Maxwell and HFSS Coupling to ANSYS 12.

Martin Vogel, PhD

Product Management

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Why couple simulators for electromagnetics and multi-physics?

Electronics produce heat, which can cause malfunctions. Courtesy of

2
ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

Existing Electromagnetics Multiphysics Links

Electromagnetic simulators: Maxwell SIwave

HFSS

ANSYS Mechanical Thermal Solvers

ANSYS FLUENT Thermodynamics and fluid flow

ANSYS ICEPAK cooling of electronics

ANSYS Mechanical Stress Solver

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Example 1 Raytheon High-Power Connector

Microstrip terminated by shorting diode Copper housing Kovar and glass More connector, gold, Teflon Semi-rigid coaxial cable, silver, Teflon, copper

Port

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Cross section of critical part:

Gold pin Kovar Glass Air Teflon Gold pin

Microstrip

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Before turning power on

Co-axial pin connecting to microstrip trace Courtesy of

6
ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

Soon after turning power on

Excessive heat has destroyed the connector. Courtesy of

7
ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

Analyze the model in HFSS

Pin connecting to trace

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Export info from HFSS

Geometry, e.g. in STEP format

Small file with link info

9
ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

Request thermal simulation(s) in Workbench. Import the geometry.

2009 ANSYS, Inc. All rights reserved.

10

ANSYS, Inc. Proprietary

Specify volume and surface losses. Workbench will access HFSS.

HFSS Volume loss HFSS Surface Loss

Simply picked all metal faces

2009 ANSYS, Inc. All rights reserved.

11

ANSYS, Inc. Proprietary

Add boundary conditions for convection and cooling.

Convection on many faces Cooling on bottom face

2009 ANSYS, Inc. All rights reserved.

12

ANSYS, Inc. Proprietary

Temperature reaches almost 300 deg C in kovar and glass.

2009 ANSYS, Inc. All rights reserved.

13

ANSYS, Inc. Proprietary

Transient simulation gives same final temperature after 20 seconds.

2009 ANSYS, Inc. All rights reserved.

14

ANSYS, Inc. Proprietary

Use one of the thermal solutions as input for a structural analysis.

2009 ANSYS, Inc. All rights reserved.

15

ANSYS, Inc. Proprietary

Deformation up to 2 m

2009 ANSYS, Inc. All rights reserved.

16

ANSYS, Inc. Proprietary

Stress mostly in inner conductor

2009 ANSYS, Inc. All rights reserved.

17

ANSYS, Inc. Proprietary

Finalize the design.

Kovar, responsible for the high temperatures, has been replaced by a different metal. Temperatures may still be high, which Teflon cannot handle. Accurate analysis wanted.

Involve CFD to analyze the cooling. Use the two-way thermal coupling to account for temperature-dependent materials.

2009 ANSYS, Inc. All rights reserved.

18

ANSYS, Inc. Proprietary

Use CFD to determine the film coefficient for the water cooling at the bottom.

Convection on many faces Cooling on bottom face

2009 ANSYS, Inc. All rights reserved.

19

ANSYS, Inc. Proprietary

Connector array with water cooling

Water, velocity 1 ft/s

2009 ANSYS, Inc. All rights reserved.

20

ANSYS, Inc. Proprietary

Mesh in Fluent

2009 ANSYS, Inc. All rights reserved.

21

ANSYS, Inc. Proprietary

Fluent velocity results

2009 ANSYS, Inc. All rights reserved.

22

ANSYS, Inc. Proprietary

Fluent temperature results

2009 ANSYS, Inc. All rights reserved.

23

ANSYS, Inc. Proprietary

Replace water cooling by film coefficients

Film coefficient ranges from 5700 to 2300 W/(m2 K) depending on position.

24
ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

Why two-way thermal?

Teflon loss tangent increases with temperature. Run-away effect possible.

Glass transition

2009 ANSYS, Inc. All rights reserved.

25

ANSYS, Inc. Proprietary

Two-way thermal link Ansoft Workbench Mechanical

Solve in Ansoft at initial temperature. Export electromagnetic loss to WB Mechanical. Determine temperatures in WB Mechanical. Export temperatures to HFSS. Material parameters change. T < threshold? Yes Done
26
ANSYS, Inc. Proprietary

Solve in Ansoft with new temperatures.

No

2009 ANSYS, Inc. All rights reserved.

Two-way thermal analysis:

Final temperatures with normal Teflon

2009 ANSYS, Inc. All rights reserved.

27

ANSYS, Inc. Proprietary

EM Power Losses as function of two-way thermal iteration

Volume Loss in normal Teflon Surface Loss on metals

Volume Loss in low-loss Teflon

2009 ANSYS, Inc. All rights reserved.

28

ANSYS, Inc. Proprietary

Temperatures as function of two-way thermal iteration

Tmax Normal Teflon

Tmax Low-Loss Teflon Tmin Normal Teflon Tmin Low-Loss Teflon

2009 ANSYS, Inc. All rights reserved.

29

ANSYS, Inc. Proprietary

Two-way thermal analysis:

Final temperatures with low-loss Teflon

2009 ANSYS, Inc. All rights reserved.

30

ANSYS, Inc. Proprietary

Example 2, with Ansoft Maxwell: battery charger for medical implants

Battery Titanium case, implanted in body Coil outside body, on skin, powered by external source Coil in implant, inductively coupled, picks up power to charge battery

Electronics

2009 ANSYS, Inc. All rights reserved.

31

ANSYS, Inc. Proprietary

Induced current has maximum at 50 kHz.

Maximum

Limited by losses in coil

Limited by skin effect in titanium case

2009 ANSYS, Inc. All rights reserved.

32

ANSYS, Inc. Proprietary

Magnetic field coupling

Induced currents in second coil reduce the magnetic field here. This is the intended behavior.
33
ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

Final temperature at 50 kHz

Maximum 43.8 0C

Due to skin effect in titanium, temperature exceeds 43 deg C after a few minutes. This would be uncomfortable and probably violates safety regulations.
34
ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

Final temperature at 10 kHz

Maximum 38.4 0C

At 10 kHz, final temperature is safe. Secondary coil picks up about as much power, but skin effect heats the titanium case much less.
35
ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

Conclusions

Links between HFSS/Maxwell and ANSYS Workbench are available in the graphical user interfaces -> easy to set up. Advanced applications can be handled.

2009 ANSYS, Inc. All rights reserved.

36

ANSYS, Inc. Proprietary