CoupledElectromagneticand

ThermalAnalysisofFerriteCore
ElectronicPlanarTransformer

MarkChristini
ANSYS,Inc
1 2011ANSYS,Inc. September6,2011
 Outline
Introduction
Maxwell3DEddyCurrentand
ElectrostaticSimulation
ANSYSMechanicalThermal
Simulation
2wayThermalCouplingbackto
Maxwell
Simplorer SystemSimulationusing
MaxwellStateSpaceDynamic
model
Summary

2 2011ANSYS,Inc. September6,2011
 Introduction
Coupledelectromagneticthermalanalysisofaferritecore
electronicplanartransformer
Magneticsimulationdoneatfundamentalfrequency=
100kHzwithharmonicsupto5MHz
Allsourcesoflossesconsideredincluding:eddycurrent,skin,
andproximitylossesinthewindingsaswellaseddycurrent
andhysteresislossesintheferritecore
LossesaredirectlycoupledintoanANSYSMechanical
Thermalsimulationinordertodeterminetemperaturerise
usingelementbyelementcoupling
TemperaturesfedbacktoMaxwellformaterialchanges
SystemsimulationdoneinsideofSimplorer usingdynamic
statespacefrequencydependentmodel
3 2011ANSYS,Inc. September6,2011
 CoupledElectromechanicalDesignFlow
Simplorer
Q3D SystemDesign RMxprt
Parasitics
MotorDesign
IA PMSYNC Torque J

A A D2D

IB ICA:
A
PP := 6
IC
A

GAIN

ANSYSCFDFluid
Flow
PExprt
Magnetics

ANSYS Maxwell2D/3D
ElectromagneticComponents
Mechanical
Thermal/Stress Model order Reduction

Co-simulation

Field Solution

Model Generation
4 2011ANSYS,Inc. September6,2011
 FEAAdaptiveMeshing
2DTransformerModel 3DTransformerModel

2DTransformerMesh 3DTransformerMesh

In3D,finite
In2D,finite elements
elements are
are tetrahedra
triangles

5 2011ANSYS,Inc. September6,2011
 Transformer DesignChallenges

Magneticeffects:
nonlinearmaterials
frequencydependentmaterials
tempdependentmaterials
eddycurrents
proximityeffects
timediffusionofmagneticfields
transientexcitations

ElectricFieldeffects:
varyingdielectricpermitivities
varyingdimensionsandshape
3Dfieldeffects

6 2011ANSYS,Inc. September6,2011
 ANSYSComprehensiveSolution
System

ANSYS
Mixed-Signal Multi-Domain
System Simulator
Circuit

ModelOrder Reduction &

Cosimulation
Component
ANSYS Workbench
Electrical Magnetic Fluid Mechanical Thermal Acoustic

7 2011ANSYS,Inc. September6,2011
 WorkbenchCouplingTechnology

Electromagnetic ThermalStressSystem

8 2011ANSYS,Inc. September6,2011
 ElectronicPlanarTransformer
FerritePQCore
Primaryturns=4
Secondaryturns=2
Insulationlayersbetweenconductors
FundamentalFrequency=100kHz

9 2011ANSYS,Inc. September6,2011
 Maxwell3DSourceSetup
LoadcasewithIpri =50A
andIsec =80A
UnbalancedAturnsfor
coreexcitation

10 2011ANSYS,Inc. September6,2011
 FerriteCoreProperties
Frequencydependentpermeabilityandimaginarypermeability
UseSimplorer Sheetscan utilitytograbpermeabilitydatapoints

Datasheet Sheetscan
11 2011ANSYS,Inc. September6,2011
 FrequencyDependentCorePropertiesin
Maxwell
s" Rs
RequiredinputsforMaxwellarerealpermeabilityand s '
losstangent s Ls
Losstangentbasedonseriesequivalentmodel
Temp=0 C
frequency perm perm_imag losstangent
100000 1939 6 0.0032
200000 1977 13 0.0068
300000 2015 22 0.0110
400000 2052 35 0.0173
500000 2090 51 0.0244
600000 2165 79 0.0363
700000 2281 119 0.0522
800000 2322 174 0.0750
900000 2446 264 0.1078
1000000 2533 336 0.1326
1500000 2581 998 0.3869
2000000 2029 2101 1.0351
3000000 828 2178 2.6306
4000000 227 1626 7.1618
5000000 97 1093 11.2199
6000000 61 663 10.8398
7000000 47 424 8.9644
8000000 39 327 8.3658
9000000 34 271 7.9437
10000000 31 228 7.4132
12 2011ANSYS,Inc. September6,2011
 CoreMaterialProperties Inputs
Datasetsusedtodefinepropertiesvs.frequency:
RelativePermeability=pwl($perm,Freq)
MagneticLosstangent=pwl($losstan,Freq)
Relativepermitivity =12
Conductivity=0.5(S/m)

