CedratNews 65en HD PDF

CEDRAT MaGaZINe - N 65 - DECeMBer 2013
CONTENTS
Highligths
2 - Flux 11.2 new release: accelerate your design... 4 - New functionalities in Flux thanks to macros. 6 - CEDRAT HPC stragtegy... 8 - Control of an induction machine using FluxPortunus coupling. 10 - Magneto-vibroacoustic analysis: a new dedicated
Editorial
Vincent March, Marketing Director - CEDRAT.
context inside Flux. 13 - Welcome in the world of multi-domain simulation. 15 - Customized tools for efficient virtual prototyping. 16 - Dramatic improvements in BLDC machines with Flux. 18 - Finite elements method modeling of contactless energy transfer systems. 22 - 2014 trainings & events.
he right partner to access the Premium Market .
Because of its acceleration 0-60 mph in 4.4 seconds amongst other features, the Tesla Model S was elected Car of the Year 2013. The recently-marketed BMW i3 will transport you just as comfortably as any traditional combustion engine-powered city car, with a range of 160 km... and very convincing, silent acceleration (0-60 mph in 7.2 seconds). The Red Bull team has topped world Formula 1 rankings for many years. Last summer, Solar Impulse crossed the United States by air, powered only by solar energy. Companies who believe in the power of innovation and use it at the heart of their design strategy are building a promising future. With the best engineers & experts, using the best tools and methods to meet the challenges of the most demanding customers, they are designing the best devices and securing their future. The premium market is the most demanding, where only the strongest survive. In the fantastic projects mentioned above and there are many others it is great to think that some of our technology and our expertise has contributed to the success of electrical component & system design. Guided by the same spirit of innovation as our customers, we want to continue to support them and you as a key partner to enter this market offering the highest added value. As you will discover in the latest issue of this magazine, our tools and professional expertise will help you design the best tomorrows world, keeping one step ahead. If youre looking to be the best, you can count on us. We are striving for the same thing.
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CEDRAT News - N 65 - December 2013
Flux 11.2 new release: accelerate your design with our new Flux!
Vincent Leconte, Benjamin Vallet - CEDRAT.
ach year, a new version of Flux software is delivered with new functionalities. Once again, the forthcoming version brings many features to 2D, 3D and Skew users, with a good balance between new modeling capabilities and enhanced userfriendliness for efficient design explorations. CEDRAT will release Flux 11.2 before the end of 2013, offering the most advanced 2D electromagnetic simulation software on the market.
Draw. Create. Design.

Design often begins with a drawing. From a free-hand drawing, a paper copy of a CAD plan or simply from a picture, just generate an image file, load it into the embedded Flux 2D sketcher, create your geometry directly with the image in the background, decide on the scale: thats it, your geometry is there, ready to be meshed! Apart from this very practical new feature, many improvements have been added to the sketcher to provide more fluidity and comfort, including enhanced previews and alignment options, detection and automatic correction of errors, movement of entities or improved parameter management.
Fig.1: Flux supervisor new interface makes its easier to learn and use. Of course, such a technique is a great help to inexperienced users because mesh generation is handled automatically and reliably, but this is also very useful for more advanced users because it gives an assessment of solution quality. Since the mesh is refined only where needed, the algorithm offers a good compromise between the number of nodes and result accuracy.
No need to be a specialist to generate a good mesh!

Since Flux 10.3, continuous efforts have been made by our development team to automate mesh generation. Flux 11.2 brings a sea change, with a mesh that can be adapted not only to the geometry, but also now to the physics. This auto-adaptive mesh option is available in 2D for magnetostatic and electrostatic applications. Even though it concerns mesh generation, this capability really takes place during the solving stage, in which the mesh will be refined in an iterative way, starting from an automatic or a user-defined mesh. At each iteration of the auto-adaptive solving process, a solution is computed and analyzed using an error map. This map is based on a physical error criterion and tells you where the mesh should be refined. As seen in Fig.3, mesh refinement is then performed and a new iteration is generated based Fig.2: Draw from an image of your on this new mesh, until a given 2D plan in Flux sketcher. accuracy threshold is reached.
A new material database manager
has sought to continue to offer experts the best electromagnetism simulation tool, which has secured the reputation of Flux for 30 years. But it hasnt forgotten beginners and less experienced users. The satisfaction expressed by these two user categories encourages us to do more of the same.
V. March - Marketing Director
In some cases, having a rough estimate of material characteristics is enough to get sufficient accuracy. But for many applications, for instance for closed magnetic circuits, material data are critical to be able to model the physics correctly. That is why the definition of material Fig.4 : New material database characteristics is central to available in Flux. the modeling process. A new dedicated interface has been developed for the new Flux version. It comes with a set of data from different manufacturers, but also lets you enter your own material data and manage several databases. Very useful tools are embedded to help you to create your B(H) curves and fit them to measured data, using smooth splines for example. Of course, as always, Flux the capability of parameterizing material Over a number of versions, CEDRAT offers characteristics for sensitivity analysis!
Anisotropic material modeling

In typical devices such as electric machines or transformers, specific or laminated materials are used to enhance performance. Laminations are mainly there to reduce joule losses and grain-oriented materials may be used to
(see continued on page 3)
Fig.3 : Auto-adaption of the mesh during the solving in 2D.
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produce better magnetic flux conduction. To get a good estimate of these effects, specific models have to be used. For laminated parts, representing each lamination in 3D is a very straight way of doing it. However, it involves very costly computations. As shown in Fig.5, a smart way of handling the situation is to use homogenized mathematical models to precisely calculate the behaviour of the material, even if the part is represented as if in one piece, from the geometry and mesh point of view. Anisotropies due to the grain-orientation of ferromagnetic materials can also be addressed. What is new is that Flux is now able to handle this kind of anisotropy in association with the nonlinear behaviour of the material.
Fig.6: New Pyflux editor window: simpler, faster, and doesnt require compiler anymore.
Vibro-acoustic analysis
Because the design in electrical engineering is not limited to magnetic aspects, Flux has to be connected to other tools as part of a more global design process. Connection to CAD tools or system-level simulation software already exists, the expansion towards multiphysics is under way. Depending on the domain (mechanical, vibrations, thermal, ) and your specific needs, Flux will be coupled to the best 3D simulation solutions, with each time a dedicated user-friendly and performing workflow. The availability of more computing power makes this kind of coupling more affordable and it brings really new information to the designers. In this version, a one-way coupling to vibro-acoustics analysis has been set-up, with a connection to vibration simulation software: MSC Nastran and LMS Virtual.Lab. It comes not only with export capabilities but also with useful dedicated tools to post-process magnetic forces, calculate harmonics and visualise results. This is the perfect tool to analyse and reduce the noise in electric rotating machines. More information are available in a separate dedicated article, pages 10 to 12.
Fig.7: Example with a hysteresis switching.
Customize, automate, be more efficient every day

Customizing the software to your specific usage and making simulation tasks automatic using scripting are really the ways you get really efficient with the tools and free up more time to do more simulations. Things like keyboard shortcuts or automatic macro loading at the start of Flux are two examples of tools that help productivity. A key element in the automation of processes is the Pyflux language which lets you fully control Flux through scripts. Flux windows have been re-arranged and a new Pyflux editor window (as seen in Fig.6) now appears with very useful tools for coding such as syntax checking, colour highlighting, indentations, etc. You can then write, copy/paste your code and test it immediately: it really helps generate and manage your scripts. The customization of Flux goes much further than scripts. You can expand Flux modeling capabilities by writing your own subroutines in Groovy (similar to Java). To do so, no compilation is needed; you can edit directly in the editor, save and execute without closing Flux. For example, you can create your own B(H) models. Fig.6 shows how this capability was used to generate a hysteresis vectorial model.
Wait no longer to download Flux11.2!

and take advantage of its many new benefits. In addition, Flux simulation power is now extended thanks to the distribution of calculations through GOT-It (dont miss the special article on page 6 !). It is not only computation power that is brought, but a really smart way to search the design space and find innovative solutions. In the last 3 years, many improvements have been done in Flux with more focus on 2D, leading to a best-in-class tool for electromagnetic simulation. In future versions, the same energy will animate the CEDRAT team to deliver state-of-the art simulation technologies and interfaces for you to bring performance, value and engineering excellence to your designs. Be ready to innovate! Note to Flux users: all these new features are detailed in the release note, which can be downloaded from our user portal: https://gate.cedrat.com.
Fig.5: Result of lamination region by homogenization process.
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New functionalities in Flux thanks to macros.

