Applied research in computer-aided design & optimization of electrical machines 30--03-2022

OPTIMIZATION OF LARGE INDUSTRIAL ELECTROMAGNETS WITH

SOURCE CODES

Abstract:
A magnetic separator is a large equipment employed in various industries for the separation of iron pieces from
coal/cement/sugar plants etc. The electrical rating varies from a few kW to about 25 kW. The tramp iron weighs
from 20 grams to 50 kg. The shape of tramp iron could be sphere, nut, cube, rod, or irregular piece, I have yet to
come across a book covering properly this equipment.

With my involvement in the installation, testing, and commissioning of large turnkey projects, I have adequate
knowledge of the equipment. There is one standard VDE 0580, 2011 which covers some aspects of magnets. The
customers & consultants have drawn the specifications for the magnetic equipment.

The key function of the magnetic separator is to lift & / or discharge the tramp piece into the iron chute. The
key parameters for measurement are gauss, current, temperature rise of coil, oil, & body, etc.

Based on various specifications, a comprehensive example has been prepared for the inline magnetic separator
(ILMS). The key design parameters that have been included with full source code in FORTRAN-77 will help in a
proper understanding of the subject. It will save time in the search of data.

FORTRAN-77 can easily be RUN on windows 10 with “g77” compilers, which are available free of cost.

Keywords:
Magnetic separator, gauss, force index, temperature rise, tramp iron, lifting &/ or discharging of the tramp,
optimization of force index, & overall dimensions of the equipment, Powell-Zangwill (PZ) algorithm, source code
of PZ technique [1,3,4]

In continuation of my earlier articles on “Design of DC Machines (Part-1,2, & 3)”, Design &
optimization of induction motors”, & “Design & optimization of power transformers”, “design &
optimization of synchronous machines”, now I wish to focus on the electromagnets. Following
materials are included:

 Block diagram showing utilizing of files

 Abbreviations & variables used in PZ program & in formulae used for design
 List of inputs used for the design of machines
 Excel sheet - Calculations of 24 kW, 250 VDC, inline magnetic separator [ 15]
 File MAGNET1.FOR contains design example in line with excel sheet file.
Subsequently, It will be converted as a subroutine PZEM0SUB.FOR
 Excel sheet format includes feasible & optimized values etc.
 PZ_EM0.FOR is the main file & contains PZ technique code
 PZEM0SUB.FOR is a subroutine file that contains design formulae
 PZ_EM0.IN contains inputs for main code and feasible values of design
 PZ_EM0.OP is showing some portion of the output
I refer BLOCK diagram, where key files have been shown. Two files “PZ_EM0.FOR &
PZEM0SUB.FOR” can individually be compiled and then linked with one command both files
can be linked at a time to create PZ_EM0.EXE.
Now, an excel sheet (table) can be seen whether any violation has taken place. Readers can
change several variables and/or constraints as they desire.
====================================================================
Applied research in computer-aided design & optimization of electrical machines 30--03-2022

Note:
All the programs have been written in FORTRAN-77. We can RUN easily FORTRAN-77 in XP. Suppose we have
to run this program in WINDOW 10, we have to download the “g77” compiler which is compatible with 64-bit
software. We have to use the command as >>gfortran -o (output file name) (input file name) (input file name), it
creates one EXE file.

>> gfortran -o PZ_EM0 PZ_EM0.FOR. PZEM0SUB.FOR … creates PZ_EM0.EXE

Now we can RUN the program from prompt.

Working example: 24 kW 250 VDC, having force index (hot) => 105 at operating height of
450 mm, inline magnetic separator, oil-filled with natural cooling & fitted with radiators [15].
The detailed design of magnetic separators will have about 20 subroutines. It will be dealt with
separately.
===================================================================================

Users have to acquire a working knowledge of FORTRAN-77 & how to do optimization.

To avoid the search of source code & detailed examples, I have taken care of both aspects. I
hope a comprehensive example with full code will help all practicing engineers and
designers.
You may explore using an f2c converter for obtaining the code in C language.
Recently, MATLAB has included a global optimization toolbox. It contains genetic
algorithms (GA), pattern search method (PS), particle swarm optimization method (PSO),
simulated annealing (SA), etc. These methods are focusing to find global solutions.
I refer to the book (5), chapter-9 on “intelligent optimization methods”. It covers many methods
following the law of “survival of the fittest”. GAs are more likely to find global optimum points
than the traditional conventional methods.
I will certainly correct all typographical, & technical errors in due course of time.
Thanks for attention

Nanak T. Dadlani
nanak.dadlani@gmail.com
INDIA
P.S:
Minor technical & typographical errors have been corrected on 30-03-2022.
Applied research in computer-aided design & optimization of electrical machines 30--03-2022

REFERENCES:
1) Optimization techniques with FORTRAN, J. L. Kuester & J. H. Mize, McGraw Hill, 1973
(page 331)
2) The performance and design of DC machines, A.E. Clayton & N.N. Hancock, third
edition, 2015
3) Computer-Aided Design of Electrical Equipments, Dr. M. Ramamoorthy, 1987
4) Design of Electromagnetic Devices, Dr. K.S.Ramarao, Ph.D (thesis), IIT Kanpur, 1977
5) Solving optimization problems with MATLAB, D. Xue, 2020
6) Applied optimization with MATLAB programming, P. Venkataraman, 2001
7) Performance and Design of AC machines, M.G.Say, 1970
8) Principles of Electrical Machine Design, H.M. Rai, 1992
9) Principles, operation, design of power transformers, S.B. Vasutinsky, 1962
10) A course in electrical machine design, A.K.Sawhney
11) Induction machines, P.L. Alger,1970
12) Design, operation & testing of synchronous machines, G.C. Jain, 1962
13) Electrical machines (I & II), M. Kostenco & L. Piotrovsky, MOSCOW
14) Eddy currents, J. Lammeraner & M. Stafl, 1966
15) VD 0580, 2011
Symbols for electromagnet: Optimisation
A ALPHA, AMB, AMPS, AC, AY, AP 6