13 2011ANSYS,Inc. September6,2011
 CoreMaterialProperties Outputs
Usenamedexpressionincalculatortoverifythe
realandimaginarypermeability
Usereporttoplotandlosstangentvs.frequency

Real permeability -

Num > Vector > 1,0,0

Material > perm > multiply Permeability and Loss Tangent Maxwell3Ddesign2 ANSOFT
3000.00 12.00

complex > real > mag Curve Info

mu_real_eval
Setup1 : LastAdaptive
Phase='0deg'
constant > mu0 > divide 2500.00 loss_tangent
Setup1 : LastAdaptive
10.00

Phase='0deg'

2000.00 8.00

Real permeability -
mu_real_eval

loss_tangent
Num > Vector > 1,0,0 1500.00 6.00

Material > perm > multiply 1000.00 4.00

complex > imag > mag

constant > mu0 > divide
500.00 2.00

0.00 0.00
0.00 1.00 2.00 3.00 4.00 5.00
Loss tangent Freq [MHz]

= /
14 2011ANSYS,Inc. September6,2011
 TemperatureSettingsinMaxwell
Initialtemperature
=22C
Coreandwindings
havetemp
dependent
materials

15 2011ANSYS,Inc. September6,2011
 Temperaturedependentcopperconductivity
for2waycouplingtoMaxwell

1

(1 0.0039 * (Temp 22))

16 2011ANSYS,Inc. September6,2011
 InitialConductivityat100kHz,22degC
Conductivity=5.8e7 (S/m)
Conductivityisconstantthroughoutwinding

17 2011ANSYS,Inc. September6,2011
 Temperaturedependentferritepermeability
for2waycouplingtoMaxwell

18 2011ANSYS,Inc. September6,2011
 2waycouplingfortemperaturedependent
permeability
perm Permeability
degC perm modifier 5000
50 1247 0.73
25 1440 0.85
4000
0 1700 1.00
25 2031 1.19
50 2442 1.44 3000
74 2982 1.75
89 3252 1.91 2000
100 3368 1.98
113 3483 2.05 1000
125 3522 2.07
137 3560 2.09
0
149 3586 2.11
50 0 50 100 150 200 250
162 3650 2.15
175 3753 2.21 temp(C)
183 3869 2.28
189 3985 2.34 Permeabilitymodifier
191 4113 2.42 3.00
194 4267 2.51
195 4370 2.57 2.50
197 4524 2.66
200 4576 2.69
2.00
202 4524 2.66
204 4422 2.60
1.50
205 4023 2.37
206 2494 1.47
209 514 0.30 1.00
211 180 0.11
213 77 0.05 0.50
216 39 0.02
221 13 0.01 0.00
225 13 0.01 50 0 50 100 150 200 250

19 2011ANSYS,Inc. September6,2011
 InitialPermeabilityat100kHz,22degC

RealPermeability ImaginaryPermeability

20 2011ANSYS,Inc. September6,2011
 CurrentDensityat100kHz
LoadcasewithIpri =50A
andIsec =80A

21 2011ANSYS,Inc. September6,2011
 MagneticFluxDensityat100kHz

22 2011ANSYS,Inc. September6,2011
 WindingEddyCurrentLossDensityat
100kHz
Windinglosses
considersskinand
proximityeffects

23 2011ANSYS,Inc. September6,2011
 CoreLossDensityat100kHz

1 * 1 *
Peddy Re J J dV Physteresis Im B H dV
2 vol
2 vol

Ohmic Loss HysteresisLoss

core hyster eddy losses ANSOFT

core_hyster_loss core_eddy_loss
Freq [kHz] Setup1 : LastAdaptive Setup1 : LastAdaptive
Phase='0deg' Phase='0deg'
1 10.000000 0.001082 0.001897
2 100.000000 1.211527 0.191875
3 500.000000 44.428733 5.032800

24 2011ANSYS,Inc. September6,2011
 SimulatedResistance

Resistance Maxwell3Ddesign1 ANSOFT

800.00
Curve Info
700.00 Matrix1.R(pri_in,pri_in)
Setup1 : LastAdaptive
Matrix1.R(sec_in,sec_in)
600.00 Setup1 : LastAdaptive

500.00
Y1 [ohm]

400.00

300.00

200.00

100.00

0.00
0.01 0.10 1.00 10.00
Freq [MHz]

