© 2011 ANSYS, Inc. September 6, 2011 1 Coupled Electromagnetic and Thermal Analysis of Ferrite Core Electronic Planar Transformer Mark Christini ANSYS, Inc
© 2011 ANSYS, Inc. September 6, 20111
Coupled Electromagnetic and Thermal Analysis of Ferrite Core Electronic Planar Transformer
Mark ChristiniANSYS, Inc
© 2011 ANSYS, Inc. September 6, 20112
• Introduction
• Maxwell 3D Eddy Current and Electrostatic Simulation
• ANSYS Mechanical Thermal Simulation
• 2‐way Thermal Coupling back to Maxwell
• Simplorer System Simulation using Maxwell State Space Dynamic model
• Summary
Outline
© 2011 ANSYS, Inc. September 6, 20113
• Coupled electromagnetic‐thermal analysis of a ferrite core electronic planar transformer
• Magnetic simulation done at fundamental frequency = 100kHz with harmonics up to 5MHz
• All sources of losses considered including: eddy current, skin, and proximity losses in the windings as well as eddy current and hysteresis losses in the ferrite core
• Losses are directly coupled into an ANSYS Mechanical Thermal simulation in order to determine temperature rise using element by element coupling
• Temperatures fed back to Maxwell for material changes
• System simulation done inside of Simplorer using dynamic state space frequency dependent model
Introduction
© 2011 ANSYS, Inc. September 6, 20114
Coupled Electromechanical Design FlowSimplorerSystem Design
PP := 6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
JPMSYNCIA
IB
IC
Torque JPMSYNCIA
IB
IC
TorqueD2D
Maxwell 2D/3DElectromagnetic Components
PExprtMagnetics
RMxprtMotor Design
Q3DParasitics
ANSYS MechanicalThermal/Stress Model order Reduction
Co-simulation
Field Solution
Model Generation
ANSYS CFD Fluid Flow
© 2011 ANSYS, Inc. September 6, 20115
FEA Adaptive Meshing2D Transformer Model
2D Transformer Mesh
In 2D, finite elements are triangles
3D Transformer Model
3D Transformer Mesh
In 3D, finite elements are tetrahedra
© 2011 ANSYS, Inc. September 6, 20116
• Electric Field effects:– varying dielectric permitivities– varying dimensions and shape– 3D field effects
• Magnetic effects: – nonlinear materials– frequency dependent materials– temp dependent materials– eddy currents– proximity effects– time diffusion of magnetic fields– transient excitations
Transformer Design Challenges
© 2011 ANSYS, Inc. September 6, 20117
Electrical Magnetic Fluid Mechanical Thermal Acoustic
Circuit
System
Component ANSYS Workbench
ANSYSMixed-Signal Multi-Domain
System Simulator
Model Order Reduction &Cosimulation
ANSYS Comprehensive Solution
© 2011 ANSYS, Inc. September 6, 20118
Workbench Coupling Technology
Electromagnetic → Thermal → Stress → System
© 2011 ANSYS, Inc. September 6, 20119
• Ferrite PQ Core
• Primary turns = 4
• Secondary turns = 2
• Insulation layers between conductors
• Fundamental Frequency = 100kHz
Electronic Planar Transformer
© 2011 ANSYS, Inc. September 6, 201110
• Load case with Ipri = 50A and Isec = 80A
• Unbalanced A‐turns for core excitation
Maxwell 3D Source Setup
© 2011 ANSYS, Inc. September 6, 201111
Ferrite Core PropertiesFrequency dependent permeability and imaginary permeability
Use Simplorer Sheetscan utility to grab permeability data points
SheetscanDatasheet
© 2011 ANSYS, Inc. September 6, 201112
Required inputs for Maxwell are real permeability and loss tangent
Loss tangent based on series equivalent model
Temp = 0° C
Frequency Dependent Core Properties in Maxwell
s
s
s
ss L
R
'
"
frequency perm perm_imag loss tangent100000 1939 6 0.0032200000 1977 13 0.0068300000 2015 22 0.0110400000 2052 35 0.0173500000 2090 51 0.0244600000 2165 79 0.0363700000 2281 119 0.0522800000 2322 174 0.0750900000 2446 264 0.1078