B BLKDEN, BLTSP, BLTWID, BLTSP1, BURDEP2, BD, BCORE, BYOKE, BPOLE 9

C COREMAX, COEFFT, CNI, CONA, CONTHK, CONWID, CDIA, COREHT, 21

COILOD, COILVOL, COST1-COST9, COST20, COST60

D DELTA, DF1, DF2, DW, DCR, DUCTS, DMEAN, DPERI, DF11 8

E EFF1, EP 2

F FI0, FINAREA, FRMS, FI1, F1-F4, F6-F7, FORCE1-FORCE4 14

G GAUSS0, GAUSS1, GAUSS_SUR, GAUSS2, G1-G3 7

H HH1, HH2, HR1, HR2, HNI, HYP1, HYP2, HDISS 8

I ICOLD, IHOT 2

K KJ, K1, KK, K3, K4 5

L LUMP, LL1, LL2, LYRS, LMT, LENCOND 6

M MAGTYP$, MU, MLMIN, MW, ML, MH, MAGGAP, MOTORKW1, MOTORKW2 11

MAGVOL, MAGWT

N NFINS 1

O OH, OH1, OHSURF 3

P PULOAD, PL, PIE, PRL, PBD, POWER, PCOLD, PHOT, PHIC, PHIY, PHIP, POT 12

R RESERVE2, RESERVE1, RATIO1, RMEAN, RCOLD, RHOT, RADAREA, 8

RATIO2
S SPGR, SP1, SP2, SP3, SPGR1, SA, SIZE, SP 8

T TPH, TISIZE, TISHAPE$, THETA1, THETA2, TRK, TIME1, TRK1, TURNS, 16

TIW1 TO TIW7

U UC1, UC2, UC20, UC3, UC4, UC5, UC6, UC60, UC7, UC8, UC9 11

V VOID, VDC 2

W WD, WW1, WW2, WT1-WT7, 10

170
Note: Compare symbols with PZ / BOX / GOLDEN / SUMT method.
 OPTIMISATION OF ELECTROMAGNET: ILMS, OIL-FILLED
29-03-2022
S.No. Symbol Formula Value Unit
Input:
A Main conveyor details:
1 TPH Rated capacity 1200 tph
2 BLKDEN Bulk density 0.96 kg/m3
3 BLTSP Belt speed 2.819 mps
4 BLTWID Belt width 1400 mm
5 VOID Void factor 0.6 pu
6 ALPHA Troughing anglle 35 degree
7 LUMP Maximum lump size -300 mm
B Specifications:
2
8 FI0 Force Index at OH in stabilised hot condition (min.) 100000 G /inch constraint
9 GAUSS0 Gauss at OH in stabilised hot condition (min.) 1000 Gauss constraint
10 OH Operating height 450 mm
11 KJ Constant 1.65 pu
12 MAGTYP$ ILMS at discharge pulley (Oil-cooled) ILMS
13 TISIZE 25 mm 25 mm
14 TISHAPE$ Sphere Sphere
15 THETA1 Specified temperature rise of conductor 85 deg.C constraint
16 THETA2 Specified temperature rise of oil 50 degree.C
17 AMB AMB…ambient temperature 50 deg.C
18 LL1 Length of irregular tramp 600 mm
19 WW1 Width of irregular tramp 125 mm
20 HH1 Height of irregular tramp 125 mm
21 LL2 Length of regular tramp 250 mm
22 WW2 Width of regular tramp 250 mm
23 HH2 Height of regular tramp 100 mm
C Constants & Constraints:
24 PULOAD per unit load 1 pu
25 PL iteration limit for tramp location in burden 1.05 pu
26 COEFFT Resistivity of AL conductor @ 20 degree C 0.028
27 SPGR Density of material 'AL' 2703 kg/m3
28 TRK Temperature coefficient …Not used 2.089
29 TRK1 Temperature rise coefficient for aluminium 0.004
30 PIE Constant 3.142857
31 WD Width of duct 10.0 mm
2
32 DF1 DF1..dissipation factor for magnet body 13 w/ m /deg.C Design variable
2
33 DF2 DF2..dissipation factor for radiators 7.8 w/ m /deg.C Design variable
2
34 FINarea FINarea=FINwid * FINht = 0.3*0.9 = 0.27 sq.m 0.27 m
35 SP1 SP1..specific heat of aluminium 830 J / kg-deg.C
36 SP2 SP2..specific heat of steel body (except core) 480 J / kg-deg.C
37 SP3 SP3..specific heat of oil 1750 J / kg-deg.C
38 HR1 HR1…one hour time lapsed after energisation 1 hour
39 HR2 HR2…two hours time lapsed after energisation 2 hour
40 UC1 Unit cost of poles (yoke & 2-end poles) 18 Rs/kg base year 1980
41 UC2 Unit cost of CAST STEEL core 42 Rs/kg
42 UC20 Unit cost of CRGO core …not used 70 Rs/kg
43 UC3 Unit cost of side covers 50 Rs/kg
44 UC4 Unit cost of coil holding plate 18 Rs/kg
45 UC5 Unit cost of bumping plates (ss) 72 Rs/kg
46 UC6 Unit cost of AL conductor 180 Rs/kg
47 UC60 Unit cost of CU conductor …not used 200 Rs/kg
48 UC7 Unit cost of mineral oil 25.0 Rs/kg
49 UC8 Unit cost of insulating material (7.5% of cond.cost) 0.075 Rs
50 UC9 Unit cost of electric panel 6.6 Rs/VA
51 spgr1 Density of oil 856 kg/m3
D Assume:
52 COREMAX Maximum core height =HNI/100 …Not used 4000 mm
2
53 DELTA (cold) Current density of coil winding 0.85 amp/mm design variable
54 TIME1 Strike time / travel time of tramp from belt to magnet 0.6 sec
55 Reserve2 Reserve2.. 35% reserve surface area
to be considered for radiators to ensure heat 1.35 pu
dissipating capacity is more than hot power.
56 Reserve1 Reserve1 = additional 10% oil quantity fo tank etc. 1.1 pu
57 MU Friction factor between pulley & ILMS belt 0.6 pu
58 EFF1 Efficiency of gear box 0.75 pu
59 POT Pull out-torque ratio of motor at 100% voltage 2.5 pu
60 TURNS Total no.of turns 2800 nos. design variable
61 TPL Turns per layer per former 1 no.
62 FRMS Number of formers 8 nos.
63 PRL Number of parallel paths for coils 1 no.
64 K1 Clearance between coil top to yoke 10 mm
KK Constant for sphere …present case 950 pu
KK Constant for cube 850 pu
KK Constant for nut 750 pu
KK Constant for rod L/D<=5 650 pu
KK Constant for irregular piece L*W*H 500 pu
65 RATIO1 Conwid/Conthk (Present 105:1) 105 pu Design variable
E Output:
E-1 Calculations for burden depth:
1 BURDEP2 BURDEP2=(TPH*494)/[(BLKDEN*BLTSP*(BLTWID/3)* 286.6 mm
2*COS(ALPHA*PIE/180)]
2 BD IF (BURDEP2>50) THEN BD=50 50 mm design var
E-2 Calculation of Gauss to remove tramp from burden:
3 OH1 OH1=OH-BD 400
4 PBD PBD=(BD/25.4)*PULOAD 1.97 inch PBD = {(BD/25.4)-EBD}*PULOAD
5 GAUSS1 GAUSS1=KK+330*(BLKDEN/1.6)*(BD/100)*PBD 1144.88 Gauss
Choose KK as per shape
6 HNI HNI=(3*796*KJ*OH*GAUSS1) / 10^4 202998 nos. DW1 = (HNI/0.79)*(1/MW)
2
7 FI1 FI1=((HNI*10^4)/(2*796*KJ))^2*{(0.45*OH+197)/ 101085 G /inch
(9*OH^2-10^4)}*(3*OH*0.9646)^ -1
E-3 Coil design
8 CNI CNI=HNI*1.46 …For 115 degree C rise. 296377 nos.
9 AMPS AMPS=CNI/TURNS 105.85 amp
2
10 CONA CONA=AMPS/DELTA 124.53 mm constraint
11 CONTHK CONTHK=SQRT(CONA/RATIO1) 1.09 mm ratio1 is used
12 CONWID CONWID=RATIO1*CONTHK 114.35 mm
13 LYRS LYRS=INT(TURNS/(TPL*FRMS*PRL)) 350 nos.
14 DW DW=LYRS*(CONTHK+0.3) 486 mm
15 CDIA CDIA=1.05*2*SQRT(HNI/(0.79*PIE)) 600 mm design var
16 COREHT COREHT=(CONWID+0.3)*TPL*FRMS*PRL 917.18 mm
17 LMT LMT=PIE*(CDIA+DW) 3415.11 mm
18 LENCOND LENCOND=LMT*TURNS/1000 9562.32 m
19 DCR DCR=COEFFT*LENCOND/CONA 2.15 ohm
20 VDC VDC=AMPS*DCR 227.58 volt constraint
21 POWER POWER=AMPS^2*DCR 24089.4 watt
22 DUCTS DUCTS=INT(COREHT/100) 9.00 nos.
23 COILOD COILOD=CDIA+2*DW+DUCTS*WD 1662.79 mm
24 DMEAN DMEAN=(COILOD-CDIA-20) 1042.32 mm
25 RMEAN RMEAN=DMEAN/2 521.16 mm Rmean / OH
26 DPERI DPERI=PIE*DMEAN 3275.86 mm
27 HYP1 HYP1=SQRT(RMEAN^2+OH^2) 688.55 mm
Check: Gauss at any operating height by changing OH, as below.
28 Goh (K3) Goh=(RMEAN^2/HYP1^3)*10^4 …constant 8.32
 29 OHSURF OHSURF..Operating height upto surface=0 0.00 mm
30 HYP2 HYP2=SQRT(RMEAN^2+OHSURF^2) 521.16 mm
31 Gtest (K4) Gtest=(RMEAN^2/HYP2^3)*10^4 …constant 19.188
32 GAUSS_SUR GAUSS_SUR= (Gtest/Goh)*GAUSS1 2640.36 G
Check: Ratio of (RMEAN to OH) …Lies in 0.9-1.3 1.158 pu RATIO2
33 Rcold Rcold=DCR…calculated earlier 2.150 ohm
34 Rhot Rhot=Rcold*(1+TRK1*THETA1) 2.881 ohm
35 Icold Icold=AMPS …calculated earlier 105.85 amp
36 Ihot Ihot=Icold/(1+TRK1*THETA1) 78.99 amp
37 Pcold Pcold=POWER …calculated earlier 24089.42 watt
38
Phot Phot=Ihot2*Rhot 17977.18 watt
E-4 Magnet body dimensions:
SP Each Side Pole 37.53 mm newly added
CLR Clearance between COIL OD & inner side of side pole 130.00 mm newly added
39 MW MW = CDIA+2*DF+2*CLR+2*SP 1908 mm constraint
Deleted
DF11 DF11 = (HNI/(0.79*MW)) 135 mm newly added
EP each End Pole 75.06 MM newly added
40 ML ML = CDIA+2*DF11+2*OH+2*EP 1920 mm constraint
Deleted
41 BLTSP1 BLTSP1=ML/(TIME1*1000) 3.180 mps
42 THK1 THK1= CDIA/4 …yoke thickness 150.12 mm
43 THK2 THK2= CDIA/8 …end-pole thickness 75.06 mm
44 THK3 THK3= CDIA/16 …side-pole thickness 37.53 mm
45 THK4 THK4= CDIA/32 …ch plate thickness 18.76 mm
46 THK5 THK5= CDIA/64 …bumping plate thickness 9.38 mm
47 MH MH=COREHT+(THK1+THK4+THK5)+K1 1105.45 mm constraint

Check Gauss with MAGGAP:

48 MAGGAP MAGGAP=OH 450.0 mm
49 GAUSS2 GAUSS2=(HNI*10^4)/(796*KJ*(2*OH+MAGGAP)) 1144.88 Gauss
Note: Due to less MAGGAP, gauss improves but sufficient volume for oil
may not be available.

50 MAGGAP MAGGAP=OH 450 mm REFER 48

51 SA Magnet surface area excluding top & bottom area
2
SA=2*[mh*ml+mw*ml) / 10 6 11.57 m
E-5 Radiator design: RADIATOR
2
52 RADarea Radiator area to be provided 42.94 m
RADarea= (1.35*Phot - SA*DF1*THETA2)/
(DF2*THETA2)
53 Hdiss Hdiss..heat dissipated by body & radiators
Hdiss=SA.DF1.THETA2+RADAREA.DF2.THETA2 =1.35*Phot 24269.19 watt
54 Nfins Nfins…No. of fins = INT(RADarea/FINarea) 159.00 nos.
E-6 Weights of various shapes of tramp iron: TI WT
55 SIZE SIZE=TISIZE …Input 25 mm
GAUSS1 GAUSS1 …as calculated earlier 1145 Gauss
56 TIW1 Ball: TIW1= (4*size 3*0.98) / 10 6 0.0613 kg Renamed
57 TIW2 Cube: TIW2= (TIW1 / 0.507) 0.1208 kg Renamed
58 TIW3 Nut: TIW3= (size/2)*size*3.14*(size+size/2)*6*0.657/10 6 0.1451 kg Renamed
59 TIW4 Rod: TIW4=(size 2 *0.7854 *5 *size* 8) / 10 6 0.4909 kg Renamed
60 TIW5 Irregular: TIW5= (size*size*5*size* 7.98) / 10 6 0.6234 kg Renamed
61 TIW6 TIW6=(LL1*WW1*HH1*7860)/10 9 73.69 kg Renamed
62 TIW7 TIW7=(LL2*WW2*HH2*7860)/10 9 49.13 kg Renamed
E-7 Lifting force on various shapes of tramp iron: TI FORCE
2 2 10
63 F1 Ball: F1=[(22/7)*size *gauss1 *0.55*(size/90)^0.5] / 10 0.0746 kg gauss1 = 1144
64 F2 Cube: F2= (gauss1 2*size2*4) / 10 10 0.3277 kg
65 F3 Nut: F3=(F1*28) / (22*0.65) 0.1461 kg
 66 F4 Rod: F4= (size*5*size*4* 0.01)*(gauss1/10 4)2 1.638 kg
67 F6 Irregular: F6=(gauss1 2*4*LL1*WW1)/10 10 39.323 kg
68 F7 Regular: F7=(gauss1 2*4*LL2*WW2)/10 10 32.769 kg
70 MOTORKW1 8.158 kw
2
MOTORKW1 =[{F6*BLTSP1)/75}*MU*0.736]/(EFF1*0.8 )

