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SM TRANSDUCER ENGINEERING
DATE PHUKET, THAILAND
dd/mm/yy
steve.mowry@ymail.com
3 CHECKER
S. MOWRY 14/01/15 B&W 800 SERIES DIAMOND DUAL MAGNET WOOFER
2 ENGINEER MOTOR ASSEMBLY TOPOLOGY WITH STEALLUS X
S. MOWRY 16/01/15 TOPOLOGY CONCEPT WOOFER SIMULATION REPORT
1 DRAFTER SIZE TYPE CLASS DOC NO REV
S. MOWRY 16/01/15 LETTER LF REPORT FE800D D
PAGE 1 of 36
1. SCOPE
This document summarizes the simulation results for the B&W 800
Series Diamond Dual Magnet Motor Assembly Topology. The
geometry was approximated by studying B&Ws transducer
sectional illustrations et al. The principal engineering tool used
was Vector Fields OPERA 2d. B&Ws R&D also uses OPERA.
Then proprietary voice coil emulating command files were used
within Nonlinear DC Static and Restart AC Steady State Harmonic
Finite Element Models.
2. OBJECTIVE
Document and report on the simulation of the 800 Series
Diamond Dual Magnet Motor Assembly Topology.
Figure 1. Illustrations of the B&W 800 Series Diamond Dual Magnet Woofers
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3. NONLINEAR DC FEA SIMULATIONS
3.1 BH CURVES:
Figure 7. Simulation of Bradial within the Voice Coil section only at x = 7mm
4. ENGINEERS COMMENTS
This motor seems well designed and implemented. The operating point
is high with a Permeance Coefficient of 1.5 that is illustrated in red in
figure 3. This motor is robust and looks okay to above 150C. BETA
was simulated at more than 50 N2/W, which is high for a woofer of this
size. The symmetric topology paid off with symmetric flux linkage with
respect to displacement.
My concerns are related to ease of assembly or lack thereof. Assembly
seems to be difficult at best. The powerful Neo magnets must be
magnetized before assembly. Their directions of magnetization are
opposed. Another concern is that even statically with the voice coil at
the rest position, a bit of anti-flux links to the voice coil. This can be
seen in figures 6 thru 8 as the minus Bradial value at the voice coil section
height extremes. Finally, the voice coil is cantilevered with a long
bobbin. As time passes and the suspension relaxes, I am concerned
about rocking modes. One could have positioned the spider at the rear
and implemented mid-motor topology with complementary suspension,
surround and spider.
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This anti-flux linkage should help to control displacement somewhat but its
onset seems too soon and is within the linear operating range. Then the
thought of what if this topology was used to implement an under-hung voice
coil and a much thicker gap plate or coin between the two magnets.
MAGNETIC
ANTI-GAP
PRIMARY
MAGNETIC
GAP
MAGNETIC
ANTI-GAP
Figure 16. Simulation of the Induced Current Density Amplitude (A/m2) @ 300 Hz
Figure 20. Simulation of the Induced Current Density Amplitude @ 300 Hz, x = 7mm
Figure 22. Simulation of the AC Flux Distribution lines @ 300 Hz, x = 7mm
Figure 24. Simulation of the Induced Current Density Amplitude @ 300 Hz, x = -7mm
Figure 26. Simulation of the AC Flux Distribution lines @ 300 Hz, x = -7mm
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Figure 27. Simulation of Le(x,0.5A) @ 1.0 kHz
160mm
SPIDER-
TERMINATED
VOICE COIL
MODULE
WITH SIMPLE
SHIM GAUGE
HARD-PART
MODULE
Figure 33. Simulation of Bradial within the Voice Coil section only at x = 0
Figure 35. Simulation of Bradial within the Voice Coil section only at x = -7mm
Figure 40. A 0.5 (A) AC Current is applied to the Voice Coil (~ 1 Wpeak)
Figure 45. Simulation of the AC Flux Distribution lines @ 300 Hz in Free Air
Figure 47. Simulation of the Induced Current Density Amplitude @ 300 Hz, x = 7mm
Figure 49. Simulation of the AC Flux Distribution lines @ 300 Hz, x = 7mm
Figure 51. Simulation of the Induced Current Density Amplitude @ 300 Hz, x = -7mm
Figure 53. Simulation of the AC Flux Distribution lines @ 300 Hz, x = -7mm
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Figure 54. Simulation of Le(x,0.5A) @ 1.0 kHz
Now with respect to figure 39, that contains the results of two virtual
voice coil sweeps, the coil used in the B&W 800 Series simulations and
a new 4-layer Al magnet wire coil. Mass, resistance and wind height are
the same but the 4-layer coil has more turns. The key here is to
understand b in terms of physical parameters of the gap and the coil.
