Maxwell 2D v12

Large Motion its Quick Implementation Using the Maxwell 2D Transient Solver
Maxwell Transient is able to consider interactions between transient electromagnetic fields and mechanical motion of objects. Maxwell Transient (with motion) includes dB/dt arising from mechanically moving magnetic fields in space, i.e. moving objects. Thus, effects coming from so-called motion induced currents can be considered. In Maxwell rotational motion can occur around one single motion axis. This paper represents a quick start to using rotational motion. It will exercise rotational motion in Maxwell 2D using a rotational actuator (experimental motor) example. Subsequent papers will demonstrate rotational motion in more depth, non-cylindrical rotational motion using a relays example, as well as translational motion which a solenoid application will serve as an example for. The goal of these papers is solely to show and practice working with large motion in Maxwell. It is neither the goal to simulate real-world applications, nor to match accurately measured results, nor will these papers show in detail how to setup and work with other Maxwell functionality. Please refer to the corresponding topics.

9.13

Basic Exercise: Transient Large Motion Rotational

Quickstart Rotational Motion Using a Rotational Actuator Example

Maxwell Transient with large motion is a set of advanced topics. Users should have thorough knowledge on Maxwell fundamentals as well as Maxwell Transient (without motion) prior to approaching large motion. If necessary, please consult the proper training papers, help files, manuals, and application notes. We will exercise the following in this document: Create a new or read in an existing rotational actuator model to serve as an experimental testbench for large motion Prepare and adapt this existing actuator model to our needs Apply large motion to the rotational actuator Create the band object Setup rotational motion Mesh

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-1

Maxwell 2D v12
Perform basic large motion tests Large Rotational Standstill test Large Rotational Constant Speed test Large Rotational Transient Motion test Compute magnetic rigidity and mechanical natural frequency Estimate timestep for transient solver Make a field animation with large motion

9.13

Basic Exercise: Transient Large Motion Rotational

Open the Rotational Actuator Model

Locate the project Ex_09_13_BasicTransient_MotionRotational_M2dTrs120.mxwl. Open it, activate the design 00_Template and start working from there. You can copy/paste 00_Template into your own working project. The other designs show the fully setup models we will be working on. The model should look like this:

Fig. 1: Rotational actuator example

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-2

Maxwell 2D v12
Setup and Verify the Electromagnetic Part
Prior to employing large motion, the electromagnetic part of the model should work correctly. Users are well advised not to setup a complex model completely at once and then try to simulate, but rather work in steps. Especially in cases eddy current effects, external circuits, and large motion are included, the correctness of the setup for each individual property should be verified. After that, all properties can be considered together. For this quickstart, please study the winding setup and background. We use stranded windings with constant current (to generate a fixed stator flux vector around which Rotor1 will oscillate later). Also, eddy effects will be excluded. Verify the symmetry multiplier being set to 1. In the project tree: RMB click on Model > Set Symmetry Multiplier (the full geometry is simulated). Verify the model depth being set to 25.4 mm. In the project tree: RMB click on: Model > Set Model Depth (taken from the original 3D project). Perform a test simulation on the electromagnetic part alone. If desired, play with various excitations, switch eddy effects in Stator1 and Rotor1 on and off, vary material properties, etc. For each test check the electromagnetic fields for correctness. Refer to the corresponding topics on materials, boundaries, excitations, meshing, transient simulations without motion, and post processing. If the electromagnetic part without motion effects yielded correct results, make sure to re-apply the same model setup as elaborated at the previous page (00_Template).

9.13

Basic Exercise: Transient Large Motion Rotational

Rotational Large Motion The Maxwell Approach

Maxwell separates moving from non-moving objects. All moving objects must be enclosed by one so-called band object. For rotational motion, the band object must be cylindrical with segmented outer surface, i.e. a regular polyhedron. Maxwell considers all moving objects (inside the band) to form one single moving object group.

Fig. 2: Band object separating rotor from stator

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-3

Maxwell 2D v12
Constant Speed mode:

9.13

Basic Exercise: Transient Large Motion Rotational

If the model is setup to operate in constant speed mode (see below), Maxwell will not compute mechanical transients. However, changing magnetic fields owing to speed m, i. e. dB/dt effects are included in the field solution. Mechanical Transient mode: In case inertia was specified, Maxwell will compute the motion equation in each time step.

