November 7

Daytime:
MagNet Training Course
(Premium registration only)


Breakfast (before the start of the day), coffee breaks (one in the AM and PM), and lunch are included with premium registration only.

Evening:
Welcome cocktail
(open to all registrations)

November 8

Daytime:
Engage 2017 Day 1


Breakfast (before the start of the day), coffee breaks (one in the AM and PM), and lunch are included.
(open to all registrations)

Evening:
Client Dinner
(open to all registrations)

November 9

Daytime:
Engage 2017 Day 2


Breakfast (before the start of the day), coffee breaks (one in the AM and PM), and lunch are included.
(open to all registrations)

Presentations

Description

Employing magnet-less motors such as switched reluctance motors (SRMs) in electric and hybrid electric vehicles (EV/HEVs) has gained attention and popularity in industry and academia, due to lower cost and more robust performance. In order to achieve the highest performance with the lowest manufacturing cost, optimal design of a SRM to meet specific characteristics for certain application involves optimization of both motor geometry and control strategy simultaneously. The most important control feature of a SRM that distinguishes it from other motors is its controllable firing angles. Inappropriate firing angles can lead to non-optimal operation of the SRM which eventually results in lower average output torque and higher torque ripple. In this situation, a common solution is to increase the motor stack length to meet the required average torque which will make the SRM oversized and costly. In this presentation, a constrained multi-objective optimization framework for design and control of a SRM, based on a non-dominated sorting genetic algorithm (NSGA-II) will be presented. The proposed optimization method optimally selects the firing angles to avoid oversizing the motor for specific torque characteristics. MotorSolve is an enabler for this optimization process which links MATLAB with Finite Element Analysis (FEA) by providing an environment to write the optimization code in MATLAB which leads to expedite the design process. The motor control and geometry variables are defined in MATLAB script, so that, for each iteration of the optimization, the motor will be plotted and simulated in MotorSolve.. All steps of programming in MATLAB and designing the SRM in MotorSolve will be presented.

What problems were resolved?

  1. MotorSolve simulates the SRM very quicker than the other FEA packages and the output characteristics is so close to 3D simulation.
  2. The feature of linking MATLAB with FEA makes it possible to enter the motor geometry and control variables in MATLAB.
  3. The SRM output characteristics can be imported into MATLAB which can be stored and analysed easier.

Technical Level

Advanced

Presenter

Bahar Anvari, Texas A&M University

Description

The last fifteen years of using Magnet has resulted in the generation of over 4300 Magnet model files in 1800 different models with more than 18,000 supporting files of graphs, spreadsheets, and reports. I will be presenting some of the more interesting cases highlighting success and the occasional failure.

Most of the work has been with static permanent and DC electromagnetic field analysis. I started using Magnet 2D on 80286 processor computers about 1986. In 2002 I became the full time lead magnetics circuit analyst. Until a few years ago I provided worldwide support for all of the Eriez affiliates. There is now a second seat of Magnet at our Eriez China facility.

The smallest analysis was for a dime sized PM position sensor and the largest for an over 500 ton High Gradient Magnetic Separator. I will present what I hope is an interesting variety of the problems we have solved using Magnet without going into particular design details. These include lifting, conveying, and a myriad of magnetic separation equipment. Most will be amazed at how these products are used in producing everyday products . I think it will be interesting without being a technically dry presentation.

Presenter

Mike Ross, Eriez

Description

Magnetically levitated motor technology allows the development of ultra high speed and efficient motor systems. Unfortunately, magnetic bearings are often times prohibitively expensive and bulky. My research solves these shortcomings by re-using the magnetic field that is already present in the motor to create magnetic bearing forces. These systems are called bearingless motors and combine the functionality of a magnetic bearing and motor into a single electromechanical device. Bearingless motors are computationally expensive to analyze, typically requiring 3D Finite Element Analysis, oftentimes unable to use symmetry conditions, and require fine air gap meshes for accurate force calculations. This presentation will investigate the integration of Matlab and MagNet to facilitate the design, simulation, and analysis of bearingless motors. The presentation will first introduce bearingless motors and their applications and then delve into the scripting interface that the author has developed to link Matlab and MagNet.

What problems were resolved?