71 FORCE2 FORCE2=F7 at surface=GAUSS_SUR^2*4*LL2*WW2 / 10^10 174.29 kg gauss_surf=2640

72 MOTORKW2 6.798 kw
2
MOTORKW2=[{F7*BLTSP1)/75}*MU*0.736]/(EFF1*0.8 )

E-9 Weights of active material in magnetic separator: MAGWT

73 WT1 Weight of poles (yoke & 2 end poles)
WT1=[mw*thk1*ml+2*mh*thk2*ml]*10 -9*7860 6826 kg
74 WT2 Weight of core
WT2=[(pie/4)*cdia 2*coreht]* 10-9* 7860 2040 kg
75 WT3 Weight of side poles / covers
WT3=(2*mh*thk3*ml)* 10 -9 *7860 1252 kg
76 WT4 Weight of coil holding plate
WT4=(mw*ml*thk4)*10 -9*7860 540 kg
77 WT5 Weight of bumping plate (SS)
WT5=(mw*ml*thk5)*10 -9*7860 270 kg
78 WT6 Weight of conductors
WT6=CONA^2*DCR/10 3334 kg
79 Weight of oil:
79.1 magvol magvol=(mw*ml*mh)/10 9 4.049 m3
79.2 coilvol coilvol=[(pie/4)*coilod 2*coreht] /10 9 1.991 m3
79.3 WT7 WT7=reserve1*spgr1*(magvol-coilvol) 1938 kg
80 MAGWT MAGWT=WT1+WT2+WT3+WT4+WT5+WT6+WT7 16202 kg
E-10 Thermal time constant: TH CONS
81 G1 G1=Weight of active material (AL)=WT6 3334 kg
82 G2 G2=Weight of steel parts=WT1+WT3+WT4 8619 kg
83 G3 G3=Weight of oil=WT7 1938 kg
2
84 TSA TSA=SA+RADAREA …total cooling area 54.51 m
85 TOU TOU..thermal time constant:
TOU=[(G1.SP1+G2.SP2+G3.SP3)/(DFACTOR1*TSA)]/3600 4.04 hours
86 TMAX TMAX=THETA1+AMB …maximum temp.(permissible) 135.00 deg.C 50+85 =135
87 TH1 TH1=temperature rise after one hour of heat run
TH1=TMAX*(1-EXP (-HR1/TOU)) 29.63 deg.C
88 TH2 TH2=temperature rise after two hours of heat run
TH2=TMAX*(1-EXP (-HR2/TOU)) 52.75 deg.C
E-11 Cost of active material: COST
89 COST1 COST1=WT1*UC1 122873 Rs
90 COST2 COST2=WT2*UC2 …used 85699 Rs
91 COST20 COST20=WT2*UC20 ….Not used. 0 Rs
92 COST3 COST3=WT3*UC3 62607 Rs
93 COST4 COST4=WT4*UC4 9725 Rs
94 COST5 COST5=WT5*UC5 19449 Rs
95 COST6 COST6=WT6*UC6 …used 600152 Rs
96 COST60 COST60=WT6*UC6 …Not used 0 Rs
97 COST7 COST7=WT7*UC7 48458 Rs
98 COST8 COST8=0.075*COST6 45011 Rs
99 COST9 COST9=POWER*UC9 158990 Rs
100 TC TC=COST1+…..+COST9 1152964 Rs

"# 39, 40, 48, 52, 53 Modified on 29-03-2022

weight & cost also changes.
C magnet1.for (24 kw, 250V DC)...pzem0sub.for
C FILE FOR OPTIMISATION OF ELECTRO-MAGNET..PZ METHOD
C
REAL ICOLD,IHOT
REAL KJ,K1,K3,K4,KK
REAL LUMP,LL1,LL2,LYRS,LMT,LENCOND
REAL MAGTYP,MU,MW,ML,MH,MAGGAP,MOTORKW1,MOTORKW2
REAL MAGVOL,MAGWT
REAL NFINS
C
NI=50
NO=66
OPEN(UNIT=50,FILE='MAGNET1.IN')
OPEN(UNIT=66,FILE='MAGNET1.OP')
C INPUTS: 7+16+28+14=65
C BELT CONVEYOR DETAILS: 7
READ (NI,*) TPH,BLKDEN,BLTSP,BLTWID,VOID,ALPHA,LUMP
C SPECIFICATIONS: 16
READ (NI,*) FI0,GAUSS0,OH,KJ,MAGTYP,TISIZE,TISHAPE
READ (NI,*) THETA1,THETA2,AMB,LL1,WW1,HH1,LL2,WW2,HH2
C CONSTANTS & CONSTRAINTS: 28
READ (NI,*) PULOAD,PL,COEFFT,SPGR,TRK,TRK1
READ (NI,*) PIE,WD,DF1,DF2,FINAREA,SP1,SP2,SP3,HR1
READ (NI,*) HR2,UC1,UC2,UC20
READ (NI,*) UC3,UC4,UC5,UC6,UC60,UC7,UC8,UC9,SPGR1
C ASSUMPTION: 14
READ (NI,*) COREMAX,DELTA,TIME1
READ (NI,*) RESERV2,RESERV1,MU,EFF1,POT
READ (NI,*) TURNS,TPL,FRMS,PRL
READ (NI,*) K1,RATIO1
C 1.Calculation of burden depth:
C ******************************
IF (ALPHA.EQ.0.0) THEN
BURDEP2=(TPH*494.)/(BLKDEN*BLTSP*BLTWID)
GO TO 20
ENDIF
BURDEP2=(TPH*494.)/(BLKDEN*BLTSP*(BLTWID/3.)*
1 2.*COS(ALPHA*PIE/180.))
20 BD=BURDEP2
IF (BD.GT.50.) THEN
BD=50.
ENDIF
C 2.Calculation of gauss to remove tramp iron from burden:
C ********************************************************
OH1=OH-BD
PBD=(BD/25.4)*PULOAD
C
IF (TISHAPE.EQ.1) KK=950.
IF (TISHAPE.EQ.2) KK=850.
IF (TISHAPE.EQ.3) KK=750.
 IF (TISHAPE.EQ.4) KK=650.
IF (TISHAPE.EQ.5) KK=500.
C
GAUSS1=KK+330.*(BLKDEN/1.6)*(BD/100.)*PBD
C
HNI=(3.*796.*KJ*OH*GAUSS1)/10**4
FI1=((HNI*10**4)/(2.*796.*KJ))**2*
1 ((0.45*OH+197.)/(9.*OH**2-10**4))*
2 (1./(3.*OH*0.9646))
C
WRITE (NO,10) BURDEP2,BD,KK,GAUSS1,HNI,FI1
10 FORMAT (2X,'BURDEP1=',F6.2,3X,'BD=',F6.2
1/2X,'KK=',F4.0,3X,'GAUSS1=',F8.2
2/2X,'HNI=',F10.0,3X,'FI1=',F10.0/)
C 3.Coil design:
C **************
CNI=HNI*1.46
AMPS=CNI/TURNS
CONA=AMPS/DELTA
CONTHK=SQRT(CONA/RATIO1)
CONWID=RATIO1*CONTHK
LYRS=INT(TURNS/(TPL*FRMS*PRL))
DW=LYRS*(CONTHK+0.3)
CDIA=1.05*2.*SQRT(HNI/(0.79*PIE))
COREHT=(CONWID+0.3)*TPL*FRMS*PRL
LMT=PIE*(CDIA+DW)
LENCOND=LMT*TURNS/1000.
DCR=COEFFT*LENCOND/CONA
VDC=AMPS*DCR
POWER=AMPS**2*DCR
DUCTS=INT(COREHT/100.)
COILOD=CDIA+2.*DW+DUCTS*WD
DMEAN=COILOD-CDIA-20.
RMEAN=DMEAN/2.
C
RATIO2=RMEAN/OH
C
DPERI=PIE*DMEAN
HYP1=SQRT(RMEAN**2+OH**2)
K3=(RMEAN**2/HYP1**3)*10000.
C
OHSURF=0.
C
HYP2=SQRT(RMEAN**2+OHSURF**2)
K4=(RMEAN**2/HYP2**3)*10000.
GAUSSSUR=(K4/K3)*GAUSS1
C
RCOLD=DCR
ICOLD=AMPS
PCOLD=POWER
 RHOT=RCOLD*(1.+TRK1*THETA1)
IHOT=ICOLD/(1.+TRK1*THETA1)
PHOT=IHOT**2*RHOT
C
WRITE (NO,50) CNI,AMPS,CONA,CONTHK,CONWID,LYRS,DW
50 FORMAT(2X,'CNI=',F10.1,3X,'AMPS=',F6.2,3X,'CONA=',F6.2
1/2X,'CONTHK=',F6.2,3X,'CONWID=',F6.2,3X,'LYRS=',F6.1
2/2X,'DW=',F8.2/)
C
WRITE (NO,60) CDIA,COREHT,LMT,LENCOND,DCR,VDC,POWER
60 FORMAT(2X,'CDIA=',F8.2,3X,'COREHT=',F8.2,3X,'LMT=',F8.2
1/2X,'LENCOND=',F8.2,3X,'DCR=',F6.4,3X,'VDC=',F6.2
2/2X,'POWER=',F8.2/)
C
WRITE (NO,70) DUCTS,COILOD,DMEAN,RMEAN,RATIO2,DPERI,HYP1,K3
70 FORMAT(2X,'DUCTS=',F8.2,3X,'COILOD=',F8.2,3X,'DMEAN=',F8.2
1/2X,'RMEAN=',F8.2,3X,'RATIO2=',F6.3,3X,'DPERI=',F8.2
2/2X,'HYP1=',F6.2,3X,'K3=',F8.2/)
C
WRITE (NO,80) HYP2,K4,GAUSSSUR,RCOLD,RHOT,ICOLD,IHOT
80 FORMAT(2X,'HYP2=',F6.2,3X,'K4=',F8.2,3X,'GAUSSSUR=',F8.2
1/2X,'RCOLD=',F6.4,3X,'RHOT=',F6.4,3X,'ICOLD=',F6.2
2/2X,'IHOT=',F6.2/)
C
WRITE (NO,90) PCOLD,PHOT
90 FORMAT(2X,'PCOLD=',F10.2,3X,'PHOT=',F10.2/)
C
C 4.Magnet body dimensions:
C *************************
C SP & CLR NEWLY ADDEDD:
C
SP=CDIA/16.
CLR=130.
C MW,ML MODIFIED. DF,DF11 & EP ADDED.
C
DF=DW
MW=CDIA + 2.*DF+ 2.*CLR + 2.*SP
DF11=HNI/(0.79*MW)
EP=CDIA/8.
ML=CDIA + 2.*DF11 + 2.*OH+ 2.*EP
BLTSP1=ML/(TIME1*1000.)
C
THK1=CDIA/4.
THK2=CDIA/8.
THK3=CDIA/16.
THK4=CDIA/32.
THK5=CDIA/64.
MH=COREHT+(THK1+THK4+THK5)+K1
C MAGGAP MODIFIED.
MAGGAP= OH
 GAUSS2=(HNI*10**4)/(796.*KJ*(2.*OH+MAGGAP))
SA=2.*(MH*ML+MW*ML)/10**6
C ADDED
WRITE (NO,55) DF, DF11, EP, SP
55 FORMAT (2X,'DF=',F8.2,3X,'DF11=',F8.2,3X,'EP=',F8.2,
1 3X,'SP=',F8.2//)
C
WRITE (NO,100) MW,ML,BLTSP1,THK1,THK2,THK3,THK4,THK5,MH
100 FORMAT(2X,'MW=',F8.2,3X,'ML=',F8.2,3X,'BLTSP1=',F6.2
1/2X,'THK1=',F6.2,3X,'THK2=',F6.2,3X,'THK3=',F6.2
2/2X,'THK4=',F6.2,3X,'THK5=',F6.2,3X,'MH=',F8.2/)
C
WRITE (NO,110) MAGGAP,GAUSS2,SA
110 FORMAT(2X,'MAGGAP=',F8.2,3X,'GAUSS2=',F10.2
1/2X,'SA=',F6.2/)
C
C 5.Radiator design:
C ******************
C HDISS MODIFIED.
C
HDISS=1.35*PHOT
RADAREA=(HDISS-SA*DF1*THETA2)/(DF2*THETA2)
NFINS=INT(RADAREA/FINAREA)
C
WRITE (NO,120) HDISS,RADAREA,NFINS
120 FORMAT(2X,'HDISS=',F8.2,3X,'RADAREA=',F8.2
1/2X,'NFINS=',F6.2/)
C
C 6.Weights of various shapes of tramp iron:
C ******************************************
C W1 TO W7 RENAMEDAS TIW1 TO TIW7.
SIZE=TISIZE
TIW1=(4.*SIZE**3*0.98)/10**6
TIW2=TIW1/0.507
TIW3=(SIZE/2.)*SIZE*PIE*(SIZE+SIZE/2.)*6.*0.657/10**6
TIW4=(SIZE**2*(PIE/4.)*5.*SIZE*8.)/10**6
TIW5=(SIZE*SIZE*5.*SIZE*7980.)/10**9
TIW6=(LL1*WW1*HH1*7980.)/10**9
TIW7=(LL2*WW2*HH2*7980.)/10**9
C
WRITE (NO,130) TIW1,TIW2,TIW3,TIW4,TIW5,TIW6,TIW7
130 FORMAT(2X,'TIW1=',F10.4,3X,'TIW2=',F10.4,3X,'TIW3=',F10.4
1/2X,'TIW4=',F10.4,3X,'TIW5=',F10.4,3X,'TIW6=',F10.4
2/2X,'TIW7=',F10.4/)
C
C 7.Lifting force on various shapesof tramp iron:
C ***********************************************
F1=((22./7.)*SIZE**2*GAUSS1**2*0.55*
1 SQRT(SIZE/90.))/1.0E+10
F2=(GAUSS1**2*SIZE**2*4.)/1.0E+10
 F3=(F1*28.)/(22.*0.65)
F4=(SIZE*5.*SIZE*4.*0.01)*(GAUSS1/10**4)**2
C Large sizes of tramp:
F6=(GAUSS1**2*4.*LL1*WW1)/1.0E+10
F7=(GAUSS1**2*4.*LL2*WW2)/1.0E+10
C
WRITE (NO,140) F1,F2,F3,F4,F6,F7
140 FORMAT(2X,'F1=',F10.4,3X,'F2=',F10.4,3X,'F3=',F10.4
1/2X,'F4=',F10.4,3X,'F6=',F10.4,3X,'F7=',F10.4/)
C
C 8.Dragging force & motor rating:
C ********************************
C FORCE1,2....force of coil at bottom surface of magnet body
FORCE6=(GAUSSSUR**2*4.*LL1*WW1)/1.0E+10
FORCE7=(GAUSSSUR**2*4.*LL2*WW2)/1.0E+10
C
FORCE1=FORCE6
FORCE2=FORCE7
C Terminal voltage=0.8 pu
MOTORKW1=(FORCE1*MU*BLTSP/75.)*0.736/(EFF1*0.8**2)
MOTORKW2=(FORCE2*MU*BLTSP/75.)*0.736/(EFF1*0.8**2)
C
WRITE (NO,150) FORCE1,MOTORKW1,FORCE2,MOTORKW2
150 FORMAT(2X,'FORCE1=',F8.2,3X,'MOTORKW1=',F6.2
1/2X,'FORCE2=',F8.2,3X,'MOTORKW2=',F6.2/)
C
C 9.Weights of active material in magnetic separator:
C ***************************************************
WT1=(MW*THK1*ML+2.*MH*THK2*ML)*7860./10**9
WT2=(PIE/4.)*CDIA**2*COREHT*7860./10**9
WT3=(2.*MH*THK3*ML*7860.)/10**9
WT4=(MW*ML*THK4*7860.)/10**9
WT5=(MW*ML*THK5*7860.)/10**9
WT6=CONA**2*DCR/10.
C
MAGVOL=(MW*ML*MH)/10**9
COILVOL=(PIE/4.)*COILOD**2*COREHT/10**9
WT7=RESERV1*SPGR1*(MAGVOL-COILVOL)
MAGWT=WT1+WT2+WT3+WT4+WT5+WT6+WT7
C
WRITE (NO,160) WT1,WT2,WT3,WT4,WT5,WT6
160 FORMAT(2X,'WT1=',F8.2,3X,'WT2=',F8.2,3X,'WT3=',F8.2
1/2X,'WT4=',F8.2,3X,'WT5=',F8.2,3X,'WT6=',F8.2/)
C
WRITE (NO,170) MAGVOL,COILVOL,WT7,MAGWT
170 FORMAT(2X,'MAGVOL=',F6.2,3X,'COILOD=',F6.2
1/2X,'WT7=',F8.2,3X,'MAGWT=',F10.2/)
C
C 10.Thermal time constant:
C *************************
 G1=WT6
G2=WT1+WT3+WT4
G3=WT7
TSA=SA+RADAREA
TOU=(G1*SP1+G2*SP2+G3*SP3)/(DF1*TSA*3600.)
C
TMAX=THETA1+AMB
TH1=TMAX*(1.-EXP(-HR1/TOU))
TH2=TMAX*(1.-EXP(-HR2/TOU))
C
WRITE (NO,180) G1,G2,G3,TSA,TOU,TMAX,TH1,TH2
180 FORMAT(2X,'G1=',F10.2,3X,'G2=',F10.2,3X,'G3=',F10.2
1/2X,'TSA=',F6.2,3X,'TOU=',F6.2,3X,'TMAX=',F6.2
1/2X,'TH1=',F6.2,3X,'TH2=',F6.2/)
C
C 11.Cost of active material:
C ***************************
COST1=WT1*UC1
COST2=WT2*UC2
C COST20=WT2*UC20
COST3=WT3*UC3
COST4=WT4*UC4
COST5=WT5*UC5
COST6=WT6*UC6
C COST60=WT6*UC60
COST7=WT7*UC7
COST8=COST6*UC8
COST9=POWER*UC9
TC=COST1+COST2+COST3+COST4+COST5+
1 COST6+COST7+COST8+COST9
C
WRITE (NO,190) COST1,COST2,COST20,COST3,COST4,COST5
190 FORMAT(2X,'COST1=',F10.2,3X,'COST2=',F10.2
1/2X,'COST20=',F10.2,3X,'COST3=',F10.2,3X,'COST4=',F10.2
1/2X,'COST5=',F10.2/)
C
WRITE (NO,200) COST6,COST60,COST7,COST8,COST9,TC
200 FORMAT(2X,'COST6=',F10.2,3X,'COST60=',F10.2
1/2X,'COST7=',F10.2,3X,'COST8=',F10.2,3X,'COST9=',F10.2
1/2X,'TC=',F10.2/)
C
END
1200.
0.96
2.819
1400.
0.6
35.
300.
100000.
1000.
450.
1.65
1.
25.
1.
85.
50.
50.
600.
125.
125.
250.
250.
100.
1.
1.05
0.028
2703.
2.089
0.004
3.142857
10.
13.
7.8
0.27
830.
480.
1750.
1.
2.
18.
42.
70.
50.
18.
72.
180.
200.
25.
0.075
6.6
856.
4000.
0.85
0.6
1.35
1.1
0.6
0.75
2.5
2800.
1.
8.
1.
10.
105.
MAGNET1_OP

