ThermalAnalysisofFerriteCore
ElectronicPlanarTransformer
MarkChristini
ANSYS,Inc
1 2011ANSYS,Inc. September6,2011
Outline
Introduction
Maxwell3DEddyCurrentand
ElectrostaticSimulation
ANSYSMechanicalThermal
Simulation
2wayThermalCouplingbackto
Maxwell
Simplorer SystemSimulationusing
MaxwellStateSpaceDynamic
model
Summary
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Introduction
Coupledelectromagneticthermalanalysisofaferritecore
electronicplanartransformer
Magneticsimulationdoneatfundamentalfrequency=
100kHzwithharmonicsupto5MHz
Allsourcesoflossesconsideredincluding:eddycurrent,skin,
andproximitylossesinthewindingsaswellaseddycurrent
andhysteresislossesintheferritecore
LossesaredirectlycoupledintoanANSYSMechanical
Thermalsimulationinordertodeterminetemperaturerise
usingelementbyelementcoupling
TemperaturesfedbacktoMaxwellformaterialchanges
SystemsimulationdoneinsideofSimplorer usingdynamic
statespacefrequencydependentmodel
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CoupledElectromechanicalDesignFlow
Simplorer
Q3D SystemDesign RMxprt
Parasitics
MotorDesign
IA PMSYNC Torque J
A A D2D
IB ICA:
A
PP := 6
IC
A
GAIN
ANSYSCFDFluid
Flow
PExprt
Magnetics
ANSYS Maxwell2D/3D
ElectromagneticComponents
Mechanical
Thermal/Stress Model order Reduction
Co-simulation
Field Solution
Model Generation
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FEAAdaptiveMeshing
2DTransformerModel 3DTransformerModel
2DTransformerMesh 3DTransformerMesh
In3D,finite
In2D,finite elements
elements are
are tetrahedra
triangles
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Transformer DesignChallenges
Magneticeffects:
nonlinearmaterials
frequencydependentmaterials
tempdependentmaterials
eddycurrents
proximityeffects
timediffusionofmagneticfields
transientexcitations
ElectricFieldeffects:
varyingdielectricpermitivities
varyingdimensionsandshape
3Dfieldeffects
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ANSYSComprehensiveSolution
System
ANSYS
Mixed-Signal Multi-Domain
System Simulator
Circuit
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WorkbenchCouplingTechnology
Electromagnetic ThermalStressSystem
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ElectronicPlanarTransformer
FerritePQCore
Primaryturns=4
Secondaryturns=2
Insulationlayersbetweenconductors
FundamentalFrequency=100kHz
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Maxwell3DSourceSetup
LoadcasewithIpri =50A
andIsec =80A
UnbalancedAturnsfor
coreexcitation
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FerriteCoreProperties
Frequencydependentpermeabilityandimaginarypermeability
UseSimplorer Sheetscan utilitytograbpermeabilitydatapoints
Datasheet Sheetscan
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FrequencyDependentCorePropertiesin
Maxwell
s" Rs
RequiredinputsforMaxwellarerealpermeabilityand s '
losstangent s Ls
Losstangentbasedonseriesequivalentmodel
Temp=0 C
frequency perm perm_imag losstangent
100000 1939 6 0.0032
200000 1977 13 0.0068
300000 2015 22 0.0110
400000 2052 35 0.0173
500000 2090 51 0.0244
600000 2165 79 0.0363
700000 2281 119 0.0522
800000 2322 174 0.0750
900000 2446 264 0.1078
1000000 2533 336 0.1326
1500000 2581 998 0.3869
2000000 2029 2101 1.0351
3000000 828 2178 2.6306
4000000 227 1626 7.1618
5000000 97 1093 11.2199
6000000 61 663 10.8398
7000000 47 424 8.9644
8000000 39 327 8.3658
9000000 34 271 7.9437
10000000 31 228 7.4132
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CoreMaterialProperties Inputs
Datasetsusedtodefinepropertiesvs.frequency:
RelativePermeability=pwl($perm,Freq)
MagneticLosstangent=pwl($losstan,Freq)
Relativepermitivity =12
Conductivity=0.5(S/m)
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CoreMaterialProperties Outputs
Usenamedexpressionincalculatortoverifythe
realandimaginarypermeability
Usereporttoplotandlosstangentvs.frequency
Real permeability -
Phase='0deg'
2000.00 8.00
Real permeability -
mu_real_eval
loss_tangent
Num > Vector > 1,0,0 1500.00 6.00
0.00 0.00
0.00 1.00 2.00 3.00 4.00 5.00
Loss tangent Freq [MHz]
= /
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TemperatureSettingsinMaxwell
Initialtemperature
=22C
Coreandwindings
havetemp
dependent
materials
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Temperaturedependentcopperconductivity
for2waycouplingtoMaxwell
1
(1 0.0039 * (Temp 22))
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InitialConductivityat100kHz,22degC
Conductivity=5.8e7 (S/m)
Conductivityisconstantthroughoutwinding
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Temperaturedependentferritepermeability
for2waycouplingtoMaxwell
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2waycouplingfortemperaturedependent
permeability