Patrick Lombard - CEDRAT.
https://gate.cedrat.com
acros have been available with Flux since 2008. Macros make it possible to add new functionalities to Flux. Macros allow sets of commands to be executed using PyFlux command language, after questioning the user. The questions can include the possibility to graphically select Flux components such as points, face regions, etc. as well as existing files opening a windows explorer. The goal of a macro is to automate tasks, making Flux easier to use. Flux is delivered with a list of ready-defined macros. The full list of macros is available in the C:\Cedrat\Extensions\Macros directory, with the macros_list_EN.pdf file. You will find more macros on the CEDRAT gate (https://gate.cedrat.com). In this paper, we will present some of the macros available: ModifyCoordinateSystemForPoints Search lines with distance lower than a reference value Regulate current with hysteresis method in motors Extrude quantity from 3D curve: compute torque from Maxwell stress along a path
Search lines with distance lower than a reference value

This macro helps find very short lines. These types of lines may appear after importing files in 3D with specific import (STEP, IGES, ProE, CATIA V5, etc.). It is usually linked to an initial file in which the intersection between 2 bodies has not been clearly defined. The purpose of this macro is to check that everything is in order and quickly localize problems. For instance, when all dimensions are set in the millimetre range, if you have length of lines within the range of micrometre, then it is urgent to check what is happening. Lets look at an example.
Modify coordinate system for points

The goal of this macro is to make it possible to modify the coordinate system of points, without modifying its position. Its scope includes the possibility of adding parameters easily, once a dxf file has been imported. It can be useful to have all the rotor points defined in a cylindrical coordinate system (instead of a conventional Cartesian system). Then with the [Edit Array] function, you can edit all the points you want to parameterize, and modify the radius, to make it dependent on a specific parameter. The steps are as follows:
Step 1 2 3 4 5 6 Actions Import dxf file Load the ModifyCoordinateSystemForPoints macro Run the macro on all points or part of them Create a geometric parameter (for instance radius parameter) Use the Edit Array function to modify the points, using the new parameter Modify the value of the parameter
Figure 3: Interface of SearchLinesminimumLength macro.
Figure 4: Result of the macro.
The result can be seen in the 2 following figures:
Figure1: Initial and modified drawing with shaft radius as parameter.
Figure 5: Example of default easily localized with the macro.
by CEDRAT
Figure2: Selection mode.
Flux
(see continued on page 5)
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Regulate current with hysteresis method in motors

In some motors, you have a voltage supply, and you need to get a regulated current, because of power limitation. We have created a new macro to simulate this specific behaviour, common in complex electronic devices. For example, we apply this functionality to a specific SRM motor. The circuit and geometry is shown in figure 6.
The procedure to follow is defined in the table below:

Step 1 2 3 4 5 6 7 Actions Create a cylindrical coordinate system CYL Create spatial quantity Bn=comp(1,VLCS(CYL,B)) Create spatial quantity Bt= comp(1,VLCS(CYL,B)) Create spatial quantity Pn=(BN*BN-BT*BT)/(2*MU0()) Create spatial quantity Pt=BN*BT/Mu0() Create a path in the airgap Create a 3D curve versus the path and time and computing the quantity Pt*radius*Nper*depth with radius the radius of airgap path, Nper is the number of periodicities (4 for one quarter), and depth is the depth of motor Run the macro ExtractFrom3DCurve Select the 3D curve Select TIME as variation parameter Type in INTEGRAL (in order to compute the integral
The macro produces a new curve. Figure 6: Circuit and geometry for SRM motor. We apply the macro to limit the current to a specific range. We define the average maximum value of current, and also the varying law around which the current will be limited. Figure 9: 3D curve of tangential force along a path in the airgap versus time.
Figure 10: Interface of the ExtractFrom3DCuve macro.
Figure 7: Current with or without regulation (with or without chopping).
Figure 11: New curve result of the ExtractFrom3DCurve macro.
Figure 12: Display of torque computed with extraction from 3D curve, superimposed. Figure 8 : Interface of CurrentRegulator macro.
Extract quantity from 3D curves

The goal of this macro is to extrude quantities from 3D curves. When a 3D curve is displayed, it can be interesting to extract the average value (or rms, max, integral, etc.) along one curve, and to display this average value versus another parameter. For example: we propose applying it to a specific problem: how to compute torque from Maxwell tensor, computed along a path in the airgap in 2D? This question is important when checking mesh before extracting density of force for mechanical analysis.
Conclusion
In this article, we have seen a number of macro applications. Macros can be used to easily create new functionalities in Flux. They can be activated at different levels when using Flux: geometry, physics, circuit, solving process and automatic postprocessing. It is a very interesting feature, making your working life easier with Flux!
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CEDRAT HPC strategy new step: distributed computing for Flux.

Diana Mavrudieva - CEDRAT.
igh-Per formance Computing (HPC ) involves using powerful computation resources to reduce computation time for software applications. There are various HPC methods, such as: multi-threading (multi-core); distributed computing; GPUs computing; message passing interface and cloud computing. Flux software has already been equipped with parallel solvers (MUMPS) that allow some Flux solving tasks to be handled simultaneously on several processors on a single machine (Fig.1).
Although the distribution process is fully automatic, CDE offers the possibility of seeing the evolution of the computing jobs in real-time and offers controls to the user to fine-tune the use of computing resources. Dedicated interface Automatic distribution and management of the computations Distribution on single multi-core PC or cluster Distribution of any Flux 2D and 3D applications Available for Windows dependent OS 64-bits
The figure 4 presents CDE performances with computation time gains according to the number of processors used.
Figure 1: Flux solving process.
Now, CEDRAT is pleased to propose to the Flux users another HPC capability for computation time gain. The Cedrat Distribution Engine (CDE) has been developed as a tool to perform and manage the distributed computing for Flux. Associated to GOT-It (since version 2.0), CDE allows numerous Flux calculations to be distributed and performed simultaneously (since version 11.1SP2) over all the processors available on a single multi-core PC or using a network (or cluster Fig.2).
Figure 4: Performances evaluated using Flux 2D and 3D parametric computations driven by GOT-It.
Efficient optimization application example

Figure 5 shows an optimization example performed with GOT-It using distributed computing. Thank to CDE, the evaluations required for the optimization are distributed across all the processors available and executed simultaneously. Thus, calculation time to find the optimum solution has been significantly reduced.
Figure 2: view of a network example (cluster).
CDE features and performances

The CDE tool has a dedicated interface (Fig.3) allowing configuration and management of computation resources, as well as supervision of the state of submitted tasks. The calculations required by GOT-It are listed in the waiting thread of the distribution manager. Many tasks are performed simultaneously as the processors become available. As soon as a resource is available, another task is launched.
Figure 5: The progress bar shows: number of evaluations done / in progress / total.
Conclusion
CEDRAT HPC capabilities for Flux have been presented in this article, as well the dedicated tool CDE for distributed computing. Thanks to the distributed computing and powerful computation resources, the optimization of any Flux model could be significantly speed-up with the same result accuracy.
Figure 3: CDE task manager.
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CEDRAT News - N 65 - November 2013
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Control of an induction machine using Flux-Portunus coupling.

Leila Nguimpi Langue - CEDRAT.
veryone will have noticed that the use of induction motors has significantly increased lately. One of the key challenges surrounding electrical machines is their precise control. CEDRAT is meeting the challenge of simulating the control of an induction machine using one of its tools: Portunus - system simulator. The next obvious step to do this as precisely as possible was to create a Flux-Portunus coupling. These equations describe the functioning of the motor. They are meant to build Isq and Isd, the current order to obtain the desired current and magnetic field vector. - PI Controller
1. Control architecture: Indirect FieldOriented Control (IFOC)

>> a - What does IFOC involve?
The main aim for a motor is to produce the maximum level of torque at a given speed, and the best machine for this purpose is the Brushed DC electric motor. With it, the current and the flux vector are always in squaring position, delivering a constant level of maximum torque. This device is pretty limited in terms of steadiness and the settings are done empirically way. Nevertheless, it is easy to build and gives excellent results when the coefficients are well calibrated.
Action Proportionnal Integrator Steadiness Precision Speed
+ ++
+ -
>> c - Benefits and limitations of an IFOC
Stator windings
The target in the FOC is to mimic this functioning by delivering current to the motor which will enforce a squaring position between the current and the flux vector within the rotor.
This method is simple to implement, as only the position of the rotor is needed to generate orders. Magnetic and torque are treated separately. An induction machine controlled via an IFOC is technically better than a DC machine with the same output power. But, in practice, implementation of this command requires a DSP controller for PARK/CLARKE transformations. IFOC depends heavily on the machines electromagnetic parameters.
2. Flux-Portunus coupling stakes

The most interesting aspect of the bridge between Flux and Portunus is simulation precision. Indeed with Flux, the finite elements deliver the closest model of the motor compared to the real machine. The control built into Portunus is applied to the most realistic model of the motor.
>> a - Design specifications and requirements

The motor considered in this case is an induction machine from the technical paper tutorial. We want to command the speed of the machine at no-load rate.
Overview of the architecture of an IFOC
>> b - Details of the architecture