BURDEP1=286.56 BD= 50.00

KK=950. GAUSS1= 1144.88
HNI= 202998. FI1= 101085.

CNI= 296376.9 AMPS=105.85 CONA=124.53

CONTHK= 1.09 CONWID=114.35 LYRS= 350.0
DW= 486.16

CDIA= 600.47 COREHT= 917.18 LMT= 3415.11

LENCOND= 9562.32 DCR=2.1501 VDC=227.58
POWER=24089.42

DUCTS= 9.00 COILOD= 1662.79 DMEAN= 1042.32

RMEAN= 521.16 RATIO2= 1.158 DPERI= 3275.86
HYP1=688.55 K3= 8.32

HYP2=521.16 K4= 19.19 GAUSSSUR= 2640.36

RCOLD=2.1501 RHOT=2.8811 ICOLD=105.85
IHOT= 78.99

PCOLD= 24089.42 PHOT= 17977.18

DF= 486.16 DF11= 134.69 EP= 75.06 SP= 37.53

MW= 1907.84 ML= 1919.95 BLTSP1= 3.20

THK1=150.12 THK2= 75.06 THK3= 37.53
THK4= 18.76 THK5= 9.38 MH= 1105.45

MAGGAP= 450.00 GAUSS2= 1144.88

SA= 11.57

HDISS=24269.19 RADAREA= 42.94

NFINS=159.00

TIW1= 0.0613 TIW2= 0.1208 TIW3= 0.1452

TIW4= 0.4911 TIW5= 0.6234 TIW6= 74.8125
TIW7= 49.8750

F1= 0.0746 F2= 0.3277 F3= 0.1461

F4= 1.6384 F6= 39.3226 F7= 32.7689

FORCE1= 209.15 MOTORKW1= 7.23

FORCE2= 174.29 MOTORKW2= 6.03

WT1= 6826.28 WT2= 2042.31 WT3= 1252.13

WT4= 540.25 WT5= 270.13 WT6= 3334.18
MAGVOL= 4.05 COILOD= 1.99
WT7= 1936.63 MAGWT= 16201.91

G1= 3334.18 G2= 8618.66 G3= 1936.63

TSA= 54.51 TOU= 4.03 TMAX=135.00
TH1= 29.64 TH2= 52.77

COST1= 122873.00 COST2= 85777.03

COST20= 0.00 COST3= 62606.68 COST4= 9724.52
COST5= 19449.05

COST6= 600151.63 COST60= 0.00

COST7= 48415.82 COST8= 45011.38 COST9= 158990.16
TC=1152999.25
Electromagnet: N=7, G=8, NC=2*(N+G)=30