Large studies of the design space of bearingless motors are challenging without a scripting interface. These challenges include generating hundreds to thousands of MagNet project files for the various design choices, solving all of the design files, extracting meaningful analysis results, and being able to compare the design differences between two files. This talk will present a Matlab scripting interface that the author has developed to overcome these challenges. The scripting interface is able to quickly set up all required simulation files, initiate solves, and extract results. Because the scripting interface is text based, differences in a large design space are easily analyzed using simple text-based diff tools.

Technical Level

Intermediate

Presenter

Eric Severson, University of Minnesota

Description

A magnetic gearbox (MG) can operate with low noise and vibration and its noncontact operation means that no gear lubrication is required. In addition, MGs have the unique ability to pole slip when overloaded rather than catastrophically failing, thereby providing built-in overload protection. An MG also has the potential for high efficiency. Coaxial MGs have experimentally been shown to be capable of achieving active region torque densities above 200 Nm/L. However, to-date single-stage coaxial MG designs have only been shown to be capable of achieving a high-torque density at a low gear ratio, typically less than 8:1. There are many applications in which a significantly higher gear ratio is desirable, such as in robotic and power generation applications.

Mechanical cycloidal gearboxes are well known for their ability to have a high gear ratio and a high-torque density. However, their operational life is relatively low. In 2008, a paper demonstrating the capability of a contact-free cycloidal MG (CMG) was published by Jorgensen. Jorgensen demonstrated that a cycloidal rotor motion enables field harmonic modulation to be created between two magnetic rotors. Using a CMG with surface-mounted magnets, it was calculated that a CMG could achieve a peak volumetric torque density of 183 Nm/L at a gear ratio of −21:1. Rens et al. demonstrated the capability of a dual stage −360:1 gear ratio CMG in which each stage of the CMG had a 150 Nm/L torque density. Recently, Chicurel-Uziel experimentally demonstrated the performance of a similar type of CMG with a 26:1 gear ratio. Davey et al. showed that an axial-type CMG can also be built. Davey et al. studied the performance of a 30:1 gear ratio axial CMG. Despite these recent publications, very little research has been published which looks at the capabilities of the CMG. The purpose of this research is to demonstrate that a CMG is capable of achieving a volumetric torque density >200 Nm/L while also operating with a high gear ratio.

What problems were resolved?

A cycloidal magnetic gear with a high gear ratio and a high torque density was designed and simulated.

The cycloidal motion was successfully simulated in Infolytica Magnet so that the performance (peak torque, losses, efficiency, etc) of the magnetic gear could be evaluated.

Technical Level

Advanced

Presenter

Kang Li, University of North Carolina at Charlotte

Description

: In 2014, a group of university students undertook the challenge of building the most eco-energetic vehicle in the world, and vowed to prove it to the world by winning the Shell Eco-Marathon in Detroit. After two years of hard work, the Beyond Team managed to demonstrate their statement by winning the competition, far ahead the rest of the other teams.

The Beyond project had something that none of the other teams had, something which gave us an overwhelming advantage over other competing teams. An electric motor, built from scratch by the electrical engineering students of the team, designed with one of the best Electric field simulation software on the market: MagNet.

During this presentation, I will briefly go over what the Beyond Project is, and what makes our vehicle so unique. I will then Present the details of the design phase and how MagNet was used to optimize the design of our motor. Finally, I will demonstrate the results of the simulation MagNet has provided us with, and how we brought the simulated design to reality by building our own motor.

What problems were resolved?

The problems resolved with the use of MagNet were the efficiency optimization and reduction of core loss by simulation of the magnetic flux created by the windings of the motor. This was done by writing a dynamic code in Visual Basic compatible with MagNet which permitted us to test several designs of motors without having to re-draw the whole thing. We were able to easily modify the design of the motor based on the results of the simulations of each iteration, until we could find the optimal motor application.