( Bl( x) )
2
( x) = N 2 /W
Re
l
Re =
S wire
S ( Bl( x) )
2
( x) = wire
l
( x) = lS wire B( x) 2
( x) = Volwire B( x) 2
Where s is the electrical conductivity (1/W/m); S is the cross section (m2)
and Vol is the volume of conductor (m3).
Now it is well known that Aluminum is a more efficient coil material than
copper. This can be shown by a simple ratio of Conductivity/Density,
where M is the figure of merit.
M = Electrical Conductivity/Mass Density (m2/W/kg)
MCu = 60 x 106/8960 = 6696
MAl = 35 x 106/2700 = 12962
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However with typical motors, the B field decreases with increasing coil
width and thus gap width. With regards to the STEALLUS X Topology,
the magnetic gaps are quasi-infinite and obviously gap width is not a
design consideration.
Both of the transducers that were analyzed were concepts and not fixed
designs. In the case of the B&W 800 Series Diamond, the transducer
was a generalized approximation meant to help understand B&Ws Dual
Magnet Woofer Motor Topology. Whereas in the later case, the
STEALLUS X woofer concept was intended as a response to concerns
regarding the B&W woofer topology. These include but are limited to
the following.
1. Manufacturability
HARD PARTS ASSEMBLY ONLY B&W STEALLUS X
NUMBER OF PARTS 7 6
NUMBER OF DIFFERENT PARTS 6 3
NUMBER OF INTERFACES 6 5
TOTAL 19 14
2. Long cantilevered voice coil bobbin and possible rocking modes
The STEALLUS X topology facilitates a much shorter voice coil bobbin
and eliminates any chance of the voice coil winding rubbing. The short
bobbin and 2 x spider make the chance of any rocking mode issue a
remote possibility. Furthermore, as theSTEALLUS X coil is heated during
operation the ID increases and if any contact does occur between the
motor and voice coil assembly, the aluminum bobbin should protect the
windings from damage.
3. Suspension linearity
STEALLUS X is intended to operate within the linear displacement range
of the suspension. The anti-magnetic DC flux coil linkage should control
maximum displacement with only mild pull-up from the spiders and or
surrounds. This extends suspension life and long term suspension
performance. Using 2 x spider inherently increases effective spider
robustness. This also reduces the probability of spider failure.
Personally, I felt that perhaps my discussion of the STEALLUS in 2007
in Voice Coil had an effect on the designer of the B&W Dual Magnet
Motor Topology. However, my opinion is that they missed an
opportunity. With regards to performance and manufacturability,
STEALLUS is simply (pun intended) hard to beat.
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Note: The STEALLUS and STEALUS X motors differ in that the X
indicates that the spacer or gap plate between the magnets is ferrous
(typically low carbon annealed steel), whereas the STEALLUS motor
uses a nonferrous material such as non-ferritic stainless steel for the
spacer. STEALLUS X facilitates smaller magnets and a higher relative
DC operating point and thus reduces cost with just a modest loss in AC
performance.
Serious questions, comments, or concerns can be sent to Steve
Mowrys attention at steve.mowry@ymail.com.