An electromagnet, ILMS with solid core (MSLC) is wound with AL conductor. H class insulation. Coil is rated for 220-250 v DC.
The magnet has to lift 25 mm dia sphere, from 50 mm burden DEPTH, from 450 mm OH. ILMS belt speed is 2.85 mps and
strike time is 0.6 sec. The ILMS belt motor is 15 kw, 415 v, 3-ph, 50 hz, IM. The magnet coil is immersed in mineral oil and
radiators are provided to limit the temperature of coil, oil, and body of the ILMS.
30-03-2022
Ref: Magnet1.for; PZ_EM0.FOR+PZEM0SUB.FOR
S. No. Variable Variable Constraints Lower limit Upper limit Feasible Optimized Unit
1 N 7
2 IPRINT 1
3 MAXIT 999
4 ESCALE 0.5
5 X1 BD G1, G16 0 50 50 49059 mm
6 X2 TURNS G2, G17 50 4000 2800 2800 nos.
7 X3 DELTA G3, G18 0.3 1.1 0.85 0.95 amp/mm2
8 X4 RATIO1 G4, G19 1 105 105 105 pu
9 X5 CDIA G5, G20 0.3*BLTWID 600 600 599.88 mm
10 X6 DF1 G6, G21 5 13 13 13 w/m2/0C
11 X7 DF2 G7, G22 5 7.8 7.8 7.8 w/m2/0C
** MAGGAP 0.5*OH OH mm
** RADarea SA 3*SA mm2
12 E(1)..E(N) 0.001 pu
13 R 15000 pu
14 C 10 pu
OUTPUT
15 TCOST 1152999.25 1072189 Rs.
16 COUNTC 1137 nos.
17 ITER 1 no.
18 ISEQ 5 nos.
Constraints
19 b1 GAUSS1 G8, G23 1000 1500 1144.88 1141.7 G
2
20 b2 FI1 G9, G24 100000 110000 101085 100518 G /inch
2
21 b3 CONA G10, G25 20 138 124.53 110.58 mm
22 b4 MW G11, G26 BLTWID 1.6*BLTWID 1907.84 1863.9 mm
23 b5 ML G12, G27 3*OH 5*OH 1919.95 1924.7 mm
24 b6 MH G13, G28 HNI/250 HNI/100 1105.45 1053 mm
25 b7 RATIO2 G14G, G29 0.8 1.3 1.158 1.089 pu
26 b8 VDC G15, G30 110 250 227.58 249.8 volt
27 ** F7 1.05*W7 1.2*W7 kg
28 ** MOTORKW2 0.625*POWER POWER kw
29 ** THETA1 50 85 deg.C
30 ** THETA2 35 50 deg.C
31 ** FD end-pole 0.5*Bcore tesla

? N=7, G=8, NC=2*(N+G)=30 Present case Note: KEY DETAILS

Note: Provide additional constraints, if required. SA 11.57 m2
1. Rartio1 = CONWID/CONTHK BLTWID 1400 mm
2. Ratio2 = Rmean / OH OH 450 mm
HNI 202998 nos.
** marked: May be added at later stage, if required. W7 50 kg
POWER 24.089 kw