- Motor model- key equations
Power 8 KW
Phase 3
Frequency Enc. Stator Bars Rotor Pole pair Inertia 50 Hz 24 20 1 0.034
(continued on page 9)
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Single speed order
Rs 1.54 W
Rr 1.44 W
Lfs 10 mH
Lm 332 mH
P 1
J 0.034 Kg.m
>> b - Transformations Block

Portunus Library already includes blocks for PARK/CLARKE transformations. - Inverse PARK/CLARKE transformation: from a (d,q) system from an (a,b,c) system.
Variable speed order
4. Conclusion
- Inverse PARK transformation: From a (d,q) system to an (,) system Thanks to coupling, we can get an idea of the behaviour of the machine in its environment. It becomes clear that analytic and finite element results are very close. However, FE curves show speed and torque fluctuations very precisely, like on an actual machine. On the other hand, Portunus is to be praised for its well-stocked library and the accuracy of its results, even for an analytic tool. And calculation time is very quick, less than 10 minutes for the Portunus simulation and around 3 hours for the coupling simulation.
3. Simulation strategy
Before coupling Flux to Portunus, we first need to have an idea of the PI controller parameters. So, preliminary simulations are run with an analytic model of the machine taken from the Portunus library. This step is very quick and easy for setting PI parameters. Once the PI parameters are known, the coupling can begin.
>> a - Portunus simulation- PI settings

Speed order Current order 5A Voltage 400 V P gain 0.1 I gain 0.1
3000 rpm
Single speed order
Variable speed order
>> b - Flux Portunus coupling

Then, the analytic model of the motor is replaced by a Flux communicator.
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Magneto-vibroacoustic analysis: a new dedicated context inside Flux11.2.

Fabrice Marion - CEDRAT.
On the other hand, to export the forces to MSC Nastran, the densities of force are computed on a circular support inside the airgap (on a circle in 2D environment or on a cylinder for 3D or Skew environments). Note that this method only applies to an electric rotating machine (with a rotating mechanical set). Whatever method is used, the main functions in the new context of Flux are the same: creation of a computation support, computation of forces and visualization and export of results. In the following paragraphs, we will focus on the method dedicated to MSC Nastran. From the computation of densities of forces under Flux through to vibration analysis in the mechanical environment, several issues are taken into account with the constant objective of securing rapid calculations to determine an optimized process. This is what we describe stepby-step below.
design offices ability to assess and control vibration and noise levels generated by an electric motor during the design stage is a key asset - particularly for ensuring the end users comfort. This is especially true for electric powertrains on electric vehicles, and also when looking for higher performance in terms of power, efficiency, reliability, and - obviously - reduced material costs linked to the supply of magnetic equipment. During the past 3 years in the context of the AVELEC project (1), CEDRAT has been working together with specialists and industrial partners to set up and validate a full vibro-acoustics analysis process for noise reduction in electric machines. Two domains have to be considered - the electro-magnetic finite element model, including its drive, and the mechanical environment for the acoustic performance study. Whilst the sources of electromagnetic excitation are calculated using Flux, the vibro-acoustic computations and analyses can be performed with mechanical simulation software such as MSC Nastran or LMS Virtual. Lab (Fig. 1).
Stator deformation Noise
Electromagnetic modeling
>> 3D effects
The vibro-acoustic context is available for 2D or 3D environments, but also for Skew. For electric rotating machines, CEDRAT has developed the ability to extract magnetic force densities from electromagnetic simulations with Skew. NB: the use of the Skew environment involves representing
Electromagnetic force
Flux Magnetic analysis
NASTRAN Vibratory analysis
Acoustic analysis
Figure 1: The need to combine two areas of physics: electromagnetics and mechanics. Flux has the inherent capacity to calculate all the physical quantities needed to determine electromagnetic forces in electric motors. The aim of Fluxs new vibro-acoustic context is to allow users to define electromagnetic forces easily as input data for a mechanical environment. On this basis the vibrations and magnetic noises generated can be calculated and analyzed. From the computation of magnetic force densities in Flux through to vibration analysis in the mechanical environment several items are taken into account with the constant objective of performing fast calculations in order to identify an optimized process. This article explains the methodology used from the electromagnetic side, and, via an example, a concrete analysis study is carried out. Figure 2: Reduced model, geometric periodicities are taken into account in 2D, 3D and Skew environments.
Main principles
On the Flux side, it is possible to model the device we have to analyze in 2D, 3D and also Skew environments. From there, we can deliver electromagnetic forces as data inputs for mechanical environment dedicated to the analysis of mechanical structures. Depending on the mechanical software used (MSC Nastran or LMS Virtual. Lab), the theoretical methods employed to compute magnetic force densities are different. On the one hand, to export forces to LMS Virtual. Lab, the force densities are computed at the borders of the regions under consideration. This is done by using the Maxwell tensor. It is the same method as that used in Flux to calculate what we call magnetic pressure (dFmag/dS). This is a generic method that can be applied to all kinds of devices.
the electric motor as n 2D slices. These n models are solved simultaneously and automatically. During post-processing, the corresponding 3D model is reconstructed automatically from the results of each of the 2D slices and physical quantities required for the users calculations extracted. It is thus possible to assess the effect of skewing of the stator slots for example, which is a purely 3D effect. With this approach, the computation time required is acceptable (comparable to 2D). The figure below (Fig. 2) shows the type of results that can be achieved through this approach.
>> Periodicity of the device
The method can allow to take into account the periodicity of the device. It is possible to represent a fraction of the electrical machine according to the parameters of electrical machine geometry and winding. Thus, the volume of the mesh elements is considerably reduced and with it the corresponding computation time. During the post-processing of results, the complete machine is restored and all physical quantities, such as magnetic pressure, can be calculated.
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Computation in transient magnetic

>> Computing time constraint
A full mechanical period (one round of the rotor) is required for vibro-acoustic analysis. The time step must be short enough to allow the frequencies associated with the way of controlling and driving machines to be taken on board (Pulse-Width Modulation - PWM - for example) = several kHz . Thus, the calculations for magneto-vibroacoustic coupling require an electromagnetic transient simulation involving a large number of time steps (several hundred calculation time steps). So everything must be implemented to minimize computation time.
Computation and distribution of magnetic force

For each surface element of the mechanical mesh, the forces are calculated from the magnetic force density defined above. Then, these forces are distributed over the nodes bordering the surface element. This is performed automatically for each time step. What happens at the slot opening area is also considered. The distribution of forces refers to time signals (Fig. 5). NB: when geometric and / or temporal periodicities are used in the Flux environment, the 3D geometry (mechanical mesh) and the time signal over the full mechanical period are automatically reconstructed.
>> Reducing the computation time range
When the context allows it, simulation can be performed taking only a fraction of a mechanical period into account. During postprocessing of results, when forces are extracted, entire signal can be re-built. The gain in computation time is very substantial.
Computation and extraction of force density

From the computed magnetic quantities and for each time step, the force density is calculated on a support within the airgap (Fig. 3). For 2D modeling a circle is used, and for 3D or Skew environment, a cylinder. Two components of force density are computed: normal and tangential. Normal component: Figure 5: Main principles for the computation and distribution of magnetic force on mechanical nodes.
Tangential component:
Bn x Ht
Figure 3: Components of force density inside the airgap.
Import of mechanical meshing

In the mechanical environment, users have to select geometry surfaces where electromagnetic excitation sources have to be computed. Then, taking all these surfaces into account, the corresponding mesh is generated and recorded in a file. NB: this is a 3D mesh. In Fluxs new vibro-acoustic context, the mechanical meshing has to be imported (Fig. 4). Length units are taken into account. NB: the relative position between the mechanical mesh and the electromagnetic model can be adjusted in Flux. After importing the mechanical mesh, visualization is available in 3D (with Flux2D as well as 3D or Skew).
Figure 4: Import and adjustment of the mechanical mesh in Flux.
Figure 6: Magnetic force on mechanical nodes in 2D, 3D or Skew.

