem:
• In case of a closed magnetic circuit with a current supply (I) it is necessary to introduce a magnetic
circuit cut
H
Magnetic
region
(permeability )
Magnetic
I circuit cut
175
Altair Flux, v2019

• Electric connectivity problem
• In case of closed electric loop with induced current (J) it is necessary to introduce an electric loop cut
Solid conductor
region
(resistivity )
J
Electric
loop cut
176
Altair Flux, v2019

• In case of models with symmetries or periodicities it is not necessary to introduce cuts
• Example:
177
ANNEX
SKEW
178
Altair Flux, v2019
WHAT IS « SKEW » ?
• 2D multilayers calculation • 3D claculation
• 3D postprocessing • 3D postprocessing
• Border Effect are not taken into account (End • Border effect are taken into account (end
winding ...etc) windings …etc)
• Calculations time are reasonable in comparison • Calculations time are relativly long in comparison
to the 3D to the Skew
179
Altair Flux, v2019
SKEWED SLOTS - GENERAL PRESENTATION

• Interest in skewed slots
• Historically , skewed slot rotor was used in order to provide a starting torque for motors having the
same number of slots.
• Minimize some drawbacks:
• Torque pulsations,
• Supplementary losses,
• Harmonics (of torque or current)
• Skewed slots modeling 2D, 3D or 21/2?

• 2D usually enough for motors (except for skewed model)
• 3D more precise results but remains costly in term of software resources
• For skewed slots, need of new model with multilayers
(21/2 dimension)
180
Altair Flux, v2019
SKEWED SLOTS - WHAT FLUX MODELS

• Principle of the method MAGNET_1
STAT_FER
FIXE_AIR
ROT_AIR
• Quasi 3D computation
• 3D aspects taken into account in the thickness of the ROT_FER
motor MAGNET_2
• Edge effect on one edge and the other is not modeled
• Principle of proposed methods

Skew calculation 3D calculation
181
Altair Flux, v2019
SKEWED SLOTS - WHAT FLUX MODELS

• Principle of the multilayers 2D method
Layer no. Shaft

• Starting process is a 2D description of the motor
• Results analysis in the postprocessing is made in 3D
5
Skew
4 slot
Phase Description 3
1 Construction by propagation of an assembly of n layers 2
starting from the base faces (2D description of the
1
machine):
• by translation for the right part
• by helicoidal transformation for the skewed part
2 2D computation on the set of layers (all together)
3 Computation by integration on the set of layers of all
postprocessed global quantities (torque, energy, …)
182
Altair Flux, v2019
SKEWED SLOTS - DESCRIPTION PRINCIPLE IN FLUX

• Specificity of the module
• Select an application
• Rotating machine (helicoidal) in magneto static rotation
angle
• Rotating machine (helicoidal) in AC steady state magnetic
• Rotating machine (helicoidal) in transient magnetic
• Specific data
• Multilayers or extruded 3D
• Choice of skewed part: rotor or stator
• Geometrical characteristics of the skewed slots
• Number of layers
• Rotation angle
183
Altair Flux, v2019
SKEWED SLOTS - DESCRIPTION PRINCIPLE IN FLUX

• Circuit coupling
• Reminder: automatic management of symmetries and periodicities
• Coil coefficient associated to the application
• Describe the entire electrical circuit
• Specific coefficients on coils and solid conductor
• Warning
• To keep the description of circuit as in previous version, select 1 as imposed coil coefficient by the user
184
Altair Flux, v2019
QUESTIONS & ANSWERS
185

5 Physic Magnetic-Altair Flux

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ALTAIR FLUX 2019

CH5 - MAGNETIC APPLICATION

CHAPTER 5 - MAGNETIC APPLICATION

• Mechanical sets (Kinematics) • Lines and points

• Electric circuit • Solid conductors

• Components • Meshed and not meshed coils

• Building process • Exercises 5A, 5B, 5C, 5D, 5E, 5F

PHYSICS – MAGNETIC APPLICATION

Mechanical set Rotor

Do not forget cuts when needed!

Flux Application Magnetic sources … Application example…

Magneto Stationary currents

An electric circuit is necessary to simulate the current !

The movement must be modelled!

• Specially relevant when they are attached to the domain definition

BOUNDARY CONDITIONS – DOMAIN DEFINITION

• Three different ways to create materials (in the Flux project)

A modification of the material properties in material manager (respectively in the Flux

Law of… Medium Medium property

Law of… Medium Medium property

MATERIALS – MAGNETIC PROPERTIES

MATERIALS – MAGNETIC PROPERTIES

• The user must create the B(H) curve by the command:

MATERIALS – MAGNETIC PROPERTIES

• Linear magnet described by the Br module

MATERIALS – ELECTRICAL PROPERTIES

• Type of electrical property J(E)

• Type of electrical property J(E, T)

MATERIALS – VOLUME MASS

MECHANICAL SET - KINEMATICS

• Mechanical set options allows the simulation of moving parts

• Under different moving conditions

MECHANICAL SET - KINEMATICS

MECHANICAL SET - KINEMATICS

Sliding line/ Compressible

MECHANICAL SET – KINEMATICS TECHNIQUES

Moving mechanical set

Compressible mechanical set

MECHANICAL SET – RE-MESHING TECHNIQUE

MECHANICAL SET – SLIDING MOTION TECHNIQUE

MECHANICAL SET – SLIDING MOTION TECHNIQUE

Half of air gap

DEFINING A MECHANICAL SET

MECHANICAL SET – ROTATION DEFINITION

Type of mechanical set

MECHANICAL SET – TRANSLATION DEFINITION

Type of mechanical set

MECHANICAL SET – DEFINITION

MECHANICAL SET – DEFINITION

MECHANICAL SET – DEFINITION

MECHANICAL SET – DEFINING THE FREE MOTION

ELECTRIC CIRCUIT - GENERAL CONCEPTS

ELECTRIC CIRCUIT – GENERAL CONCEPTS

• Define link between FEM and electrical circuit

ELECTRIC CIRCUIT – CIRCUIT COMPONENTS

ELECTRIC CIRCUIT – CIRCUIT COMPONENTS

ELECTRIC CIRCUIT – CIRCUIT COMPONENTS

• Coupled with FE simulation (see section “Sources”)

They must be linked to a source of the

ELECTRIC CIRCUIT – CIRCUIT COMPONENTS

Switches (only transient application)

ELECTRIC CIRCUIT – CIRCUIT COMPONENTS

Diodes (only transient application)