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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Maxwell 2D Transient to FLUENT 3D Steady State 2-Way
Coupling with Demagnetization
This workshop shows how Maxwell 2D transient is 2-way coupled with FLUENT
3d steady state. Time averaged but spatially distributive Ohmic losses in the
magnets and core losses in the stator and rotor are transferred from Maxwell 2D
to a 3D mesh in FLUENT for temperature calculation. Then temperature is
mapped back to Maxwell to affect electrical conductivity and B-H curves.
Demagnetization is also turned on in Maxwell.
This workshop shows steps related to transferring losses from Maxwell to
FLUENT and does not contain details about Maxwell or FLUENT. Please refer to
FLUENT Users Guide for information on FLUENT Setup

Prerequisites
Maxwell V16 and FLUENT V14.5 need to be installed in order to carry out this
workshop, which are releases under ANSYS Workbench R14.5.
ANSYS Workbench needs to be installed for the loss transfer.

Geometry and mesh

used inside FLUENT

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
The Maxwell Project
The Maxwell project contains a 2D geometry of a Prius motor
The setup of this motor has already been partially done
To obtain more details about the setup please refer to Example 11.1 of Maxwell
2D Workshops

Stator
Phase C

Rotor

Phase B

Shaft
Phase A

Magnets

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Launch Maxwell
To Lunch Maxwell
Double the Maxwell icon
Or go to All Programs and look for your Ansoft installation.

Change Material for the Magnets

RMB on NdFe35 and select Properties..
Select Add Material
Make the changes according to the panel
Name
Nonlinear
625000
Thermal Modifier
1.0-0.0010876*(Temp-20)
1.0-0.00647425*(Temp-20)

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Import Intrinsic B-H Curve
Click B-H Curve
Select Intrinsic and answer no to the pop-up question.
Select Import Dataset and select the provided B-H curve file,
intrinsic_BH.tab. This is the intrinsic B-H curve at the reference
temperature of 20 C.

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Make Copper Conductivity a Function of Temperature
RMB on Copper and select Properties..
Select View/Edit Material
Make the changes according to the panel
Thermal Modifier
1.0/(1.0+0.0068*(Temp-20))

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Set up Temperature Dependency
Go to Maxwell 2D>Set Object Temperature
Make the changes according to the panel

20 C is the
reference
temperature

Set up Demagnitization (Optional)

Go to Setup1

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Simulate and Plot Torque
Go to Analysis and do the simulation.
Plot Torque vs Time

Note that you could redo the calculation with a different

temperature. Below is the new torque results with temperature of
100 C. The torque is reduced with elevated temperature.

Save and Close Maxwell.

This concludes the Maxwell standalone calculation.

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Coupled Simulation with Fluent Will Be Performed Next
Launch ANSYS Workbench
To Launch Workbench
Select the Microsoft Start button , select All Programs > ANSYS 14.5>
Workbench 14.5

Import Maxwell Project File

Since we are using an existing Maxwell project, we will import it into Workbench.
Users can create a new Maxwell Analysis System to setup a new problem.
To Import Maxwell File
Select the menu item File > Import
Change the file type to Maxwell Project File (*.mxwl)
Browse to the location where workshop input files are located
Select the file Ex_12_4_2Way_Demag.mxwl and Open it.

Launch Maxwell
A Maxwell analysis system will be created as shown below.
To Lunch Maxwell
Double click on the solution tab of Maxwell analysis system.

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Set up Feedback
Go to Maxwell2D > Set up Object Temperature
Enable feedback

Analyze
To start the solution process
Select the menu item Maxwell 2D > Analyze All
This may take up to 5 min.

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2-Way Coupling with Demagnetization
Plot Losses
Create Parameter for Total Losses
Select the menu item Maxwell 2D > Fields > Calculator
1. Select Input > Quantity >TotalLoss
2. Select Input >Geometry >Surface > Stator
3. Select Scalar >
integrate
4. Select Add
5. Specify the name of the expression as Loss_Stator
6. Press Done
Plot Loss Vs Time
Select the menu item Maxwell 2D > Results > Create Field Reports >

Rectangular Plot

In Report window
1. Category: Calculator Expressions
2. Quantity: Loss_Stator
3. Select New Report
4. Press Close
5. Choose the range as shown to plot the results.