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Harmonic analysis
As indicated earlier, a time signal is associated with each node of mechanical meshing. For each time signal, harmonic analysis is performed. The first harmonic corresponds to one mechanical round, For each mechanical node, and for each harmonic, the magnitude and phase are computed for both normal and tangential components.
Visualization of results
The aim is to verify the smooth running of the process and confirm that the results can be exported. This allows an initial analysis of electromagnetic force distribution, display of electromagnetic force for each time step, display of electromagnetic force for each computed harmonic and the ability to visualise the corresponding magnitude vs. phase.
Export of results
Lastly, automatic file creation can be activated in *.bulk format, compatible with MSC Nastran (another more or less similar method exists to export data to LMS Virtual.Lab). The harmonics to be exported can be selected. The corresponding magnitudes and phases of harmonics of forces are exported. NB: the unit of force can be selected before exporting. In this mechanical environment a structural noise and vibration model will be set up for an acoustic noise propagation analysis - enabling a sensitivity study of the acoustic pressure in order to optimize the machines noise production. This new context with the new capabilities is available in the new version 11.2 of Flux (Fig. 7). Today, it enables the calculation, visualization and export of magnetic forces dedicated to computing environments such as MSC Nastran or LMS Virtual. LAB, which will be shown in another article in the new edition of our CEDRAT News. Undoubtedly, this new feature will be expanded in the near future with extended compatibility with other mechanical environments. The CEDRAT efficient application team remains at your disposal for any advice or to give a demonstration in this new field full of promising prospects.
(1) We have to highlight the fact that a part of the development of this new feature has been made possible thanks to the AVELEC project in which CEDRAT was involved with partners such as VibraTec, UTC, RENAULT and ADETEL Goup.
Conclusion
The elements of the new coupling procedure described above illustrate an efficient process using Flux environment in a proven methodology and offering convincing results in a reasonable computation time. Thanks to Flux motor overlays the geometry can be easily described, meshed, and efficiently post-processed in the dedicated context. This direct coupling for vibration & acoustic performance evaluation can be done with Flux 2D, 3D and skew environments.
Figure 7 : New interfaces, new features developed in Flux11.2 dedicated to the vibroacoustic field.
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Welcome in the world of multi-domain simulation.

Pascal Guitard - CEDRAT. >> A mixed analog / digital language
ortunus is a system simulator for both digital and analog components modeling. Its versatile & highly user -friendly interface makes it possible to combine modeling approaches such as conservative networks, block diagrams, and state machines. Since interoperability is a key elements of the design process, Portunus already supports VHDL-AMS and Spice standards, and has strong links to others software: Motor-CAD and InCa3D imports, connector with GOT-It and I-sight, co-simulation with Flux 3D and Simulink. New strong points of Portunus recent development are the release full implementation of advanced VHDL-AMS functions, coupling with GOT-It optimization tool, new ND-lookup tables for reduction model.
Allows modeling of logic systems, analog systems or a mix of continuous and discrete time that always features in mechatronic systems. The continuous domain is based on Kirchhoff approaches, which facilitates model setting because there is no particular structure to write equation contrary to C-model where Jacobian matrix has to be set (which is a long and fastidious work!). >> The new release provides 9 videos tutorial entitled How to use VHDL-AMS in Portunus 5.2 It shows how to use the most advance VHDL-AMS functions with Portunus and how to plug VHDL-AMS models with others models into Portunus schematic, how to build VHDL-AMS libraries
Advanced data import: N-D look-up table

N-D tables are the best descriptions in terms of accuracy vs. computation time. This methodology is commonly used for model reduction: Importing data from measurement Importing data results from another software Example with Flux 2D/skew/3D: Generation of spatial quantity tables (Flux, Force, Torque, Temperature) in terms of I/O parameters (Current, Position, Temperature...) to represent behavior of an electromagnetic system
Mechatronic language: VHDL-AMS

>> Standard language for collaborative work
Essential when cross-departmental teams have to communicate with the same language: Facilitates model and library exchanges between different teams working on the same project, sub-contractors, suppliers, etc... An IEEE standard worldwide used
>> Language for functional decomposition
Functional Virtual Prototyping methodology make it possible to model and design system from specification to the prototype with V-cycle methodology approach. Project manager is the technical solution proposed by Portunus to manage specifications, models, results and documentations generated by collaborative work. This tool helps reduce time to market & cost by limiting backward during the modeling phase Figure 1: Portunus V-cycle methodology
Data Export
Co-simulation
Actuators
Sensors
PMSM
Coupling with optimization tool

By now, it is possible to optimize your entire system for transient applications with GOT-It, CEDRATs optimization software. Parametric and sensitivity analysis will help to design your system!
by CEDRAT
GOT-It
Optimization
Data Import
SPEED
by CEDRAT
InCa3D
by CEDRAT
Flux
Co-simulation
Portunus
Motor-CAD
ICar component
Portunus

Input parameters
by CEDRAT
GOT-It
Direct optimization
Data exchange with server
CEDRAT Software

Optimization algorithm
>> A multi-physics and multi-abstraction language
Surrogate factory
Indirect optimization
Flux 2D/3D InCa3D Portunus ...
Postprocessing command file
VHDL-AMS fits all requirements for system-level modeling via its structural decomposition approach. The standard makes it possible to simulate at specification level, via description of more and more refined models through to component level. All physics can be described and coupled: VHDL-AMS takes on board the key notion of transversal view introduced by the mechatronic domain, impossible with SPICE, VHDL (without AMS extension) models
Output functions
Optimization problem definition Selection of optimization strategy Model reduction Robustness design analysis
Design of the study case Easy connection to GOT-It Device performances computation
Coupling CAE platform

Portunus can now be directly integrated into global design workflows thanks to it new connection with Isight software, which is part of Dassault Systmes SIMULIA product line.
Conclusion
Portunus 5.2 has reached an efficient level for collaborative mechatronic system design. The software brings designers several levels of modeling, different modeling capabilities, efficient postprocessing to communicate and tools to manage a project from specification-to-prototype!
Figure 2: Multi-physic under Portunus.
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Customized tools for efficient virtual prototyping:

How to perform faster and more accurate simulations: examples.
L. Frigoli & A. Tassi - SPIN Applicazioni Magnetiche Srl.
n recent years the requirement for accurate virtual design has grown constantly. In order to secure competitive run times, the need for better accuracy in simulation predictions, generating increasingly complex analytical representations, has to be compensated for by more computationally efficient models: the talk here is of virtual prototyping efficiency. Greater computational efficiency means less time to get results while performing rapid, detailed analyses on a device. The overall goal is to have a streamlined, automated and customized model creation and simulation process. This is even more important with FEM (Finite Element Method) software, where simulation run times are usually very high and the post-processing analysis sometimes complex. A flexible tool, easily linked to other software is crucial to satisfy this kind of request. This paper presents some case studies on different electromagnetic devices and explains the wide range of advantages that efficient, well-structured virtual prototyping can deliver.
Pre-processing automation
The second example involves the load computation of an embedded permanent magnet electric motor with 48 slots and 8 poles (Figure 3). A customized post-processing macro was built, for the calculation of absorbed current, mechanical torque and efficiency. These are the typical quantities involved in the permanent magnet brushless electric motor design, so this automation can substantially reduce performance analysis time in the design process.
Torque
Mechanical set vs magnetic torque rotating
Pre-processing automation
The first example is about the creation of a pre-processing interface for a three phase transformer 3-D model. The device was represented in an electromagnetic finite element simulation environment (Flux 3D by CEDRAT), and the short circuit test was studied. The software scripting capabilities, in Python language, were used to create a macro for implementing a full model parameterization, without directly interacting with the software building commands. A very user-friendly interface made it possible to change geometrical and physical parameters, such as dimensions, winding, material and circuit, simply by entering the relevant values in a table (Figure 1), and running the macro. Once the simulation was complete, the typical results in the transformer short circuit test could be checked: leakage reactance, reactive power and short circuit voltage. With this approach, the FE 3-D model was built automatically at each iteration and the simulation carried out with a simple click on a button, without time-consuming programming or other steps. Figure 2 shows the results for a three-phase transformer with a power rating equal to 150 MVA and a voltage rating equal to 132/14.1 kV. Figure 3: PM motor geometry description and post-processed results.
Automation thanks to external tools or table

The third case involves the rating of an electric motor, but focusing on a specific issue: the possible partial demagnetization of the permanent magnets in the machine. When subject to external magnetic fields and/or temperature variations, the magnetic properties of permanent magnets may change, initially leading to a reversible demagnetization, which can, at a later stage, become a permanent demagnetization. Because of its impact on the electrical machines performance, it is very important to take this phenomenon into account during the design phase, even more so during a cost reduction process, when considering, for example a reduction in permanent magnet volume or magnet grade. In particular, this problem can affect high torque electric motors as high current is generated. Figure 4 shows the three-phase brushless electric motor with 24 slots and 4 poles modeled in this case. The magnet material, Samarium Cobalt (Sm2Co17), was defined in the software tool with its proprieties in the second quadrant of the hysteresis curve (also referred to as the demagnetization curve) with a remanence value of 1.08 T @20C and intrinsic coercivity equal to 560 kA/m (Figure 5).
Leakage reactance @ 50 Hz Total reactive power @ 50 Hz Short circuit voltage
13.9 Ohm/phase (High voltage winding) 0.16 Ohm/phase (Low voltage winding) 18 MVA 9106 V/phase
Figures 1 & 2: Transformer description and results obtained.
Figures 4 & 5: Brushless electric motor and magnet demagnetization curve.