\data\magnet files.xls
C PZ_EM0.FOR ....CALLS PZEM0SUB.FOR
C Note:
C 1) all input values of PZEM0SUB are transferred here.
C 2) REAL statements increased as per new variables & constants.
C 3) COMMON statements increased as per new variables & constants.
C 4) PZ_EM0.IN modified to include 65 variables/constants.
C ***************************************************************
C EX...24 kw,100000 G^2/in, OH=450 mm ETC.
C POWEL-BOTM+ ZANGWILL'S EXTERIOR PENALTY FUNCTION
C #################################################
C LOWER & UPPER LIMITS INTRODUCED FOR VARIABLES #
C #################################################
C a) Application of Electromagnet.
C b) N=7,G=8,NC=30...change Format,Dimension statements.
C
REAL ICOLD,IHOT
REAL KJ,K1,K3,K4,KK
REAL LUMP,LL1,LL2,LYRS,LMT,LENCOND
REAL MAGTYP,MU,MW,ML,MH,MAGGAP,MOTORKW1,MOTORKW2
REAL MAGVOL,MAGWT
REAL NFINS
C
C DIMENSION X(N),W{N*(N+3)},E(N),YY(N)
C
DIMENSION X(7),W(70),E(7),YY(7)
COMMON/DEVICE/NO
COMMON/FUNXON/TC,COUNTC
COMMON/CONSTR/NC,R
COMMON/DESN1/BD,TURNS,DELTA,RATIO1,CDIA,DF1,DF2
COMMON/DESN2/GAUSS1,FI1,CONA,MW,ML,MH,RATIO2,VDC
C
COMMON/DESN3/TPH,BLKDEN,BLTSP,BLTWID,VOID,ALPHA,LUMP
COMMON/DESN4/FI0,GAUSS0,OH,KJ,MAGTYP,TISIZE,TISHAPE
COMMON/DESN5/THETA1,THETA2,AMB,LL1,WW1,HH1,LL2,WW2,HH2
COMMON/DESN6/PULOAD,PL,COEFFT,SPGR,TRK,TRK1
COMMON/DESN7/PIE,WD,FINAREA,SP1,SP2,SP3,HR1
COMMON/DESN8/HR2,UC1,UC2,UC20
COMMON/DESN9/UC3,UC4,UC5,UC6,UC60,UC7,UC8,UC9,SPGR1
COMMON/DESN10/COREMAX,TIME1,RESERV2,RESERV1
COMMON/DESN11/MU,EFF1,POT,TPL,FRMS,PRL
COMMON/DESN12/K1
COMMON/DESN13/DF,DF11,SP,EP
C
NC=30
MAXSEQ=5
C=10.
C
NI=50
NO=66
OPEN(UNIT=50,FILE='PZ_EM0.IN')
 OPEN(UNIT=66,FILE='PZ_EM0.OP')
C for N=7,E=7, Total 19 values+65=84
READ (NI,*) N,IPRINT,MAXIT,ESCALE
READ (NI,*) (X(II),II=1,N)
READ (NI,*) (E(JJ),JJ=1,N)
READ (NI,*) R
C
C INPUTS: 7+16+28+14=65 ..."Transferred to PZ_EM0.FOR".
C BELT CONVEYOR DETAILS: 7
READ (NI,*) TPH,BLKDEN,BLTSP,BLTWID,VOID,ALPHA,LUMP
C SPECIFICATIONS: 16
READ (NI,*) FI0,GAUSS0,OH,KJ,MAGTYP,TISIZE,TISHAPE
READ (NI,*) THETA1,THETA2,AMB,LL1,WW1,HH1,LL2,WW2,HH2
C CONSTANTS & CONSTRAINTS: 28
READ (NI,*) PULOAD,PL,COEFFT,SPGR,TRK,TRK1
READ (NI,*) PIE,WD,DF1,DF2,FINAREA,SP1,SP2,SP3,HR1
READ (NI,*) HR2,UC1,UC2,UC20
READ (NI,*) UC3,UC4,UC5,UC6,UC60,UC7,UC8,UC9,SPGR1
C ASSUMPTION: 14
READ (NI,*) COREMAX,DELTA,TIME1,RESERV2,RESERV1
READ (NI,*) MU,EFF1,POT,TURNS,TPL,FRMS,PRL
READ (NI,*) K1,RATIO1
C
NW=N*(N+3)
C FOLLOWING 4 LINES ADDED
ISEQ=1
500 WRITE(*,101) ISEQ,R
WRITE(NO,101) ISEQ,R
101 FORMAT (15X,'SEQUENCE NUMBER =',I4
1/2X,'R = ',F10.4/)
C
C
CALL BOTM (X,E,N,EF,ESCALE,IPRINT,MAXIT,W,NI,NO,NW)
C
WRITE (NO,001)
001 FORMAT(//,5X,23HVALUES OF THE VARIABLES)
DO 100 J=1,N
WRITE (NO,002) J,X(J)
002 FORMAT(/,5X,2HX(,I2,4H) = ,E16.8)
100 CONTINUE
C
WRITE (NO,003) EF
003 FORMAT (//,5X,21HOPTIMUM VALUE OF F = ,E16.8)
C
WRITE (*,800) BD,TURNS,DELTA,RATIO1,CDIA,DF1,DF2
800 FORMAT(2X,'BD=',F8.2,3X,'TURNS=',F8.1,3X,'DELTA=',F6.2
1/2X,'RATIO1=',F6.2,3X,'CDIA=',F8.2,3X,'DF1=',F6.2
1/2X,'DF2=',F6.2//)
C
WRITE (*,350) GAUSS1,FI1,CONA
350 FORMAT(2X,'GAUSS1=',F6.1,3X,'FI1=',F10.1,3X,'CONA=',F6.2)
WRITE (*,351) MW,ML,MH,RATIO2,VDC
351 FORMAT(2X,'MW=',F8.2,3X,'ML=',F8.2,3X,'MH=',F8.2
1/2X,'RATIO2=',F6.3,3X,'VDC=',F6.2/)
C
WRITE (NO,3500) GAUSS1,FI1,CONA
3500 FORMAT(2X,'GAUSS1=',F6.1,3X,'FI1=',F10.1,3X,'CONA=',F6.2)
WRITE (NO,3510) MW,ML,MH,RATIO2,VDC
3510 FORMAT(2X,'MW=',F8.2,3X,'ML=',F8.2,3X,'MH=',F8.2
1/2X,'RATIO2=',F6.3,3X,'VDC=',F6.2/)
C
C
C**** FOLLOWING 9 LINES ADDED AND STOP IS
C ASSIGNED AS "200 STOP OR FOR DESIRED OUPUT RESULTS***"
C
IF (ISEQ.GE.MAXSEQ) GO TO 200
C
R=C*R
DO 102 I=1,N
YY(I)=X(I)
X(I)=YY(I)
C
102 CONTINUE
ISEQ=ISEQ+1
C GO TO 500
C FINAL VALUES PRINT
C
WRITE (NO,3501) GAUSS1,FI1,CONA
3501 FORMAT(2X,'GAUSS1=',F6.1,3X,'FI1=',F10.1,3X,'CONA=',F6.2)
WRITE (NO,3511) MW,ML,MH,RATIO2,VDC
3511 FORMAT(2X,'MW=',F8.2,3X,'ML=',F8.2,3X,'MH=',F8.2
1/2X,'RATIO2=',F6.3,3X,'VDC=',F6.2/)
C
C
GO TO 500
C
200 STOP
END
C
C
C
SUBROUTINE CALCFX (N,X,F)
COMMON/DEVICE/NO
COMMON/FUNXON/TC,COUNTC
COMMON/CONSTR/NC,R
C
DIMENSION X(N),G(100)
C
CALL CALCFX1(N,X,F,G)
C
C DO 1 I=1,NC
C IF (G(I).LT.0.0) F=F+R*(G(I)*G(I))
C1 CONTINUE
C
RETURN
END
C
C
C BEGIN PAGE #338
SUBROUTINE BOTM (X,E,N,EF,ESCALE,IPRINT,MAXIT,W,NI,NO,NW)
C
DIMENSION X(N),W(NW),E(N)
C
WRITE (NO,001)
001 FORMAT(1H1,10X,32HPOWEL-BOTM OPTIMIZATION ROUTINE )
WRITE (NO,002) N,MAXIT,ESCALE,(I,X(I),I=1,N),(J,E(J),J=1,
1 N)
002 FORMAT(//,2X,10HPARAMETERS,//,2X,4HN = ,I2,4X,8HMAXIT = ,I4,4X,
1 9HESCALE = ,F5.2,//,2X,15HINITIAL GUESSES,//,7(2X,2HX(,I2,4H) =
2 ,1PE16.8),//,2X,31HACCURACY REQUIRED FOR VARIABLES,//,7(2X,2HE(,
3 I2,4H) = ,E16.3))
C
DDMAG=0.1*ESCALE
SCER=0.05/ESCALE
JJ=N*(N+1)
JJJ=JJ+N
K=N+1
NFCC=1
IND=1
INN=1
DO 4 I=1,N
W(I)=ESCALE
DO 4 J=1,N
W(K)=0.
IF (I-J) 4,3,4
C
3 W(K)=ABS(E(I))
4 K=K+1
ITERC=1
ISGRAD=2
CALL CALCFX (N,X,F)
FKEEP=2.*ABS(F)
5 ITONE=1
FP=F
SUM=0.
IXP=JJ
DO 6 I=1,N
IXP=IXP+1
6 W(IXP)=X(I)
IDIRN=N+1
 ILINE=1
7 DMAX=W(ILINE)
DACC=DMAX*SCER
DMAG=AMIN1(DDMAG,0.1*DMAX)
DMAG=AMAX1(DMAG,20.*DACC)
DDMAX=10.*DMAG
GO TO (70,70,71),ITONE
C
70 DL=0.
D=DMAG
FPREV=F
IS=5
FA=FPREV
DA=DL
8 DD=D-DL
DL=D
C PAGE 339 BEGINS
58 K=IDIRN
DO 9 I=1,N
X(I)=X(I)+DD*W(K)
9 K=K+1
CALL CALCFX(N,X,F)
NFCC=NFCC+1
GO TO (10,11,12,13,14,96),IS
14 IF(F-FA) 15,16,24
C
16 IF (ABS(D)-DMAX) 17,17,18
17 D=D+D
GO TO 8
18 WRITE (NO,019)
19 FORMAT(5X,38HMAXIMUM CHANGE DOES NOT ALTER FUNCTION)
GO TO 20
C
15 FB=F
DB=D
GO TO 21
24 FB=FA
DB=DA
FA=F
DA=D
21 GO TO (83,23),ISGRAD
23 D=DB+DB-DA
C
IS=1
GO TO 8
83 D=0.5*(DA+DB-(FA-FB)/(DA-DB))
IS=4
IF((DA-D)*(D-DB)) 25,8,8
25 IS=1
IF(ABS(D-DB)-DDMAX) 8,8,26
26 D=DB+SIGN(DDMAX,DB-DA)
IS=1
DDMAX=DDMAX+DDMAX
DDMAG=DDMAG+DDMAG
IF (DDMAG.GE.1.0E+20) DDMAG = 1.0E+20
IF(DDMAX-DMAX) 8,8,27
27 DDMAX=DMAX
GO TO 8
13 IF(F-FA) 28,23,23
28 FC=FB
DC=DB
29 FB=F
DB=D
GO TO 30
12 IF(F-FB) 28,28,31
31 FA=F
DA=D
GO TO 30
11 IF(F-FB) 32,10,10
32 FA=FB
DA=DB
GO TO 29
C PAGE 340 BEGINS
71 DL=1.
DDMAX=5.
FA=FP
DA=-1.
FB=FHOLD
DB=0.
D=1.
10 FC=F
DC=D
30 A=(DB-DC)*(FA-FC)
B=(DC-DA)*(FB-FC)
IF((A+B)*(DA-DC)) 33,33,34
33 FA=FB
DA=DB
FB=FC
DB=DC
GO TO 26
34 D=0.5*(A*(DB+DC)+B*(DA+DC))/(A+B)
DI=DB
FI=FB
IF(FB-FC) 44,44,43
43 DI=DC
FI=FC
44 GO TO (86,86,85),ITONE
85 ITONE=2
GO TO 45
C
86 IF(ABS(D-DI)-DACC) 41,41,93
93 IF(ABS(D-DI)-0.03*ABS(D)) 41,41,45
45 IF((DA-DC)*(DC-D)) 47,46,46
46 FA=FB
DA=DB
FB=FC
DB=DC
GO TO 25
47 IS=2
IF ((DB-D)*(D-DC)) 48,8,8
48 IS=3
GO TO 8
41 F=FI
D=DI-DL
DD=SQRT((DC-DB)*(DC-DA)*(DA-DB)/(A+B))
DO 49 I=1,N
X(I)=X(I)+D*W(IDIRN)
W(IDIRN)=DD*W(IDIRN)
49 IDIRN=IDIRN+1
W(ILINE)=W(ILINE)/DD
ILINE=ILINE+1
IF (IPRINT-1) 51,50,51
C
50 WRITE(NO,52) ITERC,NFCC,F,(X(I),I=1,N)
52 FORMAT(/10H ITERATION,I5,I15,16H FUNCTION VALUES,10X,3HF =,E15.8
1/5X,2(8E16.8))
GO TO (51,53),IPRINT
51 GO TO (55,38),ITONE
55 IF(FPREV-F-SUM) 94,95,95
C PAGE 341 BEGINS
95 SUM=FPREV-F
JIL=ILINE
94 IF(IDIRN-JJ) 7,7,84
84 GO TO(92,72),IND
92 FHOLD=F
IS=6
IXP=JJ
DO 59 I=1,N
IXP=IXP+1
59 W(IXP)=X(I)-W(IXP)
DD=1.
GO TO 58
96 GO TO(112,87),IND
112 IF(FP-F) 37,37,91
91 D=2.*(FP+F-2.*FHOLD)/(FP-F)**2
IF(D*(FP-FHOLD-SUM)**2- SUM) 87,37,37
87 J=JIL*N+1
IF(J-JJ) 60,60,61
60 DO 62 I=J,JJ
K=I-N
62 W(K)=W(I)
DO 97 I=JIL,N
97 W(I-1)=W(I)
61 IDIRN=IDIRN-N
ITONE=3
K=IDIRN
C
IXP=JJ
AAA=0.
DO 67 I=1,N
IXP=IXP+1
W(K)=W(IXP)
IF(AAA-ABS(W(K)/E(I))) 66,67,67
66 AAA=ABS(W(K)/E(I))
67 K=K+1
DDMAG=1.
W(N)=ESCALE/AAA
ILINE=N
GO TO 7
37 IXP=JJ
AAA=0.
F=FHOLD
DO 99 I=1,N
IXP=IXP+1
X(I)=X(I)-W(IXP)
IF(AAA*ABS(E(I))-ABS(W(IXP))) 98,99,99
98 AAA=ABS(W(IXP)/E(I))
99 CONTINUE
GO TO 72
38 AAA=AAA*(1.+DI)
GO TO(72,106),IND
72 IF(IPRINT-2) 53,50,50
53 GO TO(109,88),IND
109 IF(AAA-0.1) 20,20,76
C
76 IF(F-FP) 35,78,78
78 WRITE(NO,80)
C PAGE 342 BEGINS
80 FORMAT(5X,31HACCURACY LIMITED BY ERRORS IN F)
C
88 IND=1
35 DDMAG=0.4*SQRT(ABS(FP-F))
IF(DDMAG.GE.1.0E+20) DDMAG=1.0E+20
ISGRAD=1
C
108 ITERC=ITERC+1
IF(ITERC-MAXIT) 5,5,81
81 WRITE(NO,82) MAXIT
82 FORMAT(I5,29H ITERATIONS COMPLETED BY BOTM)
IF(F-FKEEP) 20,20,110
110 F=FKEEP
DO 111 I=1,N
JJJ=JJJ+1
111 X(I)=W(JJJ)
GO TO 20
C
101 JIL=1
FP=FKEEP
IF(F-FKEEP) 105,78,104
104 JIL=2
FP=F
F=FKEEP
C
105 IXP=JJ
DO 113 I=1,N
IXP=IXP+1
K=IXP+N
GO TO(114,115),JIL
114 W(IXP)=W(K)
GO TO 113
115 W(IXP)=X(I)
X(I)=W(K)
113 CONTINUE
JIL=2
GO TO 92
106 IF(AAA-0.1) 20,20,107
C
20 EF=F
RETURN
C
107 INN=1
GO TO 35
C
END
C pzem0sub.for (Refer magnet1.for)
C FILE FOR OPTIMISATION OF ELECTRO-MAGNET..PZ METHOD
C **************************************************
SUBROUTINE CALCFX1 (N,X,F,G)
COMMON/DEVICE/NO
COMMON/FUNXION/FUNC,COUNTC,KOUNT
COMMON/CONSTR/NC,R
COMMON/DESN1/BD,TURNS,DELTA,RATIO1,CDIA,DF1,DF2
COMMON/DESN2/GAUSS1,FI1,CONA,MW,ML,MH,RATIO2,VDC
C
COMMON/DESN3/TPH,BLKDEN,BLTSP,BLTWID,VOID,ALPHA,LUMP
COMMON/DESN4/FI0,GAUSS0,OH,KJ,MAGTYP,TISIZE,TISHAPE
COMMON/DESN5/THETA1,THETA2,AMB,LL1,WW1,HH1,LL2,WW2,HH2
COMMON/DESN6/PULOAD,PL,COEFFT,SPGR,TRK,TRK1
COMMON/DESN7/PIE,WD,FINAREA,SP1,SP2,SP3,HR1
COMMON/DESN8/HR2,UC1,UC2,UC20
COMMON/DESN9/UC3,UC4,UC5,UC6,UC60,UC7,UC8,UC9,SPGR1
COMMON/DESN10/COREMAX,TIME1,RESERV2,RESERV1
COMMON/DESN11/MU,EFF1,POT,TPL,FRMS,PRL
COMMON/DESN12/K1
COMMON/DESN13/DF,DF11,SP,EP
C
DIMENSION X(9),G(100)
C *******************************************************
C N=7,G=8,NC=2*(N+G)=30
C
REAL ICOLD,IHOT
REAL KJ,K1,K3,K4,KK
REAL LUMP,LL1,LL2,LYRS,LMT,LENCOND
REAL MAGTYP,MU,MW,ML,MH,MAGGAP,MOTORKW1,MOTORKW2
REAL MAGVOL,MAGWT
REAL NFINS
C
C INPUTS: 7+16+28+14=65 ..."Transferred to PZ_EM0.FOR".
C NI=50
C NO=66
C OPEN(UNIT=50,FILE='MAGNET1.IN')
C OPEN(UNIT=66,FILE='MAGNET1.OP')
C BELT CONVEYOR DETAILS: 7
C READ (NI,*) TPH,BLKDEN,BLTSP,BLTWID,VOID,ALPHA,LUMP
C SPECIFICATIONS: 16
C READ (NI,*) FI0,GAUSS0,OH,KJ,MAGTYP,TISIZE,TISHAPE
C READ (NI,*) THETA1,THETA2,AMB,LL1,WW1,HH1,LL2,WW2,HH2
C CONSTANTS & CONSTRAINTS: 28
C READ (NI,*) PULOAD,PL,COEFFT,SPGR,TRK,TRK1
C READ (NI,*) PIE,WD,DF1,DF2,FINAREA,SP1,SP2,SP3,HR1
C READ (NI,*) HR2,UC1,UC2,UC20
C READ (NI,*) UC3,UC4,UC5,UC6,UC60,UC7,UC8,UC9,SPGR1
C ASSUMPTION: 14
C READ (NI,*) COREMAX,DELTA,TIME1,RESERV2,RESERV1
C READ (NI,*) MU,EFF1,POT,TURNS,TPL,FRMS,PRL
C READ (NI,*) K1,RATIO1
C *************************************************************
C
C BLTWID=1400.
C BYPASS FOR OPTIMISATION FOLLOWING 7 LINES:
C X(1)=50.
C X(2)=2800.
C X(3)=0.85
C X(4)=105.
C X(5)=0.428*BLTWID=600.
C X(6)=13.
C X(7)=7.8
C
BD=X(1)
TURNS=X(2)
DELTA=X(3)
RATIO1=X(4)
CDIA=X(5)
DF1=X(6)
DF2=X(7)
C
C MAGGAP=X()
C RADAREA=X()
C BELT CONVEYOR DETAILS: 7
C TPH=1200.
C BLKDEN=0.96
C BLTSP=2.819
C BLTWID=1400.
C VOID=0.6
C ALPHA=35.
C LUMP=300.
C SPECIFICATIONS: 16