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Calculate Time Average Losses
Right click on the plot and select the option Trace Characteristics > Add
In Add Trace Characteristics window,
1. Category: Math
2. Function: avg
3. Range: Specified
4. Select Add and Done

The value displayed is around 1206.9 watts

It shows time averaged Total Losses for the stator
Since this is a 2D case, these losses are in watts per meter
We need to multiply this value with length of stator in order to calculate true
losses. Since the length is 0.08382 m, the actual total loss for the stator is :
101.2 watts (The correct answer should be 50.6 watts. The bug has been
fixed in V17.)

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Close Maxwell
To Close Maxwell window
Select the menu item File > Close Desktop

Turn on Beta Option

Go to Tools > Options > Appearances to turn on beta option.
Beta option is needed for two-way transient Maxwell steady state Fluent
coupling.

Save
To Save Workbench Project
Return to Workbench Project window
Select the menu item File > Save
Save the file with the name Ex_12_4_2Way_Demag.wbpj

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2-Way Coupling with Demagnetization
Create a FLUENT Component System
To Create a FLUENT Component System
Expand the Toolbox for Component Systems and select a Fluent
component system from it. Drag and drop the FLUENT System on Project
page

Load FLUENT Case File

A CFD case file has been provided with the workshop. The case file has all
proper setup. This workshop will demonstrate the loss mapping process.
To Load Case File
Right click on Setup tab of FLUENT Analysis system and select Import

FLUENT Case > Browse

Browse to the correct location and select the FLUENT case file
Ex_12_4_2Way_Demag.cas.gz and select Open
A FLUENT Launcher window will pop up as shown in below image. Select
Double Precision and press OK to it.
A FLUENT window will launch and case file will be imported into FLUENT

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Build Links
To Create Links
Without closing FLUENT window, return to Workbench project page
Drag and drop Solution tab of Maxwell Analysis system onto the Setup tab
of FLUENT system
Right click on Solution tab of Maxwell Analysis system and select Update
Press OK to the pop up window.

Initialize Solution
To Initialize the Solution
Go to Solution > Solution Initialization
Change the Initialization type to Standard Initialization
Press Initialize
Note: It is not necessary to initialize the solution before mapping the losses
from Maxwell. If you initialize the solution after mapping losses, mapping
will be redone automatically

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Map Losses from Maxwell
To Maps Losses from Maxwell
Select the menu item File > EM Mapping > Volumetric Energy Source
In Maxwell Mapping window,
FLUENT Cell Zones: Press Ctrl and select the four zones solidmagnet, solid-rotor, solid-teeth, and solid-yoke.
Start: 2.083e-4
Stop: 1.667e-3
Press OK

Mapped Losses
After data mapping, FLUENT will display the loss values mapped to
selected zones
The losses reported for the stator (zone 31 and 37) is 50.1watts

Remember that total losses for the stator calculated from Maxwell was 50.6
watts.
It can be verified that losses for other regions are also correct.

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2-Way Coupling with Demagnetization
Perform the Simulation
Simulate for 20 iterations using all setting in the case file

Plot Temperature Distribution

To Plot Temperature
Go to Display > Graphics and Animations and double click Contours
In Contours window,
Filled: Checked
Contour of: Temperature > Static Temperature
Surfaces: select all periodic and solid (Tip: using the Match)
Press Display and Close

Note: The windings have the highest temperature as expected. There is a

temperature gradient across the air gap. The thermal conductivity for the air gap
is increased to model the enhanced heat transfer at the gap due to motion.

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Prius Motor - Maxwell 2D Transient to FLUENT 3D Steady State

2-Way Coupling with Demagnetization
Perform Temperature Feedback and 2-Way Coupling
Go back to Workbench schematic
RMB Solution of Maxwell2D and Enable Update
Double click Solution to launch Maxwell
Reset time to zero and redo the analysis
RMB Setup1 to reset time to zero.
The torque is much less due to magnet being function of temperature.
Display temperature to show temperature distribution on the magnets.

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2-Way Coupling with Demagnetization
Perform Fluent Analysis again Following the Same Procedure
The new mapped loss is the following.

After Some Coupling Iterations, Temperature Converges to a

Level Acceptable. Below is a Plot of Temperature Convergence
History.

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