Introducing Ansys Rocky – Webinar

PADT is excited to share more information on one of the latest Ansys acquisitions, Rocky DEM.

Rocky is a powerful 3D Discrete Element Modeling (DEM) Particle Simulation Software that quickly and accurately simulates the flow behavior of bulk materials with complex particle shapes and size distributions, for typical applications such as conveyor chutes, mills, mixers, and other materials handling equipment.

Rocky is fully integrated with the Ansys Workbench suite of products, providing engineers with the ability to perform coupled analysis of particles simulation together with other physics such as structural and fluids. 

Such coupling can be performed using both 1-way and 2-way approaches, depending upon the nature of the problem to be solved. When Rocky is coupled with Ansys Mechanical software, engineers can evaluate the tension stresses and forces generated by granular matter as it interacts with materials handling equipment, such as transfer chutes and conveyor belts.

Join PADT’s Senior CFD Engineer and Rocky expert Tom Chadwick for a look at what this tool is all about, as well as how it operates in a variety of industries, such as:

  • Food & Beverage
  • Agricultural Equipment
  • Medical Devices
  • And More

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Simulating Electrical Windings: Solid or Stranded?

In Ansys Maxwell, windings can be added in Eddy Current and Transient Solvers. There are two types of conductors when assigning the windings: Solid and Stranded. What is the difference?

The Solid type considers the conductor as a solid part and therefore, the eddy current and AC effects will be taken into consideration. While the Stranded type assumes the conductor consists of infinite strands of tiny conductors and therefore, there is no eddy current inside the conductor.

Now if there is no time-varying current or magnetic field in the model, will it be the same using Solid or Stranded? The answer is NO. Figure 1 shows a simple geometry of one-turn copper conductor. The cross-section is 1 mm by 1 mm and length of each edge is 100 mm. Assume the winding type is External and the circuit is shown below in Figure 2. The winding is connected to an external resistance (0.003 ohm) and the DC voltage source is 1 V.

Fig. 1 – Geometry of the conductor
Fig. 2 – Winding external circuit.

The question will be: what is the current in the winding? Based on the physical geometry of the conductor, the conductor resistance can be calculated by R=ρ L/A, where L is the length of the conductor, A is the cross-sectional area and ρ is the resistivity of the copper material. The calculated conductor resistance is about 0.006872 ohm. The winding current will be different based on conductor type.

  • Solid type

When the conductor is selected as Solid in ANSYS Maxwell, the winding resistance will be included while calculating the current. Therefore, the winding current will be:

Note: if the winding resistance is changing, the winding current will also change.

And the winding loss will be:

The winding loss calculated by Ansys Maxwell is 70.57 W which is identical to the result above.

  • Stranded type

When the conductor is selected as Stranded in Ansys Maxwell, the winding resistance will NOT be included while calculating the current. Therefore, the winding current will be:

Note: the winding current is a constant no matter the winding resistance changes or not.

And the winding loss will be:

The winding loss calculated by Ansys Maxwell is 763.55 W which is identical to the result above.

Conclusion

  1. The Solid type is needed if the AC effect is of interest.
  2. For Voltage winding type, the DC winding current and DC winding loss will be different for Solid and Stranded types. If the load resistance is much larger/smaller than the winding resistance, this difference can be neglected.
  3. If the user is using the Voltage source and doing the EM-Thermal coupling simulation, it requires more attention as the temperature rise will increase the winding resistance and therefore, decrease the winding current (as the voltage is fixed). In this case, users can either choose Solid or add an additional scaling factor in the material property to compensate for the current difference.

If you would like more information related to this topic or have any questions, please reach out to us at info@padtinc.com.

Ansys – Software for Electric Machine Design

The electric propulsion system has drawn more and more attention in the last decade. There has been a lot of development of the electric machines which are used in automotive and aerospace. It is essential for engineers to develop electric machines with high efficiency, high power-density, low noise and cost.