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Magnet length = 7 mm
T= 20C, 500 rpm T= 20C, 1500 rpm T= 200C, 1500 rpm 18.6 Nm (no demagnetization) 9.95 Nm (no demagnetization) 7.83 Nm (7.84 Nm) *
Magnet length = 3.5 mm

15.43 Nm (no demagnetization) 9.32 Nm (no demagnetization) 6.65 Nm (7.41 Nm) *
* not considering the demagnetization tool
BCS is a really intuitive and easy to use software, featuring a userfriendly interface, where parameters and constraints are set, and a numerical optimization algorithm, which assess the configuration being analyzed at each step in order to define improvement areas, through to identification of the optimum solution. This means that no macro creation or any other form of programming is necessary, as BCS is based on a black box idea (Figure 9).
Figure 6: Torque obtained depending on the speed and temperature range, and the magnets lengths. Figure 6 presents the results of different case studies, where both the speed range and the temperature range were modified according to two magnet lengths. Examination of this figure indicates that the most critical condition for the thinner magnet is defined by a temperature of 200C and a speed of 1500 rev/min, and the resulting torque reduction is around 10%.
Optimization using GOT-It

The next case deals with the optimization of an electromagnetic actuator, carried out with a classical optimization tools (GOT-It) coupled to a finite element software (Flux 3D). GOT-It is a powerful and reliable optimization tool, based on modern mathematical optimization methods, with a user-friendly interface, including interactive command; the user has access to the most advanced optimization functions and the required input is reduced to the parameters, constraint and values to optimize. From this data, GOT-It will define the best configuration(s).
Initial configuration
Losses Force *
* target: 200 N
Initial configuration Final configuration 780 W 751 W 77.6 % 83.1 % Winding temperature 57 C 62 C Power Efficiency
Figures 9 & 10: Initial and final configuration results comparison. The efficiency increase achieved at the end of the optimization process was around 4%, as shown in Figure10. It is important to note that this result complies with the European commission regulation - (EC) 640/2009 - on Eco-design requirements for electric motors in industrial applications.
Final configuration
7.465 W 198.9 N
8.533 W 171.8 N
Conclusion
Simulation software now allows easy creation of real virtual prototypes, but only with efficient and tailored tools has it become possible to take full advantage of the potential opened up by modern computer programs. Figure 11 summarizes the softwares performance with respect to calculation time and accuracy for all the examples shown in this paper. This figure clearly show that the time involved in a new design assessment can be reduced to the magnitude of minutes/ hours, whilst if a new device had to physically built and tested, it would more likely take days/weeks.
TIME CONSUMPTION
SHORT CIRCUIT TEST for a three phase transformer LOAD COMPUTATION for an embedded permanent magnet electric motor DEMAGNETIZATION TEST for a permanent magnet OPTIMIZATION TOOLS
Figures 7 & 8: Actuator magnetic circuit and results comparison of the initial / optimized case. Figure 7 shows the electromagnetic actuator magnetic circuit analyzed in this example, consisting of two coils wrapped around a U-shaped magnetic core. The goal of this study was to optimize the actuator in respect of losses (10% reduction target), for a given generated force, while respecting the size and other physical constraints (saturation, maximum current density). Optimization was performed using the SSO algorithm, a deterministic algorithm based on the response surface and a surrogate model. The results are summarized in Figure 8. The major conclusion drawn from this case is that the sequential surrogate methods are efficient, providing quick solutions to a given problem. Moreover, the optimization process involved only 35 iterations, with an overall calculation time of approximately 30 minutes. In other words, it offers an economical way to finding solutions with a good degree of accuracy.
ACCURATE
++ ++ ++ +++
= = ++ ++
Figure 11: Simulation efficiency depending on the method used in the examples.
Optimization using BCS

Another optimization process is presented as a final example, but, in this case, the simulations were performed using electric machine design software based on lumped-circuit analysis. In particular, SPEED by CD-Adapco was chosen for electromagnetic design and Motor-CAD by Motor Design was chosen for thermal analysis. The study focused on the design optimization of a three phase induction motor, with 4 poles, 24 slots and 19 bars, with the objective of achieving maximum possible efficiency within the project constraints. A specific optimization tool developed in SPIN, named BCS (Best Configuration Searcher), was utilized to drive the overall process.
Modern and customized virtual prototyping software tools are invaluable, because they are fast and intuitive, have the capability to easily automate long sequences of time-consuming tasks, and make it possible to analyse a large number of different configurations in a very short time, identifying the best possible design option with the most appropriate optimization algorithms. In other words, these tools offer a wide range of options to support the design process and, thanks to tailored customization, their full potential can be exploited in the assessment of radical design changes, as they allow real what-if scenarios to be evaluated quickly and inexpensively.
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Dramatic improvements in BLDC machines with Flux 3D.

F. Bernot, A. Bernot, R. Medarian, J Morales, R. Mbikou - FranceCol.
ranceCol (www.francecol.com) is an industry-focused innovation company developing its own power electronics drives and electrical machines. One of its main projects is an SMC (soft magnetic composite)-based transverse flux machine, where 20 patents were presented over 5 years of intensive R&D. The key of innovation process lies in the following ideas: New ideas (enhanced by scientific capability). New technological vector to apply ideas - SMC 3D flux isotropic paths. Industrial capability in order to transfer innovation into real world under competitive cost and investment conditions. FranceCol has a partnership with two EADS sister companies, that offer real industrial vision and support. The transverse flux machine, using magnets at the rotor, and the AC flux stator are well known (over patented). Meanwhile, despite considerable existing background work, it has been possible to go much further. The biggest problem with reversed Lundelllike machines (AC Lundell stator) our basic design comes from poor airgap induction level, due to high flux concentration in teeth return path zones. It was possible to increase airgap induction from 0.4T up to 1.1T, despite SMC poor max induction (20% lack compared with iron sheets). This paper addresses that optimization work. Stator airgap field reaction.
Flux 3D analysis
Given that rotor movement imposes spatio-temporal synchronization between statoric current and rotoric position, Flux 3D is the best tool, because over a single analysis, it allows implicit rotor displacement. The next figure shows a 3D screen shot, after simulation.
Analytical model
The following detailed analytical model was performed. It allows every machine parameter to be computed in non-linear mode, including leakage fluxes. But this model, even though it allows automatic machine design, is not easy to handle when tooth shape is changed. Hence the switch to finite elements modelization.
Flux 3D optimization. This intensive work allowed us to perform numerous simulations. Various machines were studied, with direct (internal rotor) and reverse (external rotor) structures. A comprehensive catalogue was compiled using bench-tested experimental machines, and next-generation ones. Next figure presents statoric current and torque spatio-temporal synchronized results, for various rotor/current positions. Flux3D automatically moves rotor with time and current amplitude correlation. This saves engineer time.
Non-linear reluctance model. The next figure presents Mathcad simulated airgap induction, with the previous model. It illustrates the influence of statoric current on airgap flux, where attraction mode (positive statoric current) corresponds to an overmagnetization process (inducing saturation), and repulsion mode (negative statoric current) corresponds to a demagnetization process, with the risk of negative airgap magnetization, in case of high statoric currents.
Flux 3D simulated torque.

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The key benefits of our technology seem to be: Best robotics BLDC machines peak torque at the cost of induction machines Standing peak torque much longer than robotic machines Very high peak power density (up to 15 kW/kg) Much cheaper than robotics Next figure presents nominal power comparison at 3krpm. Flux 3D input current. Those datas come from Flux 3D output files, gathered from Excel tables. They directly permit torque computation and RMS current.
Conclusion
The next figure presents the internal structure of a three-phase machine, recently tested on our bench facility. Its modular design makes it easy to industrialize. We are currently delivering series machines.
Motor benchmark. Comparison reveals the following higher performances: Higher power density (up to 6 kW/kg) 5 to 30 time better than induction machines 2 to 5 time better than best BLDC robotics This intensive Flux 3D work allowed the FranceCol design team to double machine performances over just one year. Consequently, it is now possible to study a complete machine within a month, and to prototype it within a couple of months, using fast industrial prototyping methods. Embedded power electronics drives accompany these machines, including sensorless algorithms. Other SMC machines are currently being designed, including induction and BLDC magnetless machines.
Less: weight - copper - magnets volume Higher: efficiency - power per mass Technology: - green techno (fully recyclable) - cost effective - 20 patents
Industrial friendly - modular structure - Kaizen assembly Robotics level perfos at induction machine cost
Modular design. A comprehensive benchmark was completed using existing technology, producing the promising results shown in the following figures. Peak torque / mass, versus external diameter, was considered a good comparison criterion, because it makes dynamic behaviour benchmarking possible, taking into account the influence of external diameter. And the latter parameter makes it possible to mechanically increase torque density. This means it has to be considered.
FranceCol facility at Luynes (France)

Our facility includes all the resources required for rapid scientific design, industrial study and prototyping for motors.
Scientific approach & industrial methodology.
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Finite elements method modeling of contactless energy transfer systems.