C FI0=100000.
C GAUSS0=1000.
C OH=450.
C KJ=1.65
C MAGTYP=1.
C TISIZE=25.
C TISHAPE=1.
C
C THETA1=85.
C THETA2=50.
CC
C AMB=50.
C LL1=600.
C WW1=125.
C HH1=125.
C LL2=250.
C WW2=250.
C HH2=100.
C CONSTANTS & CONSTRAINTS: 28
C PULOAD=1.
C PL=1.05
C COEFFT=0.028
C SPGR=2703.
CC TRK=2.089
C TRK1=0.004
C
C PIE=3.142857
C WD=10.
CC DF1=13.
CC DF2=7.8
C FINAREA=0.27
C SP1=830.
C SP2=480.
C SP3=1750.
C HR1=1.
C
C HR2=2.
C UC1=18.
C UC2=42.
C UC20=70.
C
C UC3=50.
C UC4=18.
C UC5=72.
C UC6=180.
C UC60=200.
C UC7=25.
C UC8=0.075
C UC9=6.6
C SPGR1=856.
C ASSUMPTION: 15
C
C COREMAX=4000.
CC DELTA=0.85
C TIME1=0.6
CC BLTSP1=3 ,BLTSP1=ML/(TIME1*1000.)
C
C RESERV2=1.35
C RESERV1=1.1
C MU=0.6
C EFF1=0.75
C POT=2.5
CC TURNS=2800.
C TPL=1.
C FRMS=8.
C PRL=1.
C
C K1=10.
CC RATIO1=105.
CC RATIO2=1.2
C
C
C 1.Calculation of burden depth:
C ******************************
CC IF (ALPHA.EQ.0.0) THEN
CC BURDEP2=(TPH*494.)/(BLKDEN*BLTSP*BLTWID)
CC GO TO 20
CC ENDIF
CC BURDEP2=(TPH*494.)/(BLKDEN*BLTSP*(BLTWID/3.)*
CC 1 2.*COS(ALPHA*PIE/180.))
CC20 BD=BURDEP2
CC IF (BD.GT.50.) THEN
CC BD=50.
CC ENDIF
C 2.Calculation of gauss to remove tramp iron from burden:
C ********************************************************
OH1=OH-BD
PBD=(BD/25.4)*PULOAD
C
IF (TISHAPE.EQ.1) KK=950.
IF (TISHAPE.EQ.2) KK=850.
IF (TISHAPE.EQ.3) KK=750.
IF (TISHAPE.EQ.4) KK=650.
IF (TISHAPE.EQ.5) KK=500.
C
GAUSS1=KK+330.*(BLKDEN/1.6)*(BD/100.)*PBD
C
HNI=(3.*796.*KJ*OH*GAUSS1)/10**4
FI1=((HNI*10**4)/(2.*796.*KJ))**2*
1 ((0.45*OH+197.)/(9.*OH**2-10**4))*
2 (1./(3.*OH*0.9646))
C
C WRITE (*,10) BD,KK,GAUSS1,HNI,FI1
C10 FORMAT (2X,'BD=',F6.2,3X,'KK=',F4.0,3X,'GAUSS1=',F8.2
C 2/2X,'HNI=',F10.0,3X,'FI1=',F10.0/)
C 3.Coil design:
C **************
CNI=HNI*1.46
AMPS=CNI/TURNS
CONA=AMPS/DELTA
CONTHK=SQRT(CONA/RATIO1)
CONWID=RATIO1*CONTHK
LYRS=INT(TURNS/(TPL*FRMS*PRL))
DW=LYRS*(CONTHK+0.3)
CCC CDIA=1.05*2.*SQRT(HNI/(0.79*PIE))
COREHT=(CONWID+0.3)*TPL*FRMS*PRL
LMT=PIE*(CDIA+DW)
 LENCOND=LMT*TURNS/1000.
DCR=COEFFT*LENCOND/CONA
VDC=AMPS*DCR
POWER=AMPS**2*DCR
DUCTS=INT(COREHT/100.)
COILOD=CDIA+2.*DW+DUCTS*WD
DMEAN=COILOD-CDIA-20.
RMEAN=DMEAN/2.
C
RATIO2=RMEAN/OH
C
DPERI=PIE*DMEAN
HYP1=SQRT(RMEAN**2+OH**2)
K3=(RMEAN**2/HYP1**3)*10000.
C
OHSURF=0.
C
HYP2=SQRT(RMEAN**2+OHSURF**2)
K4=(RMEAN**2/HYP2**3)*10000.
GAUSSSUR=(K4/K3)*GAUSS1
C
RCOLD=DCR
ICOLD=AMPS
PCOLD=POWER
RHOT=RCOLD*(1.+TRK1*THETA1)
IHOT=ICOLD/(1.+TRK1*THETA1)
PHOT=IHOT**2*RHOT
C
C WRITE (*,50) CNI,AMPS,CONA,CONTHK,CONWID,LYRS,DW
C50 FORMAT(2X,'CNI=',F10.1,3X,'AMPS=',F6.2,3X,'CONA=',F6.2
C 1/2X,'CONTHK=',F6.2,3X,'CONWID=',F6.2,3X,'LYRS=',F6.1
C 2/2X,'DW=',F8.2/)
C
C WRITE (*,60) CDIA,COREHT,LMT,LENCOND,DCR,VDC,POWER
C60 FORMAT(2X,'CDIA=',F8.2,3X,'COREHT=',F8.2,3X,'LMT=',F8.2
C 1/2X,'LENCOND=',F8.2,3X,'DCR=',F6.4,3X,'VDC=',F6.2
C 2/2X,'POWER=',F8.2/)
C
C WRITE (*,70) DUCTS,COILOD,DMEAN,RMEAN,RATIO2,DPERI,HYP1,K3
C70 FORMAT(2X,'DUCTS=',F8.2,3X,'COILOD=',F8.2,3X,'DMEAN=',F8.2
C 1/2X,'RMEAN=',F8.2,3X,'RATIO2=',F6.2,3X,'DPERI=',F8.2
C 2/2X,'HYP1=',F6.2,3X,'K3=',F8.2/)
C
C WRITE (*,80) HYP2,K4,GAUSSSUR,RCOLD,RHOT,ICOLD,IHOT
C80 FORMAT(2X,'HYP2=',F6.2,3X,'K4=',F8.2,3X,'GAUSSSUR=',F8.2
C 1/2X,'RCOLD=',F6.4,3X,'RHOT=',F6.4,3X,'ICOLD=',F6.2
C 2/2X,'IHOT=',F6.2/)
C
C WRITE (*,90) PCOLD,PHOT
C90 FORMAT(2X,'PCOLD=',F10.2,3X,'PHOT=',F10.2/)
C
C 4.Magnet body dimensions:
C *************************
C SP & CLR ADDED
SP=CDIA/16.
CLR=130.
DF=DW
MW=CDIA+2.*DF+2.*CLR+2.*SP
DF11=HNI/(0.79*MW)
EP=CDIA/8.
ML=CDIA+2.*DF11+2.*OH +2.*EP
BLTSP1=ML/(TIME1*1000.)
C
THK1=CDIA/4.
THK2=CDIA/8.
THK3=CDIA/16.
THK4=CDIA/32.
THK5=CDIA/64.
MH=COREHT+(THK1+THK4+THK5)+K1
C
MAGGAP=OH
C
GAUSS2=(HNI*10**4)/(796.*KJ*(2.*OH+MAGGAP))
SA=2.*(MH*ML+MW*ML)/10**6
C
C WRITE(NO,55) DF, DF11, EP, SP
C55 FORMAT (2X,'DF=',F8.2,3X,'DF11=',F8.2,3X,'EP=',F8.2,3X,
C 1 'SP=',F8.2//)
C
C WRITE (*,100) MW,ML,BLTSP1,THK1,THK2,THK3,THK4,THK5,MH
C100 FORMAT(2X,'MW=',F8.2,3X,'ML=',F8.2,'BLTSP1=',F6.2
C 1/2X,'THK1=',F6.2,3X,'THK2=',F6.2,3X,'THK3=',F6.2
C 2/2X,'THK4=',F6.2,3X,'THK5=',F6.2,3X,'MH=',F8.2/)
C
C WRITE (*,110) MAGGAP,GAUSS2,SA
C110 FORMAT(2X,'MAGGAP=',F8.2,3X,'GAUSS2=',F10.2
C 1/2X,'SA=',F6.2/)
C
C 5.Radiator design:
C ******************
HDISS=1.35*PHOT
RADAREA=(HDISS-SA*DF1*THETA2)/(DF2*THETA2)
NFINS=INT(RADAREA/FINAREA)
C
C WRITE (NO,120) HDISS,RADAREA,NFINS
C120 FORMAT(2X,'HDISS=',F8.2,3X,'RADAREA=',F8.2
C 1/2X,'NFINS=',F6.2/)
C
C 6.Weights of various shapes of tramp iron:
C ******************************************
 SIZE=TISIZE
TIW1=(4.*SIZE**3*0.98)/10**6
TIW2=TIW1/0.507
TIW3=(SIZE/2.)*SIZE*PIE*(SIZE+SIZE/2.)*6.*0.657/10**6
TIW4=(SIZE**2*(PIE/4.)*5.*SIZE*8.)/10**6
TIW5=(SIZE*SIZE*5.*SIZE*7980.)/10**9
TIW6=(LL1*WW1*HH1*7980.)/10**9
TIW7=(LL2*WW2*HH2*7980.)/10**9
C
C WRITE (*,130) TIW1,TIW2,TIW3,TIW4,TIW5,TIW6,TIW7
C130 FORMAT(2X,'TIW1=',F10.4,3X,'TIW2=',F10.4,3X,'TIW3=',F10.4
C 1/2X,'TIW4=',F10.4,3X,'TIW5=',F10.4,3X,'TIW6=',F10.4
C 2/2X,'TIW7=',F10.4/)
C
C 7.Lifting force on various shapesof tramp iron:
C ***********************************************
F1=((22./7.)*SIZE**2*GAUSS1**2*0.55*
1 SQRT(SIZE/90.))/1.0E+10
F2=(GAUSS1**2*SIZE**2*4.)/1.0E+10
F3=(F1*28.)/(22.*0.65)
F4=(SIZE*5.*SIZE*4.*0.01)*(GAUSS1/10**4)**2
C Large sizes of tramp:
F6=(GAUSS1**2*4.*LL1*WW1)/1.0E+10
F7=(GAUSS1**2*4.*LL2*WW2)/1.0E+10
C Note: Lifting force: F6 (or F7) > W6+burden weight (or W7+BDW)
C **************************************************************
C WRITE (*,140) F1,F2,F3,F4,F6,F7
C140 FORMAT(2X,'F1=',F10.4,3X,'F2=',F10.4,3X,'F3=',F10.4
C 1/2X,'F4=',F10.4,3X,'F6=',F10.4,3X,'F7=',F10.4/)
C
C 8.Dragging force & motor rating:
C ********************************
C FORCE1,2....force of coil at bottom surface of magnet body
FORCE6=(GAUSSSUR**2*4.*LL1*WW1)/1.0E+10
FORCE7=(GAUSSSUR**2*4.*LL2*WW2)/1.0E+10
C
FORCE1=FORCE6
FORCE2=FORCE7
C Terminal voltage=0.8 pu
MOTORKW1=(FORCE1*MU*BLTSP/75.)*0.736/(EFF1*0.8**2)
MOTORKW2=(FORCE2*MU*BLTSP/75.)*0.736/(EFF1*0.8**2)
C
C WRITE (*,150) FORCE1,MOTORKW1,FORCE2,MOTORKW2
C150 FORMAT(2X,'FORCE1=',F8.2,3X,'MOTORKW1=',F6.2
C 1/2X,'FORCE2=',F8.2,3X,'MOTORKW2=',F6.2/)
C
C 9.Weights of active material in magnetic separator:
C ***************************************************
WT1=(MW*THK1*ML+2.*MH*THK2*ML)*7860./10**9
WT2=(PIE/4.)*CDIA**2*COREHT*7860./10**9
 WT3=(2.*MH*THK3*ML*7860.)/10**9
WT4=(MW*ML*THK4*7860.)/10**9
WT5=(MW*ML*THK5*7860.)/10**9
WT6=CONA**2*DCR/10.
C
MAGVOL=(MW*ML*MH)/10**9
COILVOL=(PIE/4.)*COILOD**2*COREHT/10**9
WT7=RESERV1*SPGR1*(MAGVOL-COILVOL)
MAGWT=WT1+WT2+WT3+WT4+WT5+WT6+WT7
C
C WRITE (*,160) WT1,WT2,WT3,WT4,WT5,WT6
C160 FORMAT(2X,'WT1=',F8.2,3X,'WT2=',F8.2,3X,'WT3=',F8.2
C 1/2X,'WT4=',F8.2,3X,'WT5=',F8.2,3X,'WT6=',F8.2/)
C
C WRITE (*,170) MAGVOL,COILVOL,WT7,MAGWT
C170 FORMAT(2X,'MAGVOL=',F6.2,3X,'COILOD=',F6.2
C 1/2X,'WT7=',F8.2,3X,'MAGWT=',F10.2/)
C
C 10.Thermal time constant:
C *************************
G1=WT6
G2=WT1+WT3+WT4
G3=WT7
TSA=SA+RADAREA
TOU=(G1*SP1+G2*SP2+G3*SP3)/(DF1*TSA*3600.)
C
TMAX=THETA1+AMB
TH1=TMAX*(1.-EXP(-HR1/TOU))
TH2=TMAX*(1.-EXP(-HR2/TOU))
C
C WRITE (*,180) G1,G2,G3,TSA,TOU,TMAX,TH1,TH2
C180 FORMAT(2X,'G1=',F10.2,3X,'G2=',F10.2,3X,'G3=',F10.2
C 1/2X,'TSA=',F6.2,3X,'TOU=',F6.2,3X,'TMAX=',F6.2
C 1/2X,'TH1=',F6.2,3X,'TH2=',F6.2/)
C
C 11.Cost of active material:
C ***************************
COST1=WT1*UC1
COST2=WT2*UC2
C COST20=WT2*UC20
COST3=WT3*UC3
COST4=WT4*UC4
COST5=WT5*UC5
COST6=WT6*UC6
C COST60=WT6*UC60
COST7=WT7*UC7
COST8=COST6*UC8
COST9=POWER*UC9
TC=COST1+COST2+COST3+COST4+COST5+
1 COST6+COST7+COST8+COST9
C ***********************************************
C FOR PZ METHOD:
F=TC
FUNC=TC
C LOWER LIMITS:
C *************
C Variables: G=7
G(1)=BD-0.
G(2)=TURNS-50.
G(3)=DELTA-0.3
G(4)=RATIO1-1.
G(5)=CDIA-0.3*BLTWID
G(6)=DF1-5.
G(7)=DF2-5.
C
C G()=RATIO2-0.8
C G()=MAGGAP-0.5*OH
C G()=RADAREA-SA
C Constraints: G=8
G(8)=GAUSS1-1000.
G(9)=FI1-100000.
G(10)=CONA-20.
G(11)=MW-BLTWID
G(12)=ML-3.*OH
G(13)=MH-(HNI/250.)
G(14)=RATIO2-0.8
G(15)=VDC-110.
C G()=THETA1-50.
C G()=THETA2-35.
C G()=F5-1.05*W5
C G()=MOTORKW2-0.625*POWER
C G()=TESLA-
C UPPER LIMITS:
C *************
C Variables:
G(16)=50.-BD
G(17)=4000.-TURNS
G(18)=1.1-DELTA
G(19)=105.-RATIO1
G(20)=0.6*BLTWID-CDIA
G(21)=14.-DF1
G(22)=14.-DF2
C Constraints:
G(23)=1500.-GAUSS1
G(24)=110000.-FI1
G(25)=138.-CONA
G(26)=1.6*BLTWID-MW
G(27)=5.*OH-ML
G(28)=(HNI/100.)-MH
G(29)=1.3-RATIO2
 G(30)=250.-VDC
C G()=85.-THETA1
C G()=50.-THETA2
C G()=1.2*W5-F5
C G()=POWER-MOTORKW2
C
C
C
C WRITE (*,190) COST1,COST2,COST20,COST3,COST4,COST5
C190 FORMAT(2X,'COST1=',F10.2,3X,'COST2=',F10.2
C 1/2X,'COST20=',F10.2,3X,'COST3=',F10.2,3X,'COST4=',F10.2
C 1/2X,'COST5=',F10.2/)
C
C WRITE (*,200) COST6,COST60,COST7,COST8,COST9,TC
C200 FORMAT(2X,'COST6=',F10.2,3X,'COST60=',F10.2
C 1/2X,'COST7=',F10.2,3X,'COST8=',F10.2,3X,'COST9=',F10.2
C 1/2X,'TC=',F10.2/)
C
C WRITE (*,202) TC
C202 FORMAT(2X,'TC=',F10.2/)
C
C ***********************************************
C ADD FOR POWELL-ZANGWILL METHOD
DO 1 I=1,NC
IF (G(I).LT.0.0) F=F+R*(G(I)*G(I))
1 CONTINUE
C
COUNTC=COUNTC+1
KOUNT=KOUNT+1
WRITE (*,1001) FUNC
1001 FORMAT(2X,'FUNC=',F10.2/)
WRITE (NO,1002) FUNC
1002 FORMAT(2X,'FUNC=',F10.2/)
WRITE (*,1003) KOUNT
1003 FORMAT(20X,'KOUNT=',I8//)
WRITE (NO,1004) COUNTC
1004 FORMAT(20X,'COUNTC=',F10.1/)
C
C WRITE (NO,1005) BD,TURNS,DELTA,RATIO1,CDIA,DF1,DF2
C1005 FORMAT(2X,'BD=',F6.2,3X,'TURNS=',F8.1,3X,'DELTA=',F6.2
C 1/2X,'RATIO1=',F6.2,3X,'CDIA=',F8.2,3X,'DF1=',F6.2
C 2/2X,'DF2=',F6.2/)
C
C WRITE (NO,1006) GAUSS1,FI1,CONA,MW,ML,MH,RATIO2,VDC
C1006 FORMAT(2X,'GAUSS1=',F8.2,3X,'FI1=',F10.1,3X,'CONA=',F8.2
C 1/2X,'MW=',F8.2,3X,'ML=',F8.2,3X,'MH=',F8.2
C 2/2X,'RATIO2=',F6.2,3X,'VDC=',F8.2/)
C
RETURN
END
7
1
999
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50.
2800.
0.85
105.
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13.
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.001
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15000.
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0.96
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1.65
1.
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1.
85.
50.
50.
600.
125.
125.
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100.
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2703.
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3.142857
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13.
7.8
0.27
830.
480.
1750.
1.
2.
18.
42.
70.
50.
18.
72.
180.
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6.6
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 SEQUENCE NUMBER = 1
R = 15000.0000