Jm d2m(t) / dt2 + kD(t) dm(t) / dt = T(t) + Tm(t)

See Appendix A for a variable explanation.

Apply Large Motion to the Rotational Actuator Create the Band Object and Mesh
First, lets examine the moving parts to comply with Maxwells conventions: All moving objects can be separated from the stationary objects and can be combined to one single rotating group. All moving objects be considered to perform the same cylindrical motion. Create the band object: We want a regular polyhedron that encloses all moving objects. Outer surface segmentation should be between 1 and 5, i. e. we will have between 360 and 72 outer surface segments. The band object should preferably cut through the middle of the airgap, leaving about the same space to Rotor1 and Stator1. However, this is not a must. Hide all objects except Rotor1 and Stator1. Determine the required radius:

Modeler > Measure > Position

In the geometry, click first on the origin, then move so that the mouse pointer snaps to one outer corner point of Rotor1. Read the Distance value from the Measura Data window (51.05 mm). Then move over so that the pointer snaps to one inner corner point of Stator1. Read the Distance value (53.75 mm). See Fig. 3 next page. Thus, band should have a radius of 52.4 mm. Here, 52.5 mm was used.

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-4

Maxwell 2D v12

9.13

Basic Exercise: Transient Large Motion Rotational

Fig. 3: Rotor1 radius measurement Draw the band:

Draw > Regular Polygon, have X = 0, Y = 0, Z = 0 for the Center

position. When asked for the Radius, enter 52.5 into the dX (or dY) field, leaving dZ and dY (or dX) zero. Set the number of segments to 72.

Rename the thus created object to Band1, apply a transparency of 0.9, and maybe use some nicer color. The created Band1 object should look like Fig. 4.

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-5

Maxwell 2D v12

9.13

Basic Exercise: Transient Large Motion Rotational

Fig. 4: Band object Band1 We have now created Band1 that encloses all rotating objects (only Rotor1 in this example). 72 outer segments means a new segment every 5. For more accurate simulations we should apply more segments. Setup rotational motion: In the history tree, right mouse click on the Band1 object and choose:

Assign Band...
This automatically separates moving from stationary objects. Under Motion Type, check Rotational for the Motion Type, leave Non-Cylindrical unchecked, and select Global:Z Positive for the Rotation Axis. On the Data tab, apply zero for the initial position. Thus, motion will start at t = 0 with the rotor position being as drawn. Applying m0 0 would start with Rotor1 rotated by m0 from the drawn position. Leave Rotate Limit unchecked (allowing the rotor to spin continuously) and leave Non-Cylindrical unchecked. Under Mechanical, uncheck Consider Mechanical Transient and apply an Angular Velocity of zero.

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-6

Maxwell 2D v12
Now, we have setup large rotational standstill. Positive magnetic torque is generated around the positive z-axis (global coordinate system, Fig. 5). In the project tree > active design > Model, two new entries have been created Band and Moving. Clicking on Moving inspect the motion setup. Applying the same constant current as before, we can expect the same constant magnetic torque (provided a good mesh).

9.13

Basic Exercise: Transient Large Motion Rotational

Fig. 5: Motion setup Mesh Meshing is a very critical issue with respect to simulation speed and accuracy. For here, we will apply a rather coarse mesh only, by which the solver will just yield satisfactory results. Band1: For torque computation, the most critical areas are the airgap and its immediate proximity. Thus, the band mesh is crucial for accurate results. We will apply a length based mesh on the surface and inside of Band1. We will restrict the number of elements to 5000. This will do for these tests.
Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-7

Maxwell 2D v12

9.13

Basic Exercise: Transient Large Motion Rotational

Right mouse click on Band1 > Assign Mesh Operation > Inside Selection > Length Based. Rename this mesh entry to Band_Length, Restrict Length of Elements unchecked, Restrict Number of Elements checked, set to 5000, OK. For all other objects we will also just restrict the number of elements for simplicity reasons only. The mesh will be assigned one by one. For each, right click the object > Assign Mesh Operation > Inside

Selection > Length Based.

