ANSYS Advantage Multiphysics AA V8 I2
ANSYS Advantage Multiphysics AA V8 I2
ANSYS Advantage Multiphysics AA V8 I2
SPOTLIGHT ON
MULTIPHYSICS
6
Multiphysics:
The Future of Simulation
11
Robust Electric Machine Design
Through Multiphysics
16
Magnetic Appeal
Get Caught Up
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EDITORIAL
esigning products can be relatively straightforward when they are simple, contain just a few
parts and perform a single function and when
operating conditions can be perfectly controlled.
But as every engineer knows, this is not the world
in which we live, 2014.
Todays products are more complex, and deliver more sophisticated functionality, than ever before. Consider the simple design
and few moving parts of a rotary telephone versus the advanced
engineering that goes into every smartphone.
While not all products have been transformed so dramatically, engineers in every industry recognize that their designs are
growing in complexity. The integration of smart electronics in our
everyday appliances and the increasingly digital nature of our cars
represent just two very visible examples of a quiet revolution that
has occurred in engineering over the past decade.
Just as engineering has evolved from relying on paper calculations and physical experiments to leveraging computer simulation, our tools and methods must continue to evolve to reflect the
incredible complexity of todays products. Engineers can no longer
be guided by even the most general assumptions about how their
designs will perform or focus on the one physical force that seems
most important. Instead, they require a new toolset that brings
together a full range of physical phenomena, accurately replicating the physical environment in which their designs will operate.
Multiphysics simulation enables engineers to understand and
weigh the trade-offs they make when they improve one aspect of
their products complex performance. For example, if turbomachinery engineers focus on blade weight reduction, they risk affecting structural deformation and flow path performance. As electronics engineers seek ever-smaller footprints, they must minimize
stress and failure rates caused by heat build-up. Electric motor
designers can easily assess how their focus on weight reduction
and greater energy efficiency impacts acoustic performance. None
While multiphysics analysis was once the domain of only the most
advanced users, today ANSYS has democratized this technology,
making it possible for every engineering team to couple physics
and assess performance at the systems level.
2014 ANSYS, INC.
TABLE OF CONTENTS
16
FEATURES
20
24
20
30
Exhaustive Simulation
Cool Head
BEST PRACTICES
11
16
32
24
ROBUST ELECTRONIC
SYSTEMS DESIGN
Change of Heart
Balance of Power
27
36
ROBUST ELECTRONIC
SYSTEMS DESIGN
Neat as a Pin
ADVANCED MATERIALS
SYSTEMS DESIGN
ADVANCED MATERIALS
SYSTEMS DESIGN
Magnetic Appeal
27
30
SIMULATION@WORK
DEPARTMENTS
40
50
Fast, Accurate
Simulations for Fuel
Combustion Applications
ROBUST ELECTRONIC
SYSTEMS DESIGN
ANSYS electronics tools work together
to solve coupled power integrity and
signal integrity problems in designing
robust electronic systems.
43
ADVANCED MATERIALS
SYSTEMS DESIGN
46
ROBUST ELECTRONIC
SYSTEMS DESIGN
36
ANALYSIS TOOLS
54
ANALYSIS TOOLS
A Foundation for
Collaboration
NEWS
TURBOMACHINERY SIMULATION
KEY TO WIND ENERGY AND
ENERGY EFFICIENCY
TechWeek
techweek.es, March 2014
The recent European Wind Energy
Association in Barcelona brought together
wind industry experts to discuss how to
improve energy efficiency. Gilles Lebiez
from ANSYS discussed turbomachinery
simulation, noting that wind energy
is increasing its contribution to the mix
overall. Although turbomachinery applications are incredibly diverse, efficiency
is a common challenge for all design engineers. ANSYS simulation software helps
to ensure that critical systems are also
reliable, secure and low-maintenance.
2014 ANSYS, INC.
SpaceClaims 3-D
tools combined
with ANSYS proven
simulation software
are ideally suited
to the rapid pace of
todays business.
TURBULENCE MODELING:
NEW SOLUTIONS FOR (ALMOST)
EVERY INDUSTRY
High Performance Computing
hpcmagazine.com, February 2014
As CFD applications
become more
complex, more
sophisticated
turbulence models
are needed.