Daho Taghezout - APPLIED MAGNETICS.
ontactless energy transfer (CET) systems are used in many industrial sectors. These include conveyors, trolleys, storage and retrieval units, baggage handling, battery charging stations, mobile phones and medical implants. The energy transfer model is quite similar to a conventional transformer, except for the weak coupling between the primary and secondary windings and partial or non-existent ferromagnetic closing paths. Inductive coupling is commonly used in a range from a few mW to a few hundred kW. Figure 1 shows a schematic view of a transmission and reception antenna for an electric car battery charging device. The transmitting coil is stationary and fed by a high frequency switching power source. The reception antenna is inductively coupled to the transmission antenna and supplies electric power storage (battery or supercapacitors). The operational frequency is above the audible range but remains below 100 kHz to limit switching losses in the power source. Resonant circuits are used on the primary and secondary sides to boost transmitted power and minimize voltage and current in the device. Total efficiency is usually above 90%.
System simulation and 2D FEM analysis

For battery charging devices, the distance between the coils may be substantial (typically 100 mm) and misalignments between transmitting and receiving antenna must be addressed. Due to the large airgap between the primary and secondary windings, mutual inductance is low compared to leakage inductances. Therefore the magnetizing current is high and generates excessive Joule losses.
Figure 3: Equivalent circuit for a CET with power source and load under Portunus. A popular solution is to use a resonant circuit based on additional capacitors connected in series or parallel with the primary and secondary windings. The equivalent circuit for a compensated CET device supplied by a three phase rectifier and feeding a battery via an H-bridge is shown in figure 3. The equivalent circuit of the coupled antennas is inside the yellow box. A simple CET model comprises primary and secondary linear inductances (L1 and L2), a mutual inductance and winding resistances. Due to the high supply frequency (25 to 60 kHz), the coils will be Litz wires which, despite the low fill factor, dramatically reduce eddy current and proximity effect losses in the windings. The external capacitors C1 and C2 are used to build up a resonant circuit. The primary and secondary resonance frequencies are usually equal and can be approximately defined by:
Figure 1: Iron core and coreless CET coils (Pavol Bauer, TU Delft). The upper CET configurations in figure 1 use a soft ferrite yoke while the lower ones build up an ironless transformer. The left hand side models can be investigated via a 2D axisymmetric model while the right hand side models require 3D analysis. A hybrid model can also consist of an air coil and back yokes made of ferrite disks (fig. 2). In this model, the ferrite yokes comprise a full disk (shown in light blue and dark blue over 180) or sectors. The emitting and receiving coils are shown in yellow and red colours. L1 is the primary inductance and L2 the secondary inductance. C1 and C2 are capacitors connected in series with the primary and secondary phases. The model shown in figure 3 may be efficiently used in a system simulation software such as Portunus to optimize device performances (choice of operational frequency, switching losses, number of turns, influence of load variation). The CET lumped circuit model does not include additional losses within the CET system (ferrite hysteresis losses, losses in the housing or in shielding plates). If such phenomena need to be integrated into the model, it is possible to conduct a co-simulation between Portunus and Flux using a macro model of the CET. The lumped circuit model shown in figure 3 would be replaced by a component describing the FEM model of the transformer. This model is solved using Flux and coupled to a circuit defined under Portunus. This method is more accurate as it takes into account any iron saturation and other complex physical phenomena. It is however more time-consuming, especially if the FEM model is three-dimensional.
Figure 2: Schematic view of a coreless CET coils with ferrite back yokes.
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CEDRAT News - N 65 64 - December January 2013 November 2013 2013
A dynamic simulation using the lumped circuit model of the antennas requires good knowledge of winding inductances. These can be derived from an AC harmonic analysis with Flux 2D or Flux 3D. To determine the primary inductance L1, the primary winding is supplied with AC current. The primary inductance L1 and the coupling inductance M are easily derived from the coupled fluxes. The same procedure is applied to the secondary winding to derive the secondary inductance L2. This model is valid for CET devices without ferrite or with linear ferrite permeability and without conducting regions (shielding plates for instance). Due to the large airgaps, the assumption on the linear behaviour of the system is often valid. Figure 4 shows an academic case of a CET device exhibiting transmission and reception coils, ferrite back yokes and aluminium shielding above the moving coil. The CET device was modeled with Flux 2D using a current source on the primary side, series compensation capacitors and a resistive load. The primary and secondary capacitors were determined using the classical formula mentioned above in order to satisfy a resonance frequency of 40 kHz. It is worth mentioning that the formula does not take into account ferrite losses or losses in housing or shielding plates. The flux lines are displayed in figure 4 for a resistive load at resonance frequency. We notice that the upper shielding prevents the flux lines from extending out of the CET environment.
Contactless energy transfer offer cost reductions in energy transfer, compact design, maintenancefree equipment, versatility and greater reliability. Daho Taghezout - APPLIED MAGNETICS
The output power takes ferrite losses into account via complex permeability and its dependence over the supply frequency. Also, eddy currents are assumed to flow in an aluminium shielding plate (upper region). The transmitted power calculation is based on a constant copper and ferrite temperature. The maximum transmitted power will however be limited by losses in the coils and in the ferrite, as well as the current density in the coils. The temperature distribution in the device can also be determined using the thermal analysis application of Flux . Fluxs parametric solver can furthermore be used to assess various configurations. Also, the influence of the number of primary and secondary turns, resonance capacitances or saturation can be investigated. The designer can make use of Fluxs parametric solver to determine the influence of key parameters. These include resonance frequency for a rated load, variations of transmitted power vs. airgap, device efficiency, influence of number of turns, power factor, etc.
3D finite element method analysis

3D FEM analysis is compulsory for some design cases: investigation of antenna misalignment, use of rectangular coils or ferrite yokes containing sectors. Low penetration depth in conducting regions can make the simulation very tedious and requires extensive computation time. Flux 3D provides some interesting features to conduct studies on CET devices. Nonmeshed coils are superposed to the finite element domain and need not be meshed. They can help model very complicated coil shapes, provided that eddy current and proximity effects are neglected. Furthermore, non-linear surfacic impedances are available for AC analysis. They efficiently model conducting regions where penetration depth is low vs. region depth. On the other hand, lossy ferrites are modeled using complex permeabilities depending on operational frequency. Figure 6 shows a case where sectored ferrite yokes are used. In this case only the primary winding is supplied with a current source at 40 kHz. Thin aluminium shielding plates are inserted below the emitting antenna and above the receiving antenna. The ferrite yokes are modeled as magnetic conducting regions. Due to the high frequencies and low penetration depth in the aluminium, a volumic meshing of the shielding plates would require a larger number of meshes. These regions tend to be modeled in Flux3D via surfacic impedances (boundary condition on the region
Figure 4: Flux lines in a CET device (AC Harmonic analysis with Flux 2D.
Figure 5: Transmitted power vs. operational frequency F and load resistance RL. Figure 5 shows a 3D view of the power in a resistive load vs. operational frequency and load resistance. The computation is made on a 2D model. The resonance frequency is relatively constant when the load changes. Airgap variations can however create a drift on the resonance frequency and a fixed or variable frequency control must be decided depending on the working environment.
Figure 6: Flux lines distribution in a CET device (AC Harmonic analysis with Flux 3D).
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Fig 7: Current density distribution in the CET shielding plates (AC Harmonic analysis with Flux 3D). surface). This allows a coarse discretisation of the shielding plates as the magnetic field is only computed on the surface. The devices ferrite yokes each comprise nine ferrite sectors. The symmetry of the domain means that the study can be limited to a 40 sector. Also, the device model is included in an infinite region while the magnetic field is assumed to expand out of the airgap. This feature allows assessment of the influence of the charging device on electronic components or optimizes shielding to limit the field radiated within the car body. Figure 6 shows flux density magnitude in the ferrite blocs. It should be noted that saturation flux density in MnZn ferrites hardly exceeds 0.5 T and that Curie temperature is around 220C. Therefore it is strongly recommended to check losses in this region and to assess their influence on ferrite temperature. Figure 7 shows loss density in the aluminium shielding plates in this configuration. The use of ferrite sectors instead of a ferrite disk can be justified on cost, but the design must be carefully assessed in order to avoid hot points in the shielding plates. Even if symmetry conditions are applied, a 3D transient analysis of a CET device is quite time-consuming. It should therefore be used for AC analysis or at the final validation stage if transient analysis is required. Numerous tests might be necessary to assess the influence of misalignment and variable airgap over the transmitted power, the amount of losses in the car body, near-field radiation, etc. AC analysis of a single configuration takes a few minutes calculation time. On the other hand, the optimization of a 3D CET device may require hundreds of parametric computations. This is where the use of the optimization tool GOT-It can dramatically reduce computation time. The user can set a set of constraints (coil volume, maximum current density, maximum airgap, coil shape,) and objective functions (transmitted power, robustness vs. misalignment, power factor) and search for optimum configurations.
This procedure provides accurate results for the systems dynamic behaviour but at a higher computation-time cost. In order to assess the efficiency of the system, it is also possible to rely on a full FEM analysis with Flux. Additionally, the parametric solver allows various configurations to be investigated, resonance frequency variation vs. different parameters to be determined (coil shape, airgap, misalignment, load resistance) and necessary modifications to be made to achieve the system requirements. A novel approach might also include the optimization tool GOT-It. Searching several hundred configurations to find the most suitable one can be tedious, and sometimes impossible when relying on parametric analysis. GOT-It allows an intelligent choice of a preferred solution to be made using surface responses and various types of deterministic and stochastic optimization algorithms. The new GOT-It V2.0 version is also able to control a distributed Flux resolution in parallel on several PCs, thus dramatically decreasing optimization costs.
Electricity is provided from the ground transmission unit to the vehicle receiver unit through electromagnetic induction.
Conclusion
Depending on the configuration of the CET device, a 2D or a 3D FEM analysis might be required to assess device performances. This can be conducted using various strategies. Based on a simple model of the device (self and mutual inductances between emitting and receiving antenna, coil resistances), fast prediction of system behaviour and switching losses can be achieved using the system simulation software Portunus. The lumped circuit model of the CET must beforehand be determined under Flux. It can be easily and accurately derived from an AC harmonic analysis. For a more sophisticated approach, it is interesting to rely on a co-simulation model where the CET device is modeled under Flux and the circuit defined under Portunus. This strategy allows any saturation and hysteresis losses in the ferrites to be predicted along with eddy current losses in the housing and shielding plates.
NISSAN LEAF wireless charging system - Courtesy of NISSAN.
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CEDRAT News - N 65 - December November 2013 2013
2013 Flux Conference: a great success!