Restrict Length of Elements unchecked, Restrict Number of Elements checked. Following, first the object names are listed, second the maximum number of elements to apply, and third the name given to the resulting mesh entry: Rotor1 1000 Rotor_Length Stator1 1000 Stator_Length CoilA and CoilB 100 Coils_Length (simultaneously selecting CoilA and CoilB will try to assign 100 tetrahedrals to both objects, i. e. about 50 to each) Background 1000 Background_Length. Once done assigning, you should see project tree entries like Fig. 5. Assign a solution setup: In the project tree, right mouse click Analysis > Add Solution

Setup... ClickOK to accept the default values for now.

We need this setup just to allow meshing and check the mesh, we will care about its values later. In the project tree right mouse click Analysis > Setup1 > Apply Mesh Operations. Watch the progress bar (usually bottom right). Watch the message window (usually bottom left) for a message that says that the Simulation has been successfully completed. Now, meshing is done. Select all objects except for Region1. Maxwell > Fields > Plot Mesh. Your mesh plot should look similar to Fig. 6.

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-8

Maxwell 2D v12

9.13

Basic Exercise: Transient Large Motion Rotational

Fig. 6: Mesh entries

Fig. 7: Resulting mesh

Perform Basic Large Motion Tests

These basic tests serve model verification. They can be executed rather quickly. Should they fail in whatever respect, there is no use going further and working with more complex models (like mechanical transients, external circuits, eddy currents, etc.). Simulate the Large Rotational Standstill test: Refer to design 11_GeoFull_MagI_MchStandstill. Setup Solution In the project tree, double click on: Setup1. Set 20 ms for the stop time. Set 5 ms for the time step. Leave all other properties of Setup1 untouched. Exit by OK. We have now told Maxwell Transient to simulate five timesteps only (icl. zero), because we are expecting a quasi magnetostatic result. Right mouse click Analysis > Setup1 > Analyze will start the simulation process. Its progress can be monitored in the progress window. Post process: We will just look at the force function at the moment. In the project tree, right mouse click Results > Create Transient Report. > Rectangular Plot, select Category = Torque, and Quantity = Moving.Torque, press New Report, and Close. Your report should show constant force of about 0.4 Nm.

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-9

Maxwell 2D v12

9.13

Basic Exercise: Transient Large Motion Rotational

Perform the Large Rotational Constant Speed test: Refer to design 12_GeoFull_MagI_MchSpeedslow. We will now operate the rotational actuator at a very slow constant speed. Remember, there is only one magnetic excitation present in the model namely constant coil current with stranded windings. Alternatively, Rotor1 could have been assigned permanent magnet properties. Eddy effects are switched off for all objects. We can now use Transient with Large Motion to monitor cogging torque effects. Setup motion In the project tree, right mouse click on the current Model > MotionSetup1 and select Properties. Under Data, set Initial Position to -61 deg. Under Mechanical, set Angular Velocity to 1 deg_per_sec. Rotor1 as drawn has a -29 offset. This is taken to be the zero position for the transient solver. By giving an extra -61, positive rotation of 1 /s starts at: -61 -29 = -90. Setup Solution Right mouse click on Analysis > Setup1 > Properties. Set Stop Time to 180 s. Set Time Step to 5 s By rotating at a speed of 1 /s 180 s long, Rotor1 will move 180, i. e. from -90 to +90, at 5/step. Apply the mesh operations and analyze Setup1. During solving, you can already open the report Torque(t). The plot is going to build up with each timestep completed. See Fig. 7.
Ansoft Corporation
500.00 400.00 300.00 200.00 Torque [mNewtonMeter] 100.00 0.00 -100.00 -200.00 -300.00 -400.00 -500.00

Torque(t)

12_GeoFull_MagI_MchSpeedslow
Curve Info Torque Setup1 : Transient

Fig. 8: Magnetic torque T(t)

