Experimental verification and
comparison of analytical and FE models
for calculation of a bitter solenoid
Part II: Numerical simulation
Dr.-Ing. Vladimir Kolchuzhin
Chemnitz University of Technology, Chemnitz, Germany
I²FG Workshop on Impulse Forming
Gent, 7 May 2013
vladimir.kolchuzhin@etit.tu-chemnitz.de
1
Content
 introduction
 study of coil system by 3D BEM analysis
 study of coil system by 2D FEM analysis
 parametric study of coil system by 3D FEM analysis
 conclusions and outlook
vladimir.kolchuzhin@etit.tu-chemnitz.de
2
Appropriate and available Software
LS-DYNA v980a
MPP alpha
ANSYS 14.0

 980 alpha version contains emmodul in test stage
 circuit coupled and multiphysics
capability
 first tests show capability
for highly nonlinear mechanical
problems (contact, material)
 nonlinear magnetic capability for
modeling B-H curves
 mag. materials (nonlinear
B-H dependency  ferromagnetic materials) are nonimplemented
 coupling method between magnetic and
electric degrees of freedom (low-frequency
formulation)
ANSOFT Maxwell (2D/3D FEM) (now part of ANSYS)
FEMM (2D FEM)
COMSOL (2D/3D FEM)
QuickField (2D FEM)
FastHenry (3D BEM)
multiphysics
capability
vladimir.kolchuzhin@etit.tu-chemnitz.de
3
Department of Microsystems and Precision Engineering, TU Chemnitz
Our Research Profile





Design of microsystems (sensors and actuators) and their application in a device environment
Modeling, simulation and experimental validation of the behavior of microsystems
Development of design tools and methods
Characterization of MEMS and precision engineered structures
Measurement and test technology for microsystems
Hardware
Software
Workstation
Intel® Core™ i7-3930K CPU @3.20GHz
64.0GB RAM
 ANSYS Academic Associate product
 ANSYS Academic Research product
 ANSYS Simplorer
 MathCad
 MATLAB
http://www.tu-chemnitz.de/etit/microsys
vladimir.kolchuzhin@etit.tu-chemnitz.de
4
3D BEM
FastHenry from MIT
output: Impedance matrix Z=R+jL
http://www.rle.mit.edu/cpg/research_codes.htm
“Current path”
Topology of coil
input
3D model
file.inp
N1
N2
x=1.50e+01 y=0.00e+00 z=0.00e+00
x=1.80e+01 y=0.00e+00 z=0.00e+00
E1
N1
N2 w=9.0 h=4.0
vladimir.kolchuzhin@etit.tu-chemnitz.de
5
2D axisymmetric MVP FE analysis in ANSYS
FE-mesh
vladimir.kolchuzhin@etit.tu-chemnitz.de
6
2D axisymmetric MVP FE analysis in ANSYS
f=0.1 Hz, I=75kA
transient analysis
f=10kHz, I=75kA
PLANE53 (quadratic) element
 = 4.0E-8 Ohmm
Jtz
L
2Wmag
I2
R
Jtz
Prms
2
I rms
f=10kHz, I=75kA
energy
ET,1,PLANE53,1,,1
Bsum
N_turn=3
Rcoil(0.1) = 71.232 µOhm
Lcoil(0.1) = 2.131 µH
Bsum
Rcoil( f ) = 994.251 µOhm
Lcoil( f ) = 1.608 µH

vladimir.kolchuzhin@etit.tu-chemnitz.de
7
2D axisymmetric MVP FE analysis in ANSYS
transient analysis
PLANE53 (quadratic) element
f=10kHz, I=75kA
 = 4.0E-8 Ohmm
path
f=0.1 Hz, I=75kA
1
1
POST1
APR
STEP=11
SUB =1
TIME=2.5
PATH PLOT
NOD1=54989
NOD2=23806
1.926
BY
By
8 2013
17:16:58
1.85
POST1
By
1.771
2.107
1.873
1.692
1.639
1.613
1.405
1.534
APR 8 2013
16:43:21
STEP=11
SUB =1
TIME=.250E-04
PATH PLOT
NOD1=54989
NOD2=23806
2.339
BY
1.171
1.455
.937
1.376
.703
1.297
.469
1.218
.235
(x10**-2)
1.139
0
1.8
.9
3.6
2.7
5.4
4.5
7.2
6.3
9.004
8.1
DIST
By=1.4…1.9 T
(x10**-2)
.001
0
1.8
.9
3.6
2.7
5.4
4.5
7.2
6.3
9.004
8.1
DIST
By=1.3…2.3 T