Karoline Ballini - CEDRAT.
On October 16 and 17, a number of industrial companies, researchers and academics took part in the 2013 Flux Conference. Held at the Centre des Congrs Aix-les-Bains, the meeting highlighted the industrial applications and new functionalities of CEDRAT software, and of course the future of Flux software! Prior to the conference, some participants attended the Advanced methods for the design of electrical machines training session. A great opportunity to learn more about the new features of Flux Version 11.2! The symposium offered a varied agenda thanks to the industrial companies who accepted our invitation to present their work. Thank you for helping us to make it a success! If you want another chance to see one of the presentations, go to CEDRAT Gate, and access all Flux Conference 2013 presentations (https://gate.cedrat.com). We look forward to seeing you next year! Best regards - The CEDRAT Team
" Judging by the smiles on participants faces, the 2013 edition of Flux Conference was a great success! "
Karoline Ballini - Organization of Flux Conference.
PRESENTATIONS, SPEAKERS & COMPANIES

Additional Parameters to Consider when Simulating Soft Magnetic Materials - Mr Thomas Wery - Aperam Hall Effect Magnetic Sensors Design for Automotive Application - Mr Samir Guerbaoui - Valeo Design Evolution of High Voltage Insulators - Mr Christophe Rech - ALSTOM GRID Dedicating Electrical Engineering to Sustainable Power Systems: From Energy Conversion to Reliability Issues Mr Vincent Mazauric - Schneider Electric Simulation of the Noise Radiated by an Electric Device Thanks to a Magneto Vibro-Acoustic Analysis Mr Pascal Bouvet - VibraTec Transverse Flux Induction Heating of Magnetic Non Linear Sheets - Mr Virgiliu Fireteanu POLITEHNICA University of Bucharest Using Flux and InCa3D for an Induction Heating Device: Evolutions Since 2010 Flux Conference - Mr B. Paya - EDF Using Flux Coupled to AMESim to Design a Fuel Injection System - Mr Luca Gregorio Frigoli - SPIN System Simulation of an Electronic Trip Unit - Mr Bertrand du Peloux - Schneider Electric 3D Calculation and Modeling of Eddy Current Losses in a Large Power Transformer - A. MILAGRE - SIEMENS Investigation of Electromagnetic and Thermal Behavior During Fast Dynamics in a PMSM Flux 2D and Motor-CAD Simulation - Mr Liviu Iepure - AVL TRIMERICS Dramatic Improvement in Transverse Flux Machine with Flux 3D - Mr Franois Bernot - FRANCECOL
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2014 TRAINING SCHEDULE

TRAINING COURSES
New Flux 11.2: Update functions presentation Flux 2D introductory course Flux 2D advanced course Flux 3D introductory course Flux 3D advanced course Flux 2D and Rotating Machines Flux 3D and Rotating Machines Flux and Induction Machines E-Mobility Simulation Solutions Flux and the Linear Magnetic Actuators CAD import for Electrostatic study with Flux Flux 3D and Non Destructive Testing Flux and the PyFlux command language Flux/Portunus Co-simulation Portunus introductory course (VHDL-AMS option) GOT-It introductory course InCa3D introductory course Rotating Electrical Machines SPEED PC-IMD Design of Induction Machines SPEED PC-BDC Design of Brushless PM motors Thermal Analysis of Electric Motors and Generators
Code ref
FNV-en F2DB-en F2DA-en F3DB-en F3DA-en F2DRM-en F3DRM-en FIMA-en FLMA-en FLMA-en IMPF-en FNDT-en PYF-en FPCOS-en PORT-en GOTIT-en INCAB-en TREM-en SIMD-en SBDC-en TAEM-en
Date
On request 18-20 March ; 18-20 November On request 11-13 March ; 04-06 November On request 21-23 October 17-19 June On request On request On request On request On request On request 21-23 October 21-22 May 13-14 November 17-18 November On request On request On request 15-17 April
Nb of days
1 3 2 3 2 3 4 3 3 3 3 3 2 2 2 2 2 3 2 2 3
Other training courses according to your needs on request. At the end of your training you will be offered two months to evaluate the full version.
PLANNING DES FORMATIONS 2014

FORMATIONS
Flux 11.2 : Dcouverte et prise en main Flux 2D stage de base Flux 2D stage de perfectionnement Flux 3D stage de base Flux 3D stage de perfectionnement Flux 2D et les machines tournantes Flux 3D et les machines tournantes Flux et les machines asynchrones Nos solutions de simulations pour lE-Mobilit Flux et les actionneurs magntiques linaires Flux et le langage de commande PyFlux Flux et les imports CAO pour les tudes lectro-statiques Flux 3D et le contrle non destructif Co-simulation Flux/Portunus Portunus stage de base (VHDL-AMS option) GOT-It stage de base InCa3D stage de base Les machines lectriques tournantes SPEED PC-IMD Conception de machines asynchrones SPEED PC-BDC Conception de machines aimant permanent Analyse thermique des moteurs lectriques et des gnratrices
Code ref
FNV-fr F2DB-fr F2DP-fr F3DB-fr F3DP-fr F2DMT-fr F3DMT-fr FMAS-fr SSEM-fr FAML-fr PYF-fr FIMP-fr FCND-fr FPCOS-fr PORT-fr GOTIT-fr INCAB-fr TMET-fr SIMD-fr SBDC-fr ATME-fr
Date
A la demande 04-06 mars ; 19-21 novembre A la demande 13-15 mai ; 23-25 septembre A la demande 03-05 juin 02-05 dcembre A la demande A la demande A la demande A la demande A la demande A la demande 21-22 mai 19-20 mars A la demande 26-27 mars 25-27 novembre A la demande A la demande A la demande
Nb de jours
1 3 2 3 2 3 4 3 3 3 2 2 3 2 2 2 2 3
CEDRAT, 30 years of experience in Electrical Engineering
7 modeling and simulation tools, 11 international partners, 30 years of experience and more than 50 engineers, developers and consultants. With its expertise in the field of Electrical Engineering, CEDRAT and its multidisciplinary team of engineers offers innovative solutions and top of the line tools geared towards the specific needs of each industry. Strong of its tied connections with industries and research institutes, including a close collaboration with G2Elab, CEDRAT focuses on today and tomorrows goals of energy efficiency, cost reduction and smart features.
2 2 3
Guiding your Technical Innovation

A wide range of analysis
Electrical Magnetic Thermal Multiphysics Electromagnetic compatibility Vibrations & noise System-level Material characterization Consulting
TRAINING COURSES Formations

Catalogue 2014
Not just tools!