perm Permeability
degC perm modifier 5000
50 1247 0.73
25 1440 0.85
4000
0 1700 1.00
25 2031 1.19
50 2442 1.44 3000
74 2982 1.75
89 3252 1.91 2000
100 3368 1.98
113 3483 2.05 1000
125 3522 2.07
137 3560 2.09
0
149 3586 2.11
50 0 50 100 150 200 250
162 3650 2.15
175 3753 2.21 temp(C)
183 3869 2.28
189 3985 2.34 Permeabilitymodifier
191 4113 2.42 3.00
194 4267 2.51
195 4370 2.57 2.50
197 4524 2.66
200 4576 2.69
2.00
202 4524 2.66
204 4422 2.60
1.50
205 4023 2.37
206 2494 1.47
209 514 0.30 1.00
211 180 0.11
213 77 0.05 0.50
216 39 0.02
221 13 0.01 0.00
225 13 0.01 50 0 50 100 150 200 250
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InitialPermeabilityat100kHz,22degC
RealPermeability ImaginaryPermeability
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CurrentDensityat100kHz
LoadcasewithIpri =50A
andIsec =80A
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MagneticFluxDensityat100kHz
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WindingEddyCurrentLossDensityat
100kHz
Windinglosses
considersskinand
proximityeffects
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CoreLossDensityat100kHz
1 * 1 *
Peddy Re J J dV Physteresis Im B H dV
2 vol
2 vol
core_hyster_loss core_eddy_loss
Freq [kHz] Setup1 : LastAdaptive Setup1 : LastAdaptive
Phase='0deg' Phase='0deg'
1 10.000000 0.001082 0.001897
2 100.000000 1.211527 0.191875
3 500.000000 44.428733 5.032800
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SimulatedResistance
500.00
Y1 [ohm]
400.00
300.00
200.00
100.00
0.00
0.01 0.10 1.00 10.00
Freq [MHz]
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SimulatedInductance
40.00
35.00
Curve Info
30.00 Matrix1.L(pri_in,pri_in)
Setup1 : LastAdaptive
Y1 [uH]
Matrix1.L(sec_in,sec_in)
25.00 Setup1 : LastAdaptive
20.00
15.00
10.00
5.00
0.01 0.10 1.00 10.00
Freq [MHz]
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SimulatedCapacitance
UseDCconductionsolvertoassign+1Vand
1Vtocoilsandoncore
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WorkbenchCoupling
Maxwell3DEddy
Currentcalculates
lossesandcouples
directlytoANSYS
thermal
Maxwell3D
Electrostaticcalculates
capacitancesbetween
windingandcore
Maxwell3DEddy
CurrentcalculatesR,L
vs.frequencyand
inports directlyinto
Simplorer viathe
Statespacedynamic
link
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WorkbenchCoupling
EngineeringDataallowsmaterialstobechosenincludingthermalconductivity
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WorkbenchCoupling
Workbench
geometry
imported
directlyinto
Workbench
Appropriate
materials
canthenbe
assigned
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WorkbenchCoupling
Workbenchmeshis
differentthanMaxwell
3Dmesh
Setmaximumelement
size=0.5mm
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WorkbenchCoupling
Fixed
temperature
coldplate
assignedtobase
=22C
Convection
boundaries
assignedto
outersurfaces
ofcoreandcoils
=5W/m2C
32 2011ANSYS,Inc. September6,2011
WorkbenchCoupling
ImportedLossDensityoncoreandwindingsat100kHz
MatchesMaxwell3Dlossdensity total losses ANSOFT
1
Freq [kHz] 100.000000
pri_loss
Setup1 : LastAdaptive 6.657984
Phase='0deg'
sec_loss
Setup1 : LastAdaptive 6.712708
Phase='0deg'
core_loss_top
Setup1 : LastAdaptive 0.701290
Phase='0deg'
core_loss_bot
Setup1 : LastAdaptive 0.702112
Phase='0deg'
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FerriteCoreTransformerTemperatureat
100kHz
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ExporttemperaturebacktoMaxwell
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ResolveinMaxwellwithactualtemp
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UpdatedCopperConductivitywith2way
coupling
Uniformconductivity
=5.8e7 (S/m)at22C
Varyingconductivitywith
varyingtemperature
(decreasesastempincreases)
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SimplorerArchitecture
Co-Simulation
C/C++ Matlab
User Defined Real Time Matlab ANSYS ANSYS
Model Workshop Simulink MBD Maxwell
Maxwell3DFrequencySweep
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Simplorer SystemSimulation
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Simplorer SystemSimulation
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Conclusions
Maxwell3Ddetermineslosscomponents(eddy
current,hysteresis,proximity,skin)atmultiple
frequenciesaswellasR,LandC
WorkbenchallowsMaxwelllossestobespatially
coupledtoANSYSMechanicalfortemperaturerise
calculation
Resultingtemperaturerisecanbecoupledbackto
Maxwellinordertousedtochangematerial
propertiessuchaspermeabilityandconductivity
Maxwell3Dcanexportafrequencydependent
transferfunctionusingDynamicStateSpacecoupling
insideofSimplorer toallowforacompletesystem
simulation
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