1000000 2533 336 0.13261500000 2581 998 0.38692000000 2029 2101 1.03513000000 828 2178 2.63064000000 227 1626 7.16185000000 97 1093 11.21996000000 61 663 10.83987000000 47 424 8.96448000000 39 327 8.36589000000 34 271 7.9437
10000000 31 228 7.4132
© 2011 ANSYS, Inc. September 6, 201113
Datasets used to define properties vs. frequency:• Relative Permeability = pwl($perm,Freq)• Magnetic Loss tangent = pwl($losstan,Freq)
Relative permitivity = 12
Conductivity = 0.5 (S/m)
Core Material Properties ‐ Inputs
© 2011 ANSYS, Inc. September 6, 201114
Use “named expression” in calculator to verify the real and imaginary permeability
Use report to plot µ’ and loss tangent vs. frequency
Core Material Properties ‐ Outputs
Real permeability - µ’
Num > Vector > 1,0,0 Material > perm > multiply complex > real > magconstant > mu0 > divide
Loss tangent
δ = µ” / µ’
0.00 1.00 2.00 3.00 4.00 5.00Freq [MHz]
0.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
mu_
real
_eva
l
0.00
2.00
4.00
6.00
8.00
10.00
12.00
loss
_tan
gent
Maxwell3Ddesign2Permeability and Loss Tangent ANSOFT
Curve Infomu_real_eval
Setup1 : LastAdaptivePhase='0deg'
loss_tangentSetup1 : LastAdaptivePhase='0deg'
Real permeability - µ”
Num > Vector > 1,0,0 Material > perm > multiply complex > imag > magconstant > mu0 > divide
© 2011 ANSYS, Inc. September 6, 201115
Temperature Settings in Maxwell
• Initial temperature = 22 °C
• Core and windings have temp dependent materials
© 2011 ANSYS, Inc. September 6, 201116
Temperature dependent copper conductivity for 2‐way coupling to Maxwell
))22(*0039.01(1
Temp
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Initial Conductivity at 100kHz, 22 deg C
• Conductivity = 5.8e7 (S/m)
• Conductivity is constant throughout winding
© 2011 ANSYS, Inc. September 6, 201118
Temperature dependent ferrite permeability for 2‐way coupling to Maxwell
© 2011 ANSYS, Inc. September 6, 201119
2‐way coupling for temperature dependent permeability
0
1000
2000
3000
4000
5000
‐50 0 50 100 150 200 250temp (C)
Permeabilitydeg C perm
perm modifier
‐50 1247 0.73‐25 1440 0.850 1700 1.00
25 2031 1.1950 2442 1.4474 2982 1.7589 3252 1.91
100 3368 1.98113 3483 2.05125 3522 2.07137 3560 2.09149 3586 2.11162 3650 2.15175 3753 2.21183 3869 2.28189 3985 2.34191 4113 2.42194 4267 2.51195 4370 2.57197 4524 2.66200 4576 2.69202 4524 2.66204 4422 2.60205 4023 2.37206 2494 1.47209 514 0.30211 180 0.11213 77 0.05216 39 0.02221 13 0.01225 13 0.01
0.00
0.50
1.00
1.50
2.00
2.50
3.00
‐50 0 50 100 150 200 250
Permeability modifier
© 2011 ANSYS, Inc. September 6, 201120
Initial Permeability at 100kHz, 22 deg C
Imaginary PermeabilityReal Permeability
© 2011 ANSYS, Inc. September 6, 201121
Current Density at 100kHz
• Load case with Ipri = 50A and Isec = 80A
© 2011 ANSYS, Inc. September 6, 201122
Magnetic Flux Density at 100kHz
© 2011 ANSYS, Inc. September 6, 201123
Winding losses considers skin and proximity effects
Winding Eddy Current Loss Density at 100kHz
© 2011 ANSYS, Inc. September 6, 201124
Core Loss Density at 100kHz
Hysteresis LossOhmic Loss
dVHBPvol
hysteresis *Im21 dVJJP
voleddy *Re
21
Freq [kHz]core_hyster_lossSetup1 : LastAdaptivePhase='0deg'
core_eddy_lossSetup1 : LastAdaptivePhase='0deg'
1 10.000000 0.001082 0.0018972 100.000000 1.211527 0.1918753 500.000000 44.428733 5.032800
core hyster eddy losses ANSOFT
© 2011 ANSYS, Inc. September 6, 201125
Simulated Resistance
0.01 0.10 1.00 10.00Freq [MHz]
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
800.00
Y1
[ohm
]
Maxwell3Ddesign1Resistance ANSOFT
Curve InfoMatrix1.R(pri_in,pri_in)