BEST PRACTICES
Multiphysics:
THE FUTURE of
SIMULATION
As part of its comprehensive set of solutions for engineering
simulation, ANSYS introduces new technology developments
that make multiphysics simulations faster, more seamless and
higher-fidelity as well as more accessible than ever.
By Chris Wolfe, Lead Product Manager for Multiphysics, ANSYS
2014 ANSYS, INC.
The Hyperthermia Group at Duke University relies on multiphysics simulation to develop new, non-
invasive approaches to treat bladder cancer. Researchers leveraged ANSYS HFSS to design a miniature
water-loaded microwave antenna that is used to investigate how to deliver chemotherapeutics to the
bladder in a heat-activated manner. The simulated power deposition pattern is then incorporated in
ANSYS Fluent, where engineers model the effects of biological mechanisms such as blood perfusion and
metabolism which are critical to analyzing heat transfer in biological systems. To avoid overheating
tissues, the antenna is cooled with a circulating fluid modeled in ANSYS CFD. All physics analyses are
coupled to optimize selective heating of the bladder region.
BEST PRACTICES
The Institute for Plasma Research (IPR), part of Indias Under Department of Atomic Energy,
leverages the power of multiphysics simulation to investigate how nuclear fusion can be accomplished
via magnetically confined plasmas. While fusion is possible, a substantial energy barrier of electrostatic
forces must be overcome before it can occur. The components for fusion machines are specifically
designed for very large loading conditions and are very complex in their design. To address this
complexity and to reflect very demanding operating conditions IPR researchers conduct a large
number of iterative simulations that bring together structural, thermal and electromagnetic analyses.
ansys.com/82multiphysics
Multiphysics studies help engineers to solve complex challenges such as designing plastic
packaging that is both strong and lightweight while also meeting user needs. ANSYS Polyflow enables
simulation of the manufacturing blow-molding process, using inputs including geometry, material and
process conditions. Next, the liquid dispensing process is modeled via a fluidstructure interaction
simulation with ANSYS Fluent. This simulation simultaneously employs ANSYS Mechanical to model
bottle wall deformation during squeezing. Any thickness variation in the bottles material from the
blow-molding process can be mapped from ANSYS Polyflow to the ANSYS Mechanical model.
design process, ANSYS developed powerful capabilities to facilitate multiphysics studies by making them faster, more
streamlined and more intuitive. The leadership of ANSYS in individual physics,
coupled with its support for parametric
design optimization, makes ANSYS the
perfect solution set for solving todays
complex design challenges including
fluidthermal and fluidmechanical systems, robust electric machines and electronics, and product applications for
advanced materials.
Ongoing improvements in ANSYS
Workbench have produced an easy, adaptable multiphysics simulation solution
right out of the box. Drag-and-drop coupling in Workbench makes it easy to
set up a range of multiphysics studies,
ansys.com/82multiphysics2
BEST PRACTICES
ITMA Materials Technology a Spanish company focusing on applied research and development
To ensure a long product life, printed circuit
ansys.com/82multiphysics3
in the field of materials science uses multiphysics simulation to optimize materials performance.
An engineering team at ITMA used ANSYS CFD and ANSYS Mechanical software to perform fatigue
analysis of a storage tank. Because this tank has to perform reliably under extreme temperature
changes, ensuring its structural integrity is critical. Using the physics integration capabilities in ANSYS
Workbench, ITMA researchers first conducted transient analyses of the tanks start-up and shut-down
cycles in ANSYS CFX, then transferred the temperature distributions to ANSYS Mechanical.
10
ROBUST ELECTRIC
MACHINE DESIGN
ROBUST ELECTRIC
MACHINE DESIGN
THROUGH
MULTIPHYSICS
Electromagnetic, mechanical and thermal simulation plus
design optimization help to improve energy efficiency, noise
and bearing life of robust electric motors.
By Cassiano A. Cezario, Briam C. Bork, Marcelo Verardi, Research and Technological Innovation Department, and Jos R. Santos,
Product Development and Application Department, WEG Equipamentos Eltricos S.A. Motores, Jaragu do Sul, Brazil
2014 ANSYS, INC.
11
ROBUST ELECTRIC
MACHINE DESIGN
lectric motors are the single biggest consumer of electricity, accounting for about two-thirds of industrial power
consumption and about 45 percent of global power consumption, according to an analysis by the International Energy
Agency. The World Energy Outlook 2012 states that the developed world is planning to increase its energy efficiency by
1.8 percent annually over the next 25 years. Much of this
improvement must come from advancements in electric motor
design. Companies that develop these devices must ensure that
motors have low operating noise and long life. Engineers have
worked to balance these demands to improve and optimize the
design of electric motors for almost two centuries, and now new
methods and tools are needed to generate further progress.