Technical Level

Intermediate

Presenter

Raphaël De Roy, Project Beyond / Universite de Sherbrooke

Description

This talk will present visual basic code snips; and explain how to use MotorSolve as an object within a Visual Basic Application using Visual Studio. The main point of the talk is to teach a person with a beginner to intermediate level of Visual Basic experience how to write an simple application that uses Motorsolve to run a variety of motor simulations, and create a report that is ready to deliver to the customer, and that contains all of the simulation results the customer asked for. Significant time is saved by using the VB application because the user is able to set the inputs of the various MotorSolve analysis ahead of time, into a form in the application, and hence allowing the various simulation to run in the back ground while the user is working on other things. The application delivers the simulation inputs to Motorsolve, runs the simulation, places the results into the report and then starts over again with the next simulation and repeats until all the simulation are done. This is all done without user interaction, other than filling in a form and starting the process. When all of the simulations are complete, the results are assembled into a single MotorSolve report containing the various MotorSolve results. The VB code at the various level of the program are explained and a demonstration of the program will be done.

Presenter

Steve Huard, Parker Hannifin Corporation

Description

During development of a variable electrical water pump, based on an eddy-current magnetic coupling, the analytical solution should be proved and the design for prototype assembly tested by simulation. The FEA analysis was important to check all machine function and test method, based on the theory developed by DAVIES[1965]. This theory is a 2D analytical solution for eddy-current coupling, for heteropolar and homopolar configuration. Based on that, initially, an 2D-transient simulation was done to compare the analytical torque calculation with the simulation result. After theory validation, it was possible to test and develop different magnet materials to improve the energy conversion efficiency. Finally, an 3D-transient simulation was done due the geometry complexity in order to predict the real performance by simulation. The software in use is Magnet.

What problems were resolved?

Magnet circuit simulation to validate the analytical solution.

  • Performance prediction.
  • Simulation method for machine optimization.

Technical Level

Advanced

Presenter

Rodrigo Bronzeri, Pricol

Description

The paper presents a specific simulation model for the analysis of brushless synchronous alternators with skewed stator. Modeling implementation is based on a simultaneous multi-slice technique. The model enables the simulation of the alternator’s overall performance under various load conditions, taking into account the effect on damper bar design for skewed stator. The model is also compared to the single-slice multi-run case at which the effect of skewing the stator is modeled in the post-processing calculations.

What problems were resolved?

Accurate modeling of skewed stator/rotor without using a 3D time-expensive simulation

Technical Level

Intermediate

Presenter

Ashraf Atalla, Meggitt

Description

Around the world, vast networks of pipelines transport natural gas and liquid petroleum from the wellhead to end users. Safe and successful pipeline operation depends upon owners understanding the condition of their pipelines and identifying, assessing, and mitigating threats that could lead to loss of containment. Among the leading causes of eventual pipeline failure are third-party mechanical damage – including dents and gouges from typically unintentional contact with excavation equipment – and corrosion leading to metal loss.

Magnetic flux leakage (MFL) is one of the most common non-destructive inspection methods for providing data about pipeline corrosion and pitting. An inline inspection (ILI) tool traverses the pipeline, detecting variations in magnetic field that imply metal loss. However, the parametric relationship between the magnetic field response and the size of metal loss defects is complex and depends on many factors, including pipeline material properties (grade, dimensions, etc.), wall thickness, magnetic field strength, and even the size and speed of the ILI tool.

To accurately understand flux leakage response in the field relative to pipeline metal loss, T.D. Williamson (TDW) utilizes Infolytica MagNet modeling software By pairing MagNet Transient 3D with Motion dynamic simulation modeling with laboratory test data, TDW has increased performance analysis accuracy for existing tools and developed predictive models for the performance of concept tool designs. Confidently predicting magnetic field response for concept designs gives TDW the ability to iterate across design parameters quickly and efficiently, and accelerate its research and development (R&D) efforts.

This presentation will provide an overview of advances in the use of Infolytica MagNet software for predicting dynamic flux leakage field response near pipeline metal-loss features.

What problems were resolved?

TDW has been able to correlate Infolytica MagNet simulation models of complex dynamic magnetic response to ‘real world’ tool data. The simulation capability allows TDW to quickly and efficiently iterate across design parameters without incurring significant material cost and time.

Technical Level

Intermediate

Presenter

Matthew Romney, T.D. Williamson

Description

We designed a solenoid in-house for use on an electro-mechanical flow control device. The solenoid was to be manufactured at an offshore low cost country vendor. Occasionally we would receive solenoid that either had random units that produced low magnetic force or at times complete shipments with low force.