Setup1 : LastAdaptiveMatrix1.R(sec_in,sec_in)
Setup1 : LastAdaptive
© 2011 ANSYS, Inc. September 6, 201126
Simulated Inductance
0.01 0.10 1.00 10.00Freq [MHz]
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
Y1 [u
H]
Maxwell3Ddesign1Inductance ANSOFT
Curve InfoMatrix1.L(pri_in,pri_in)
Setup1 : LastAdaptiveMatrix1.L(sec_in,sec_in)
Setup1 : LastAdaptive
© 2011 ANSYS, Inc. September 6, 201127
Simulated Capacitance
Use DC conduction solver to assign +1V and ‐1V to coils and on core
© 2011 ANSYS, Inc. September 6, 201128
Workbench Coupling
• Maxwell 3D Eddy Current calculates losses and couples directly to ANSYS thermal
• Maxwell 3D Electrostatic calculates capacitances between winding and core
• Maxwell 3D Eddy Current calculates R,L vs. frequency and inports directly into Simplorer via the State‐space dynamic link
© 2011 ANSYS, Inc. September 6, 201129
Workbench CouplingEngineering Data allows materials to be chosen including thermal conductivity
© 2011 ANSYS, Inc. September 6, 201130
Workbench Coupling
• Workbench geometry imported directly into Workbench
• Appropriate materials can then be assigned
© 2011 ANSYS, Inc. September 6, 201131
Workbench Coupling
• Workbench mesh is different than Maxwell 3D mesh
• Set maximum element size = 0.5mm
© 2011 ANSYS, Inc. September 6, 201132
Workbench Coupling
• Fixed temperature cold plate assigned to base = 22 °C
• Convection boundaries assigned to outer surfaces of core and coils = 5 W/m2‐°C
© 2011 ANSYS, Inc. September 6, 201133
Workbench Coupling• Imported Loss Density on core and windings at 100kHz
• Matches Maxwell 3D loss density1
Freq [kHz] 100.000000pri_lossSetup1 : LastAdaptivePhase='0deg'
6.657984
sec_lossSetup1 : LastAdaptivePhase='0deg'
6.712708
core_loss_topSetup1 : LastAdaptivePhase='0deg'
0.701290
core_loss_botSetup1 : LastAdaptivePhase='0deg'
0.702112
total losses ANSOFT
© 2011 ANSYS, Inc. September 6, 201134
Ferrite Core Transformer Temperature at 100kHz
© 2011 ANSYS, Inc. September 6, 201135
Export temperature back to Maxwell
© 2011 ANSYS, Inc. September 6, 201136
Resolve in Maxwell with actual temp
© 2011 ANSYS, Inc. September 6, 201137
Updated Copper Conductivity with 2‐way coupling
Uniform conductivity = 5.8e7 (S/m) at 22°C
Varying conductivity with varying temperature (decreases as temp increases)
© 2011 ANSYS, Inc. September 6, 201138
MatlabSimulink
Simplorer Architecture
Simulation Data Bus/Simulator Coupling Technology
Co-Simulation
Circuits: States:
Electromagnetic (FEA)
Mechanical(FEA)
Model Extraction: Equivalent Circuit, Dynamic State Space, Impulse Response Extracted LTI, Stiffness Matrix
Fluidic (CFD)
VHDL-AMSIF (domain = quiescent_domain)V0 == init_v;
ELSECurrent == cap*voltage'dot;
END USE;
Matlab
Real TimeWorkshop
C/C++ User Defined
ModelANSYSMBD
ANSYSMaxwell
Blocks:
Thermal (FEA)
© 2011 ANSYS, Inc. September 6, 201139
Simplorer System Simulation
Maxwell 3D Frequency Sweep
© 2011 ANSYS, Inc. September 6, 201140
Simplorer System Simulation
© 2011 ANSYS, Inc. September 6, 201141
Simplorer System Simulation
© 2011 ANSYS, Inc. September 6, 201142
• Maxwell 3D determines loss components (eddy current, hysteresis, proximity, skin) at multiple frequencies as well as R, L and C
• Workbench allows Maxwell losses to be spatially coupled to ANSYS Mechanical for temperature rise calculation
• Resulting temperature rise can be coupled back to Maxwell in order to used to change material properties such as permeability and conductivity
• Maxwell 3D can export a frequency dependent transfer function using Dynamic State Space coupling inside of Simplorer to allow for a complete system simulation
Conclusions