25 2011ANSYS,Inc. September6,2011
 SimulatedInductance

Inductance Maxwell3Ddesign1 ANSOFT

45.00

40.00

35.00
Curve Info
30.00 Matrix1.L(pri_in,pri_in)
Setup1 : LastAdaptive
Y1 [uH]

Matrix1.L(sec_in,sec_in)
25.00 Setup1 : LastAdaptive

20.00

15.00

10.00

5.00
0.01 0.10 1.00 10.00
Freq [MHz]

26 2011ANSYS,Inc. September6,2011
 SimulatedCapacitance
UseDCconductionsolvertoassign+1Vand
1Vtocoilsandoncore

27 2011ANSYS,Inc. September6,2011
 WorkbenchCoupling
Maxwell3DEddy
Currentcalculates
lossesandcouples
directlytoANSYS
thermal
Maxwell3D
Electrostaticcalculates
capacitancesbetween
windingandcore
Maxwell3DEddy
CurrentcalculatesR,L
vs.frequencyand
inports directlyinto
Simplorer viathe
Statespacedynamic
link

28 2011ANSYS,Inc. September6,2011
 WorkbenchCoupling
EngineeringDataallowsmaterialstobechosenincludingthermalconductivity

29 2011ANSYS,Inc. September6,2011
 WorkbenchCoupling

Workbench
geometry
imported
directlyinto
Workbench
Appropriate
materials
canthenbe
assigned

30 2011ANSYS,Inc. September6,2011
 WorkbenchCoupling
Workbenchmeshis
differentthanMaxwell
3Dmesh
Setmaximumelement
size=0.5mm

31 2011ANSYS,Inc. September6,2011
 WorkbenchCoupling
Fixed
temperature
coldplate
assignedtobase
=22C
Convection
boundaries
assignedto
outersurfaces
ofcoreandcoils
=5W/m2C

32 2011ANSYS,Inc. September6,2011
 WorkbenchCoupling
ImportedLossDensityoncoreandwindingsat100kHz
MatchesMaxwell3Dlossdensity total losses ANSOFT

1
Freq [kHz] 100.000000
pri_loss
Setup1 : LastAdaptive 6.657984
Phase='0deg'
sec_loss
Setup1 : LastAdaptive 6.712708
Phase='0deg'
core_loss_top
Setup1 : LastAdaptive 0.701290
Phase='0deg'
core_loss_bot
Setup1 : LastAdaptive 0.702112
Phase='0deg'

33 2011ANSYS,Inc. September6,2011
 FerriteCoreTransformerTemperatureat
100kHz

34 2011ANSYS,Inc. September6,2011
 ExporttemperaturebacktoMaxwell

35 2011ANSYS,Inc. September6,2011
 ResolveinMaxwellwithactualtemp

36 2011ANSYS,Inc. September6,2011
 UpdatedCopperConductivitywith2way
coupling

Uniformconductivity
=5.8e7 (S/m)at22C

Varyingconductivitywith
varyingtemperature
(decreasesastempincreases)

37 2011ANSYS,Inc. September6,2011
 SimplorerArchitecture
Co-Simulation
C/C++ Matlab
User Defined Real Time Matlab ANSYS ANSYS
Model Workshop Simulink MBD Maxwell

Simulation Data Bus/Simulator Coupling Technology

Blocks: Circuits: States:

Model Extraction: Equivalent Circuit, Dynamic State VHDL-AMS

Space, Impulse Response Extracted LTI, Stiffness Matrix IF (domain = quiescent_domain)
V0 == init_v;
Electromagnetic Mechanical Thermal Fluidic ELSE
Current == cap*voltage'dot;
(FEA) (FEA) (FEA) (CFD) END USE;
38 2011ANSYS,Inc. September6,2011
 Simplorer SystemSimulation

Maxwell3DFrequencySweep

39 2011ANSYS,Inc. September6,2011
 Simplorer SystemSimulation

40 2011ANSYS,Inc. September6,2011
 Simplorer SystemSimulation

41 2011ANSYS,Inc. September6,2011
 Conclusions
Maxwell3Ddetermineslosscomponents(eddy
current,hysteresis,proximity,skin)atmultiple
frequenciesaswellasR,LandC
WorkbenchallowsMaxwelllossestobespatially
coupledtoANSYSMechanicalfortemperaturerise
calculation
Resultingtemperaturerisecanbecoupledbackto
Maxwellinordertousedtochangematerial
propertiessuchaspermeabilityandconductivity
Maxwell3Dcanexportafrequencydependent
transferfunctionusingDynamicStateSpacecoupling
insideofSimplorer toallowforacompletesystem
simulation

42 2011ANSYS,Inc. September6,2011