vladimir.kolchuzhin@etit.tu-chemnitz.de
8
3D edge-flux formulation FE analysis in ANSYS
2D model
Z
3D model
Y
X
Generates volumes by dragging an area pattern along a path
Model status:
Solid236
3D edge-flux formulation
number of nodes = 5 775 365
number of elements = 1 438 560
number of edge-flux DoF = 4 325 372
number of equations = 3 253 926
solution time: 6:44 h
vladimir.kolchuzhin@etit.tu-chemnitz.de
9
3D edge-flux formulation FE analysis in ANSYS
1
1
ELEMENT SOLUTION
Jtz
STEP=3
SUB =1
TIME=.182E-04
JTSUM
SMN =9910.53
SMX =.347E+10
 = 4.0E-8 Ohmm
ELEMENT SOLUTION
STEP=3
SUB =1
TIME=.182E-04
JTSUM
SMX =.347E+10
APR 22 2013
08:50:13
APR 22 2013
08:57:30
f=10kHz, I=75kA
MX
transient analysis
MN
Rcoil( f ) = 1.943 mOhm
Lcoil( f ) = 2.446 µH
Z
9910.53
.760E+09
.380E+09
.152E+10
.114E+10
X
Y .190E+10
.228E+10
.304E+10
.266E+10
0
.347E+10
.760E+09
.380E+09
.152E+10
.114E+10
.228E+10
.190E+10
.304E+10
.266E+10
.347E+10
PulsarCoil_b2
PulsarCoil_b2
1
1
NODAL SOLUTION
1
NODAL SOLUTION
Bsum
STEP=3
SUB =1
TIME=.182E-04
BSUM
(AVG)
RSYS=0
SMN =.297E-04
SMX =2.31203
APR 22 2013
08:50:52
NODAL SOLUTION
STEP=3
SUB =1
TIME=.182E-04
BSUM
(AVG)
RSYS=0
SMN =.432E-05
SMX =1.0113
APR 22 2013
08:54:13
Volt
STEP=3
SUB =1
TIME=.182E-04
VOLT
(AVG)
RSYS=0
SMN =-586.246
SMX =9324.99
APR 22 2013
08:49:52
MN
MX
MN
MX
Z
.297E-04
.505779
.252904
PulsarCoil_b2
1.01153
.758654
X
Y 1.2644
1.51728
0
2.02303
1.77015
.875
.4375
2.31203
1.75
1.3125
2.625
2.1875
Z
3.5
3.0625
4
-586.246
1581.84
497.795
PulsarCoil_b2
3749.92
2665.88
X
Y 4833.96
5918
8086.08
7002.04
9324.99
PulsarCoil_b2
vladimir.kolchuzhin@etit.tu-chemnitz.de
10
Parametric study
R
R, mOhm
Rdc  
2,0
L
A
R, mOhm
2,0
2,0
2,0
1,8
1,8
1,8
1,6
1,6
1,6
1,4
1,4
1,4
1,4
1,2
1,2
1,2
1,2
1,8
1,6
1,0
1,0
50
70
90
L
L, µH
1,0
150
L 2
2,0
1,8
1,6
1,4
1,2
1,0
0,8
0,6
170
190
 0 r1 ( ,  )
4
1,4
1,2
1,0
0,8
0,6
Inner radius,
mm
90
20
25
2,0
1,8
1,6
1,4
1,2
1,0
0,8
0,6
1,6
70
15
150
170
1,0
30
1
2
3
4
2
3
4
L, µH
1,8
50
10
190
Outer radius,
mm
1,8
1,6
1,4
1,2
1,0
0,8
10
15
20
25
Turn thickness,
mm
0,6
30
1
Connection thickness,
mm
vladimir.kolchuzhin@etit.tu-chemnitz.de
11
Sensitivity analysis
0,030
Sensitivity
G / p
0,020
0,010
R
L
R
0,000
‐0,010
‐0,020
Inner radius
L
Outer radius
Turn Thickness
R
L
Connection Thickness
R
L
‐0,030
‐0,040
‐0,050
‐0,060
Design parameter
vladimir.kolchuzhin@etit.tu-chemnitz.de
12
Results
Software
Analysis type
R, mOhm
L, µH
B, T
dc
0.152
6.914
n.a.
ac 10kHz
3.616
6.013
n.a.
dc
0.109
n.a.
n.a.
0.1 Hz 3 turn
0.071
2.131
1.4…1.9
10kHz 3 turn
0.994
1.608
1.3…2.3
10kHz 3 turn
-
-
1.4…2.4
dc
0.110
4.093
-
ac 0.1 Hz
0.110
2.047
1.30…2.23
ac 10kHz
3.478
1.541
1.45…2.17
Analytical
10kHz
6.588
1.838
1.2
Experimental
10kHz
7.441
1.504
0.76…1.9
FastHenry 3D
ANSYS 3D electro-conductivity
ANSYS 2D emag
FEMM 2D
ANSYS 3D emag
vladimir.kolchuzhin@etit.tu-chemnitz.de
13
Conclusions and Outlook
A short conclusion is given in the following:
 parametric study of coil system by 3D BEM and FEM analyses has been presented
Further work will be focused on:
 iterative verification and validation of presented models
 application of efficient algorithm (e.g. Variational Technology method within ANSYS)
vladimir.kolchuzhin@etit.tu-chemnitz.de
14
The end
Thank You for Your Attention!
vladimir.kolchuzhin@etit.tu-chemnitz.de
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