Therefore, simulation tools are needed to design the electric machines that can meet the requirement. The product launching time can be reduced significantly with the help of the simulation tools. The design process of electric machine involves the area of Electromagnetics, Mechanical, Thermal and Fluids. This makes Ansys the perfect tool for designing electric machines as it is a multi-physics simulation platform. Ansys offers a complete workflow from electromagnetics to thermal and mechanical which provides accurate and robust designs for electric machines.

To design high performance, more compact and reliable electric machines, design engineers can start with three Ansys tools: RMxprt, Maxwell and Motor-CAD. The capabilities and differences of these three tools will be compared and discussed.

1. Ansys RMxprt

Ansys RMxprt is a template-based tool for electromagnetic designs of electric machines. It covers almost all of the conventional radial types of electric machines. Starting from Ansys 2020R2, some axial types have also been included in RMxprt (IM, PMSM, BLDC).

Fig. 1. Electric machine types in Ansys RMxprt.

Users only need to input the geometry parameters and materials for the machines. The performance data and curves can be obtained for different load types. Since RMxprt uses analytical approaches, it can generate results very fast. It is also capable of running fast coupling/system simulations with Simplorer/Twin Builder. Ready-to-run Maxwell 2D/3D models can be created directly from RMxprt automatically.

2. Ansys Maxwell

Ansys Maxwell is a FEA simulation tool for low-frequency electromagnetic applications. Maxwell can solve static, frequency-domain and time-varying electromagnetic and electric fields. The Maxwell applications can be but not limited to electric machines, transformers, sensors, wireless charging, busbars, biomedical, etc.

Unlike RMxprt which uses analytical method, Maxwell uses the FEA approach which allows it to do high accuracy field simulations. Engineers can either import the geometry or create their own models in Maxwell. Therefore, there is no limit of types of machines that can be modeled in Maxwell. It can model all types of electromagnetic rotary devices such as multi-rotor and multi-stator designs.

Fig. 2. Electric machine detailed model in Ansys Maxwell.

Maxwell can do more detailed electromagnetic simulations for electric machines, for example, the demagnetization of the permanent magnets, end winding simulations and magnetostrictive effects. With Maxwell, engineers are able to run parametric sweep for different design variables and to do optimizations to achieve the optimal design. Maxwell is also capable of creating equivalent circuit extraction (ECE) models. The ECE is one of the reduced order modelling (ROM) techniques, which automatically generates an efficient system-level model. There are several Ansys customization toolkit (ACT) available for Maxwell to quickly create efficiency map and simulate impact of eccentricity. Furthermore, Maxwell can be coupled with Ansys Mechanical/Fluent/Icepak to do thermal and mechanical analysis.

3. Ansys Motor-CAD

Ansys Motor-CAD is suitable to make design decisions in early design phase of electric machines. It includes four modules: electromagnetic, thermal, lab and mechanical. Motor-CAD can perform multiphysics simulations of electric machines across the full torque-speed range. Motor-CAD uses a combination of analytical method and FEA, and it can quickly evaluate motor topologies and optimize designs in terms of performance, efficiency and size.

Motor-CAD is capable of simulating the radial types of electric machines. With its lab module, it can do the duty cycle simulations to analyze electromagnetic, mechanical and thermal performances of electric machines. The thermal module is a standard tool in industry which can provide fast thermal analysis with insight of each thermal node, pressure drop, losses. Motor-CAD mechanical module uses 2D FEA to calculate the stress and deformation. Engineers can also manually correlate the models in Motor-CAD based on the manufacturing impacts or testing data.

Fig. 3. Ansys Motor-CAD GUI and machine types.

Motor-CAD can provide links to Ansys Maxwell, Mechanical, Icepak and Fluent for more detailed analysis in the later phases of motor designs.

  • What to use?

RMxprt and Motor-CAD both can handle most of the radial types of electric machines. RMxprt can also model some conventional axial flux machines. RMxprt can purely model the electromagnetic performance of the machines, while Motor-CAD can simulate electromagnetic, thermal and mechanical performances.