On the drawing is a resistance and inductance spec that we typically use as an indication of the units having the correct number of turns of the proper size wire (resistance) and the proper material with the proper heat treatment properties (inductance). Much to our surprise most if not all of these units would meet these requirements.

However there was one very important physical characteristic that was called out on the drawing, but as it turned out was not always being met. Our vendor insisted that there failure to meet this print requirement was not the issue as they showed how both good and bad part met the resistance and inductance requirement.

What problems were resolved?

Through the use of Infolytica Magnet software we were able to show that it is indeed important to meet the physical characteristic for the solenoid to work correctly at all energy input levels. And that while the resistance and inductance checks told us the proper of amount and size of copper was used and that the individual component where of the proper material and heat treatment, that if the components are not assemble accurately the device will not work due to a flux return path bottle neck.

Technical Level

Basic

Presenter

David Hurayt, Standard Motor Products, Inc.

Description

The next generation Rotorcraft will rely more and more on Brushless DC motors for flight and vibration control to improve reliability.
MotorSolve software is an indispensable tool for the design and analyses of motor configurations to facilitate the rapid growth of electric propulsion, flight control and system elements for rotorcraft platforms.

What problems were resolved?

Rotorcraft platforms require special attention to redundancy and reliability due to the fundamental concept of rotary wing flight. In addition, severe vibration is generated due to the environment of high frequency operation of rotor and wing. Utilizing electric controls poses difficult challenges to meet safety and reliability needs. The optimization of the motor configuration is critical to ensure weight and envelope goals.

Technical Level

Advanced

Presenter

John Kopp, Moog

Description

The latest development of the compact CPAP and lung ventilation devices powered from batteries required designing small electric motors with low power consumption. Due to the high rotational speed application, the motors are designed to work with high frequency voltage and current. In this case the additional requirements to the accurate efficiency estimation of such motors on the design stage become more important. Thus, the simulations of such motors should take into account all types of losses related to the high frequency application: stator core losses, losses in the magnet and losses in the bearings from stray magnetic fields. The presentation will show the methodology and the simulation results for small high speed motor used in CPAP medical devices for sleep apnea treatment.

What problems were resolved?

The accurate efficiency estimation by modeling and simulation of high speed brushless DC motor by using Magnet 3D transient solver

Technical Level

Intermediate

Presenter

Aleksandr Nagorny, ResMed Motor Technologies

Description

TRANSVERSE flux machines (TFMs) are known for their high power and torque density capabilities. It is expected that TFMs will find their applications in some low-speed high torque direct drive applications such as wind turbine generators or traction motors for electric vehicles. Among all existing TFM geometries,the Clawpole TFM (CTFM) may be the one offering the best compromise between torque density and ease of construction and manufacturing. CTFM magnetic circuits are usually made from soft magnetic composite materials (SMC) for their isotropic properties and for manufacturing purposes. A CTFM version using a hybrid stator made of a combination of SMC and Fe-Si laminations or amorphous material is presented. Compared to CTFMs made of SMC only, this configuration offers reduced iron losses while further improving its manufacturing.

Technical Level

Advanced

Presenter

Maxime Dubois, Université de Sherbrooke

Description

Using MagNet parameterization function has greatly improved the efficiency of my simulation project, which involves numerous calculations for various magnets with different dimensions at twenty-three air gaps. The user-defined parameters can be set either using MagNet Modeling Toolbox or using the component’s properties box at the Parameters tab. One example is for the rectangular prism shaped magnets: by creating user-defined parameters length and width from 1 to 50 with increment 1, one such parameterization run results in 2500 data points for one thickness. Another example is for ring magnets: by creating user-defined parameters radius 1-25 with increment 0.5 and thickness 1-25 with increment 1, one simulation run results 1225 data points for a fixed inside diameter. Different setting can also be used for rings, cylinders, or other shapes. Details and figures will be shown in the presentation.

Accuracy is always one of the main goals in our project. If the mesh is set very fine for an accuracy in certain level, the simulation may be very time consuming, and one run for 2500 problems takes 48+ hours. If the mesh is set not fine enough, the accuracy may be questionable, especially for small magnets at large gap with weak magnetic field. Using balanced setting can make the simulation in an efficient way. It is also observed that two objects with larger volume difference in one system may have very different accuracy in resulted force, but they should be the same.In this case, select the force extracted from the steel can save time and obtained good accuracy.