Long term experience in both software development and consulting work make CEDRAT and its distribution network a valuable partner to support and train you when using our softwares. Training and support competencies: Use of the programs Numerical methods Adapted methodology Application / Device specific Limits of the models validity Customers models resolution
For a wide range of applications

Electric rotating machines Actuators Transformers & inductance Sensors Heat treatment Electromagnetic compatibility Electrical connections
Consulting services
Lack of competence? Temporary overloaded department? Missing software know-how? Improvement on methodology needed? CEDRAT provides consulting and computation services. A team of experienced design engineers is available to create, design or optimize innovative solutions. If you are interested in contracting our consulting services, please contact us or visit our website.
The new 2014 training catalogue for CEDRAT is now published. Software or technical training, there is always one for you! CEDRAT provide comprehensive training courses dedicated to engineers and technicians who wish to discover, improve or recover their knowledge in various fields of electrical engineering. A full list of training programs can be obtained from our training department at CEDRAT SA, or from our web site http://www.cedrat.com/en/services/training.html.
Quality assurance
Flux is controlled and developed under Quality Assurance procedures. It ensures a constant validation of the capabilities and the results of the software. CEDRAT for Europe & the Middle East
CEDRAT S.A. 15 chemin de Malacher Inovalle 38246 MEYLAN CEDEX FRANCE Phone: +33 (0)4 76 90 50 45 Fax: +33 (0)4 56 38 08 30 Email: cedrat@cedrat.com
[ www.cedrat.com ]
4
Copyright CEDRAT
www.cedrat.com
MAGSOFT for Americas & Asia www.magsoft-flux.com
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Events
Jan. 29-30, 2014 (Magsoft Corp.) March 15-20, 2014 (Magsoft Corp.) April 08-10, 2014 (CEDRAT) May 20-22, 2014 (MACCON) May 25-28, 2014 (CEDRAT) June 03-05, 2014 (MACCON) June 24-26, 2014 (CEDRAT) July 01-03, 2014 (CEDRAT) August 26-28, 2014 (CEDRAT) Sept. 01-04 2014 (CEDRAT)
CEDRAT, MAGSOFT Corp. and partners will take part in the below mentioned exibitions.
Motor Design and Drive Systems 2014, Orlando, USA. APEC (Applied Power Electronics Conference and exposition), Fort Worth, Texas, USA. PEMD (Power Electronics Machines and Drives), Manchester, United Kingdom. PCIM Europe 2014, Nuremberg, Germany. CEFC 2014, Conference on Electromagnetic Field Computation, Annecy, France. MEDTEC Europe 2014, Stuttgart, Gemany. CWIEME 2014, Coil Winding Insulation and Electrical Manufacturing, Berlin, Germany. CEM 2014, Exposition sur la Compatibilit Electromagntique, Clermont, France. EPE (European Conference on Power Electronics and Applications), Lappeeranta, Finland. EMC Europe 2014, Gothenburg, Sweden.
CEDRATs Newsletter...
Stay informed about our products launch, news, articles, projects, demo cases, webinars, company magazine and much more Please subscribe to our Newsletter by filling the following registration form: http://www.cedrat.com/en/news-events/newsletter.html.
CEFC 2014
It is our great pleasure to announce the Sixteenth Biennial IEEE Conference on Electromagnetic Field Computation (CEFC 2014). The Conference will be held in Annecy, France, from May 25 to May 28, 2014, in a hotel facing the purest lake in Europe and the exceptional setting of the French Alps. We welcome you to participate in one of the most important biennial scientific and technical events. No doubt, this conference will be a very good opportunity to share the results of your recent research activities with other scientists from all over the world and to discover new advances in the field of numerical computation of electromagnetic effects. From numerical methods to material modeling, from micro systems to large rotating machines, all the usual topics that make Compumag and CEFC conferences unique will be of course in the scope of CEFC 2014. CEDRAT in collaboration with G2Elab (Grenoble Electrical Engineering Laboratory) for many years, is glad to be part of this event. The CEDRAT team will be happy to welcome you at its booth! The aims of the IEEE CEFC is to discuss the latest developments in modeling and simulation methodologies for the analysis of electromagnetic fields and wave interactions, with the application emphasis being on the computer-aided design of low and high frequency devices, components and systems. Scientists and engineers worldwide are invited to submit original contributions in the areas of Static and Quasi-static Fields, Wave Propagation, Material Modeling, Coupled Problems, Numerical Techniques, Optimization and Design, Software Methodology, Nanomagnetics, Nano photonics, Bioelectromagnetic Field Computation as well as Devices and Applications More information about Conference is available on the web site : http://cefc2014.org
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CEDRAT, 30 years of experience in Electrical Engineering

7 modeling and simulation tools, 11 international partners, 30 years of experience and more than 50 engineers, developers and consultants. With its expertise in the field of Electrical Engineering, CEDRAT and its multidisciplinary team of engineers offers innovative solutions and top of the line tools geared towards the specific needs of each industry. Strong of its tied connections with industries and research institutes, including a close collaboration with G2Elab, CEDRAT focuses on today and tomorrows goals of energy efficiency, cost reduction and smart features.
Guiding your Technical Innovation

A wide range of analysis
Electrical Magnetic Thermal Multiphysics Electromagnetic compatibility Vibrations & noise System-level Material characterization Consulting
Not just tools!

Long term experience in both software development and consulting work make CEDRAT and its distribution network a valuable partner to support and train you when using our software. Training and support competencies: Use of the programs Numerical methods Adapted methodology Application / Device specific Limits of the models validity Customers models resolution
For a wide range of applications

Electric rotating machines Actuators Transformers & inductance Sensors Heat treatment Electromagnetic compatibility Electrical connections
Consulting services
Lack of competence? Temporary overloaded department? Missing software know-how? Improvement on methodology needed? CEDRAT provides consulting and computation services. A team of experienced design engineers is available to create, design or optimize innovative solutions. If you are interested in contracting our consulting services, please contact us or visit our website.
Quality assurance
Flux is controlled and developed under Quality Assurance procedures. It ensures a constant validation of the capabilities and the results of the software.
MAGSOFT for Americas & Asia www.magsoft-flux.com
CEDRAT S.A. 15 chemin de Malacher Inovalle 38246 MEYLAN CEDEX FRANCE Phone: +33 (0)4 76 90 50 45 Fax: +33 (0)4 56 38 08 30 Email: cedrat@cedrat.com
[ www.cedrat.com ]
CEDRAT for Europe & the Middle East
www.cedrat.com

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CEDRAT MaGaZINe - N 65 - DECeMBer 2013

he right partner to access the Premium Market .

CEDRAT News - N 65 - December 2013

Draw. Create. Design.

No need to be a specialist to generate a good mesh!

A new material database manager

Anisotropic material modeling

Fig.3 : Auto-adaption of the mesh during the solving in 2D.

CEDRAT News - N 65 - December 2013

Fig.7: Example with a hysteresis switching.

Customize, automate, be more efficient every day

Wait no longer to download Flux11.2!

Fig.5: Result of lamination region by homogenization process.

CEDRAT News - N 65 - December 2013

New functionalities in Flux thanks to macros.

Search lines with distance lower than a reference value

Modify coordinate system for points

Figure 3: Interface of SearchLinesminimumLength macro.

Figure 4: Result of the macro.

The result can be seen in the 2 following figures:

Figure1: Initial and modified drawing with shaft radius as parameter.

Figure 5: Example of default easily localized with the macro.

(see continued on page 5)

CEDRAT News - N 65 - December 2013

Regulate current with hysteresis method in motors

The procedure to follow is defined in the table below:

Figure 10: Interface of the ExtractFrom3DCuve macro.

Figure 7: Current with or without regulation (with or without chopping).

Figure 11: New curve result of the ExtractFrom3DCurve macro.

Extract quantity from 3D curves

CEDRAT News - N 65 - December 2013

CEDRAT HPC strategy new step: distributed computing for Flux.

Figure 1: Flux solving process.

Efficient optimization application example

CDE features and performances

CEDRAT News - N 65 - November 2013

CEDRAT News - N 65 - December 2013

Control of an induction machine using Flux-Portunus coupling.

1. Control architecture: Indirect FieldOriented Control (IFOC)

>> c - Benefits and limitations of an IFOC

2. Flux-Portunus coupling stakes

>> a - Design specifications and requirements

Overview of the architecture of an IFOC

>> b - Details of the architecture

Frequency Enc. Stator Bars Rotor Pole pair Inertia 50 Hz 24 20 1 0.034

CEDRAT News - N 65 - December 2013

Single speed order

>> b - Transformations Block

Variable speed order

>> a - Portunus simulation- PI settings

Single speed order

Variable speed order

>> b - Flux Portunus coupling

CEDRAT News - N 65 - December 2013

Magneto-vibroacoustic analysis: a new dedicated context inside Flux11.2.

Flux Magnetic analysis

NASTRAN Vibratory analysis

>> Periodicity of the device

CEDRAT News - N 65 - December 2013

Computation in transient magnetic

Computation and distribution of magnetic force

>> Reducing the computation time range