1 POWEL-BOTM OPTIMIZATION ROUTINE

PARAMETERS

N = 7 MAXIT = 999 ESCALE = 0.50

INITIAL GUESSES

X( 1) = 5.00000000E+01 X( 2) = 2.80000000E+03 X( 3) = 8.50000024E-01 X(

4) = 1.05000000E+02 X( 5) = 6.00000000E+02 X( 6) = 1.30000000E+01 X( 7) =
7.80000019E+00

ACCURACY REQUIRED FOR VARIABLES

E( 1) = 1.000E-03 E( 2) = 1.000E-03 E( 3) = 1.000E-03 E(

4) = 1.000E-03 E( 5) = 1.000E-03 E( 6) = 1.000E-03 E( 7) =
1.000E-03
FUNC=1152216.50

COUNTC= 1.0

FUNC=1152223.75

COUNTC= 2.0
COUNTC= 1133.0

..
.
. MANY PAGES DELETED
.
.

FUNC=1072190.50

COUNTC= 1134.0

FUNC=1072189.63

COUNTC= 1135.0

FUNC=1072189.00

COUNTC= 1136.0

ITERATION 1 326 FUNCTION VALUES F = 0.10721890E+07

 0.49586212E+02 0.28000171E+04 0.95250362E+00 0.10499986E+03
0.59988422E+03 0.13002001E+02 0.78000002E+01
FUNC=1072189.00

COUNTC= 1137.0

MAXIMUM CHANGE DOES NOT ALTER FUNCTION

VALUES OF THE VARIABLES

X( 1) = 0.49586212E+02

X( 2) = 0.28000171E+04

X( 3) = 0.95250362E+00

X( 4) = 0.10499986E+03

X( 5) = 0.59988422E+03

X( 6) = 0.13003001E+02

X( 7) = 0.78000002E+01

OPTIMUM VALUE OF F = 0.10721890E+07

GAUSS1=1141.7 FI1= 100518.6 CONA=110.81
MW= 1863.99 ML= 1924.79 MH= 1053.43
RATIO2= 1.099 VDC=249.82