Maxwell can simulate any types of machines (radial, axial, linear, hybrid, etc.) as it can import or draw any geometry. Both static and transient analysis can be conducted in Maxwell.

  • When to use?

RMxprt and Motor-CAD are most suitable in the early design stages of the electric machines. Engineers can get fast results about the machine performance and sizing which can be used as a guideline in the later design phase.

Maxwell can be used in the early design stages for more advanced types of electric machines as well. Maxwell is also capable of doing more detailed electromagnetic designs in the later stage and can be used to do system-level transient-transient co-simulation (coupled with Ansys Simplorer/Twin Builder). More detailed geometries, advanced materials and complex electromagnetic phenomenon can be modeled in Maxwell. In the final stages of running more advanced CFD and NVH analysis, Maxwell can be linked with Ansys Fluent/Icepak/Mechanical to ensure the design robustness of the machines before going into prototyping/production.

  • Who can benefit?

RMxprt and Motor-CAD do not require strong FEA simulation skills as no boundary conditions or solution domain need to be set. Engineers with basic knowledge of electric machines can get familiar with the tools and get results very quickly.

Maxwell requires users to setup the mesh, boundary and excitations as it uses the FEA method. Engineers will need to acquire not only the basic concepts of machines but also some FEA simulation skills in order to get more reasonable results.

Summary

RMxprt: It is a template-based tool for initial electric machine designs which uses analytical analysis approach.

Maxwell: It uses FEA approach model both 2D and 3D models. It is capable of simulating either simple or mode advanced electromagnetics in electric machines.

Motor-CAD: It is suitable for initial machine designs which uses analytical and FEA methods. It can do electromagnetic, thermal and initial mechanical analysis.

If you would like more information related to this topic or have any questions, please reach out to us at info@padtinc.com.

Signal & Power Integrity Updates in Ansys 2021 R1 – Webinar

The use of Ansys Electronics solutions minimizes the testing costs, ensures regulatory compliance, improves reliability and drastically reduces your product development time. All this while helping you build the best-in-class and cutting-edge products.

With signal and power integrity (SI & PI) analysis products, users can mitigate many electrical and thermal issues affecting printed circuit boards such as electromagnetic interference, crosstalk, overheating, etc. Ansys integrated electromagnetics and circuit simulation tools are essential for designing high-speed serial channels, parallel buses, and complete power delivery systems found in modern high-speed electronic devices.

Leverage the simulation capability from Ansys to solve the most critical aspects of your designs. Join PADT’s Electronics expert and application engineer Aleksandr Gafarov for a detailed look at what is new for SI & PI in Ansys 2021 R1, including updates available within the following tools:

• SIwave – Granta support & differential time domain crosstalk

• Q3D – Uniform current terminals

• Circuits – Network data explorer & SPISim

• HFSS 3D – Parallel meshing, encrypted 3D components & IC workflow improvements

• Electronics Desktop – Ansys cloud, Minerva & optiSLang integration

• And much more

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All Things Ansys 087: Introducing Rocky DEM – The latest in 3D Discrete Element Modeling Technology

 

Published on: May 3rd, 2021
With: Eric Miller, Robert McCathren, Ahmad Haidari & Marcus Reis
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Application Engineer, Robert McCathren, as well as Ahmad Haidari – Senior Director of Strategy & Business Development at Rocky DEM, and Marcus Reis – VP of Sales, Support & Marketing at Rocky DEM to discuss the company’s partnership with Ansys and what their tool is capable of.

Rocky is a powerful 3D Discrete Element Modeling (DEM) Particle Simulation Software that quickly and accurately simulates the flow behavior of bulk materials with complex particle shapes and size distributions, for typical applications such as conveyor chutes, mills, mixers, and other materials handling equipment.