0.00 20.00 40.00 60.00 80.00 100.00 Time [s] 120.00 140.00 160.00 180.00

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-10

Maxwell 2D v12

9.13

Basic Exercise: Transient Large Motion Rotational

Perform the Large Rotational Transient Motion test: We will now operate the actuator as a one-body oscillator. Inertia will be specified as well as some damping. We can expect Rotor1 to oscillate around the stator flux axis (y-axis) at some natural frequency f0, which can be approximated as:

f0 =

1 2

c J

understood as a mechanical spring spanned between Rotor1 and Stator1, whose force coming from the magnetic field. We can roughly calculate rigidity c from the cogging torque function (stable limb):

J in kgm2 is the total moment of inertia acting on Rotor1. c in Nm/rad is the magnetic rigidity. As an analogy it can be

c =

T m

400 mNm = 2.3 Nm/rad rad(10)

Assuming inertia J = 0.0024 kgm2, an approximated f0 = 5 Hz results. This is sufficient for estimating the necessary timestep as far as mechanical oscillations are regarded. Refer to design 13_GeoFull_MagI_MchTransient. Motion Setup (Model > MotionSetup > Properties): Under Data, set Initial Position = 0. Under Mechanical (see Fig. 9), set Consider Mechanical Transient = checked Initial Angular Velocity = 0, Moment of Inertia = 0.0024 kgm2, Damping = 0.015 Nms/rad, and Load Torque = 0. This causes 15 mNm resistive torque at 1 rad/s speed. We thus expect oscillation between -29 and +29 (w. r. t. stator flux axis) at f0 < 5 Hz with damped amplitudes.

Fig. 9: Motion setup

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-11

Maxwell 2D v12

9.13

Basic Exercise: Transient Large Motion Rotational

Solution Setup: Under Analysis > Setup1 > General, set Stop Time = 0.5 s, Time Step = 0.01 s From f0, we can expect a >200 ms cycle. At 10 ms timestep we will sample one cycle >20 times. Analyze this design. Open the already generated report Torque(t). This and the two additional reports for speed and position should look like Fig. 9-11.
500.00 400.00 300.00 200.00 100.00 0.00 -100.00 -200.00 -300.00
100.00 -400.00 80.00 60.00 40.00 20.00 0.00 -20.00 -40.00 -60.00 -80.00 50.00
Curve Info Torque Setup1 : Transien

Torque [mNewtonMeter]

Fig. 10: Torque T(t)

Curve Info Moving1.Speed Setup1 : Transient

Moving1.Speed [rpm]

Fig. 11: Mechanical speed m(t)

Curve Info Moving1.Position Setup1 : Transient

40.00

Moving1.Position [deg]

30.00

20.00

10.00

0.00

Fig. 12: Mechanical position m(t)

0.00 100.00 200.00 Time [ms] 300.00 400.00 500

Ansoft Maxwell 2D Field Simulator v12 Users Guide

9.13-12

Maxwell 2D v12

9.13

Basic Exercise: Transient Large Motion Rotational

The transient reports have been created using: Category: Speed, Quantity: Moving.Speed, and Category: Position, Quantity: Moving.Position. Fig. 10-12 on the previous page: T looks as expected from previous simulations. m corresponds to Ts first derivative and is correct. m oscillates around +29, which is the stator flux axis (y) with respect to the initial position.

Appendix A: Variable Explanation:

m(t) m0
dm(t) / dt, m(t) Mechanical angular position in rad (angles can also be given in degrees). Initial m in rad. Note that the drawn rotor position is considered as m0 = 0. Mechanical angular speed in rad/s. Initial m in rad/s. Mechanical angular acceleration in rad/s2. Moment of inertia in kgm2. This is the total inertia acting on the moving object group. If extra inertia needs to be included (i. e. inertia not geometrically modeled), just add this to Jm. Damping koefficient in Nms/rad. For kD = 1 Nms/rad, resistive torque of 1 Nm would be generated if the moving parts turn at 1 rad/s. kD can be a function of t, m, or m. Magnetically generated torque in Nm. Mechanical extra torque in Nm, this can be a constant or a function of t, m, or m. Note, that a positive Tm value will accelerate rather than brake. The current simulation time in s.
9.13-13

m0
d2m(t) / dt2

Jm

kD(t)

T Tm

Ansoft Maxwell 2D Field Simulator v12 Users Guide