Technical Level

Intermediate

Presenter

Christina Chen, Magnet Energy LLC

Description

The dynamic performance of a 4-way solenoid operated hydraulic spool valve has been analyzed by means of a one-dimensional modeling approach capturing flow, magnetic and fluid forces, valve inertia forces, fluid compressibility and damping. Increased model accuracy was achieved by analyzing the detailed three-dimensional electromagnetic behavior of the solenoids and flow behavior through the spool valve body for a set of relevant operating conditions, thereby allowing the accurate mapping of flow and magnetic forces on the moving valve body, in lieu of representing the respective forces by lower-order models or by means of simplistic textbook correlations. The resulting high-fidelity one-dimensional model provided the basis for specific and timely design modification eliminating experimentally observed valve oscillations.

What problems were resolved?

  1. Investigate valve instability
  2. Correlated the results with test data
  3. Recommended solutions to fix the valve oscillation issues

Technical Level

Basic

Presenter

Ashok Zopey, Parker Hannifin

Description

This presentation has several purposes: (a) to show a method for accurate high-frequency modeling of transformer windings based on magnetic and electric field simulations for parameter extraction of the detailed equivalent circuit of the entire winding system; (b) to demonstrate a method for fast and accurate transient solution of the circuit differential equations that describe the transient voltage distribution over the winding system; (c) to present a method for taking into account frequency dependent transformer parameters in time domain simulations; and (d) to evaluate the accuracy of the obtained simulation results by comparison with measurement.

What problems were resolved?

  1. MagNet modeling of a winding system in its full geometrical complexity in order to extract the L-matrix of magnetic coupling between different winding turns.
  2. ElecNet modeling of a winding system in its full geometrical complexity in order to extract the C-matrix of electric coupling between different winding turns.
  3. Transient simulation of the large equivalent circuit of a winding system.
  4. E- and H-field visualization and evaluation at each time step of the circuit simulation.

Technical Level

Advanced

Presenter

Jasmin Smajic, University of Applied Sciences of Eastern Switzerland (HSR)

Description

Dynamic behavior of electrical machines can cause effects that are difficult to describe and understand. This is particularly important under fault conditions such as different variants of short-circuits occurring due to the failure of the insulation system or the attached power electronics components. Short-circuits are very hazardous for machine and human. They could destroy the machine itself and cause heavy damage to the power supply unit and mechanical coupling components.

Transient FEM simulations of electrical machines under short-circuit conditions are an important tool for understanding the dynamic effects without the risk of damaging the machine by experiments. In this presentation modeling details and simulation approaches for dynamic analysis of synchronous machines will be presented in detail. The accuracy of the obtained 2-D and 3-D transient electromagnetic simulations will be demonstrated by comparison against the available measurements performed on a chosen testing salient pole synchronous machine under the conditions of three-phase, two-phase and single-phase short-circuit of the stator winding system.

Technical Level

Advanced

Presenter

Jasmin Smajic, University of Applied Sciences of Eastern Switzerland (HSR)

Description

: A design update to improve the manufacturability of an existing product is clearly beneficial, but must be implemented in a manner that maintains backward compatibility with both the mechanical fit and the magnetic performance of the prior design. This presentation discusses the analysis conducted to determine the viability of a design change, as well as how optimal choices for material properties and dimensions for the magnet array components were derived using MagNet FEA tools from Infolytica.

What problems were resolved?

Material selection and dimensions for the magnets and cover.

Technical Level

Intermediate

Presenter

Tracy Clark, MagneMotion, Inc.

Description

Classical modeling techniques of Permanent Magnet (PM) machines include extracting the machine characteristics such as Ld and Lq to represent machine behavior and identify optimal operating point for maximum torque per ampere (MTPA). High order models include capturing saturation as function of inductances in their respective axis. This talk provides insights on how to create flux linkage maps using MagNet software and use that information to create an operating point map for an available voltage to achieve maximum torque per ampere.

Technical Level

Intermediate

Presenter

Jagadeesh Tangudu, United Technologies Research Center