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Additive & Structural Optimization Updates in Ansys 2021 R1 – Webinar

The most powerful simulation solution for metal additive manufacturing, the Ansys Additive Suite delivers the critical insights required by designers, engineers and analysts to avoid build failure and create parts that accurately conform to design specifications. This comprehensive solution spans the entire workflow — from design for additive manufacturing (DfAM) through validation, print design, process simulation and exploration of materials.

Ansys 2021 R1 delivers enhancements across all portfolio products — Ansys Additive Prep, Ansys Additive Print, Ansys Additive Science and Ansys Workbench Additive — empowering users to further advance their additive manufacturing capabilities.

Join PADT’s Simulation Support & Application Engineer Doug Oatis for a webinar covering both the structural optimization and additive updates made to Ansys 2021 R1 including enhancements for: 

  • Process Simulation

  • Part Qualification

  • Design for AM

  • Build Setup

  • Shape & Lattice Optimization

  • And much more

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All Things Ansys 083: Digital Mission Engineering & the Acquisition of AGI

 

Published on: March 8th, 2021
With: Eric Miller, Anthony Dawson & Paul Graziani
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by Anthony Dawson, Vice President & General Manager at Ansys, and Paul Graziani, CEO and Co-Founder of Analytical Graphics, Inc. (AGI) to discuss the acquisition of AGI and what it means for those simulating in the aerospace and defense industry.

Digital mission engineering, pioneered by AGI, combines digital modeling, simulation, testing, and analysis for aerospace, defense, telecommunication, and intelligence applications to evaluate mission outcomes at every phase of a system’s life cycle. Using this tool you can evaluate the full effect of every change you make and find problems before they become crises.

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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High Frequency Updates in Ansys 2021 R1 – Webinar

Whether leveraging improved workflows or leading-edge capabilities with Ansys 2021 R1, teams are tackling design challenges head on, eliminating the need to make costly workflow tradeoffs, developing next-generation innovations with increased speed and significantly enhancing productivity, all in order to deliver high-quality products to market faster than ever.

When it comes to high frequency electromagnetics, Ansys 2021 R1 delivers a plethora of groundbreaking enhancements. Ansys HFSS Mesh Fusion enables simulation of large, never before possible electromagnetic systems with efficiency and scalability. This release also allows for encrypted 3D components supported in HFSS 3D Layout for PCBs, IC packages and IC designs to enable suppliers to share detailed 3D component designs for creating highly accurate simulations.

Join PADT’s Lead Electromagnetics Engineer and high frequency expert Michael Griesi for a presentation on updates made to the Ansys HF suite in the 2021 R1 release, including advancements for:

  • Electronics Desktop
  • HFSS
  • Circuits
  • EMIT
  • And Much More

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All Things Ansys 080: 2020 Wrap-up & Predictions for Ansys in the New Year

 

Published on: January 25th, 2021
With: Eric Miller & PADT’s Ansys Support Team
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by the simulation support team to look back at the past year of Ansys technology and make some predictions regarding what may happen in the year to come.

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Discussions on the Past, Present & Future of Optimizing Topology for Manufacturing – Webinar

Traditional design approaches don’t make the most of new manufacturing methods, like additive manufacturing, which are removing design constraints and opening up new possibilities. The optimal shape of a part is often organic and counterintuitive, so designing it requires a different approach.

Topology optimization lets you specify where supports and loads are located on a volume of material and lets the software find the best shape.

Kick off the year by learning about one of the most exciting advancements in modern design and manufacturing. Join experts from PADT and nTopology for an interactive roundtable discussion on the ins and outs of topological optimization.

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Optimize Additive Topology with FDM Fixture Generator – Webinar

Additive Manufacturing has profoundly impacted all aspects of manufacturing. With the ability to increase speed-to-market, lower production costs, and customize specialty parts, it continues to fuel innovation. Manufacturing jigs, fixtures, and other tooling accounts for more than 20% of all end-use parts produced with 3D printing today. Yet, without tools that make the design of custom jigs and fixtures simpler, many users are kept from reaching the full benefits of Additive Manufacturing on the factory floor.

One tool that is helping engineers bypass this roadblock is the latest collaborative effort from Stratasys and nTopology, the FDM Fixture Generator.

This innovative software tool allows you to automate the design of 3D printed jigs & fixtures. Generate custom designs and streamline operations on your factory floor without spending time in CAD. Ready to print with a few clicks.

Join nTopology and PADT to learn more about FDM Fixture Generator and how it stands to disrupt the manufacturing environment.

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Optimization & Automation Updates in Ansys 2020 R2 – Webinar

Simulation is becoming an integral part of our customers’ product development processes, and new horizons await. By combining different physics into a multidisciplinary approach, phenomena can be investigated more holistically and optimized to a greater degree. Additionally, simulation processes can be standardized and shared across teams, allowing simulation novices to gain more direct access to simulation.

Time-consuming manual searches for the best and most robust design configuration can now be accelerated by adding state-of-the-art algorithms for design exploration, optimization, robustness and reliability analysis. Through the power of interactive visualization and artificial intelligence technologies, engineers and designers can gain a better understanding of their design and make the right decisions in less time.

The process integration and design optimization solution that enables all the above is Ansys optiSLang.

Join PADT’s Mechanical Application Engineer and Systems Expert Josh Stout for an exploration of this interconnected tool and what new capabilities are available in it’s 2020 R2 release.

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All Things Ansys 077: Multibody Dynamics Updates in Ansys Motion 2020 R2

 

Published on: November 30th, 2020
With: Eric Miller & Jim Peters
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Senior Staff Technologist Jim Peters for a discussion on the new capabilities available within Ansys Motion 2020 R2. With an integration into Mechanical, users can take advantage of multi-use models resulting in substantial time savings.

If you would like to learn more about this update, you can view Jim’s webinar on the topic here:

https://www.brighttalk.com/webcast/15747/455203

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Introducing Level Up – An Ansys Mechanical Virtual Conference

PADT & Ansys are excited to announce Level Up with Ansys Mechanical, a free virtual technical conference on Wednesday, December 2, 2020 at 10 a.m. EST.

For the past 50 years, Ansys Mechanical continues to be the go-to finite element analysis platform for structural analysis, and they’re just getting warmed up. Join visionary Ansys product development, product management and engineering leaders as they provide expert insights on Mechanical’s technology advances and preview the platform’s future.

From those engineers looking to boot up their simulation experience to those seeking to step up their simulation skills, and even those operating in “beast mode”, who execute large and complex workflows, this action-packed event showcases how Mechanical radically transforms product design.

Highlights include: 

  • Learn the latest with scripting and automation to save valuable time
  • Discover how to lightweight product designs with structural optimization methods
  • Understand how to couple multiple physics to assess performance in the real world
  • And so much more

Catch the thought-provoking plenary presentation, engage with Ansys’ brightest during the live Q&A, and interact with fellow engineers during live polls. 

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Optical System Design & Disruption in Ansys SPEOS 2020 R2 – Webinar

When customers evaluate products, the overall look and details can make all the difference. Ansys physics-based imaging, photonics and illumination software streamlines the design process, so you can better understand how your product will look and operate under real-world lighting and usage conditions.

Whether you are designing a TV screen, street lighting network, smart headlight, head-up display or interior mood lighting in an automobile, Ansys optical simulation software helps you make your design more efficient and appealing. Optical sensors are the eyes of any intelligent system, and Ansys physics-based simulations can help you assess raw signals from camera and lidar systems in their operating environments.

Ansys 2020 R2 empowers Ansys SPEOS users to go further than ever before with enhancements that improve the handling of complex sensors, project preview and computation.

Enhancements include:

 •  Highly accurate camera models drastically improve camera simulation experience 

•  Faster simulation times when using light sources and provides nearly real-time review 

•  4X faster simulation setup thanks to optimized GUI

Join PADT’s Application Engineer Robert McCathren for a first hand look at the capabilities of optical simulation, followed by what’s available for SPEOS in the Ansys 2020 R2 update.

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