ansys.com/82robust
TECHNOLOGY
EXPECTED RESULTS
OR TARGET
COMPUTATIONAL FLUID
DYNAMICS (CFD)
ELECTROMAGNETIC
SIMULATION
ELECTROMAGNETIC
STRUCTURALTHERMAL
ANALYSES
REDUCE OPERATING
TEMPERATURE OF
BEARING
CFDTHERMAL
SIMULATIONS
AUTOMATE DESIGN
EXPLORATION
ANSYS DESIGNXPLORER
AND ANSYS WORKBENCH
12
WEG engineers used ANSYS CFD software to model the airflow through the
interior of the motor. They defined key
parameters, such as the openings where
air passes through the frame, as parametric dimension variables. Since many
of these design parameters impact the
motors electromagnetic performance,
engineers produced an ANSYS Maxwell
electromagnetic model of the motor with
the same parametric variables as the CFD
model. They generated a table of varying
values for each of the parameters.
WEG employed ANSYS DesignXplorer
to create a design of experiments (DOE)
that subdivided the design space to efficiently explore it with a relatively small
number of simulation experiments and
to run multiphysics simulations without human intervention. Comprehensive
simulation tools in the ANSYS Workbench
environment and design optimization
with ANSYS DesignXplorer enabled WEG
to increase the number of simulations performed from four per month in 2005 to 800
per month currently. High-performance
computing (HPC) also helped enable this
improvement. WEG uses HPC Packs for
CFD, and Maxwell runs with 64 cores distributed across eight workstations.
Output results for each design point
were stored in a table and visualized
with a response surface map that completely maps out the design space. The
response surface was used to graphically
plot the effect of variables on fan losses.
Simulations were not coupled in this case
due to computing resource limitations;
however, in the future, WEG will use coupled multiphysics simulations to even
more accurately determine optimal values for parametric variables by considering all of the physics. WEG engineers
manually compared response surface
maps, plots and tables for the CFD and
electromagnetic analysis to determine the
Before-and-after comparison of ANSYS CFX simulations shows improved airflow that reduces fan losses in W50 motor compared to
previous-generation design.
13
ROBUST ELECTRIC
MACHINE DESIGN
ANSYS Maxwell simulation helps to optimize the trade-off between fan losses and
electromagnetic performance.
Fan efficiency plotted against two design variables (one on x axis and other in multiple plots)
14
15
ADVANCED MATERIALS
SYSTEMS DESIGN
16
CERN
17
ADVANCED MATERIALS
SYSTEMS DESIGN
analysis environments along with different mesh densities, element types, solution setups and algorithms. CERN still
designs superconducting magnets with a
specialized electromagnetic simulation
program called ROXIE for accelerator
magnets developed in-house. Engineers
analyzed the previous design using both
Emag and Maxwell, which use different
laws, solvers and methodologies, and
both programs came up with the same
results as ROXIE.
The electromagnetic forces known as
Lorentz forces were calculated by Emag
and Maxwell and then transferred to
ANSYS Mechanical as body force densities through the direct linkage provided
Response surface model of design space for three important design parameters
18
CERN
UNDERSTAND AND IMPROVE YOUR DESIGN FASTER
WITH ELECTROMAGNETICS
ansys.com/82magnetic
rigidity as the previous generation of magnets. Using design exploration to produce the response surface, to conduct sensitivity analysis and to understand the design space, engineers were able to
find the best set of design parameters to create an 11T magnetic
field while keeping the coil stress below 150 MPa and minimizing any irreversible degradation of the electrical properties of the
Nb3Sn conductor. It was also possible to find the best match among
all crucial assembly parameters to ensure safe operation conditions for the accelerator magnet. This method reduced the overall
engineering time compared to the previous design method. In addition, the company decreased time over the previous method that
involved writing APDL input files and macros to link different simulation tools. ANSYS Workbench saved three weeks in the design
optimization process and also saved time during model setup, so
it will be used for designing future superconducting accelerator
magnets.
References
Karppinen, M.; Andreev, N.; Apollinari, G.; Auchmann, B.; Barzi, E.; Bossert, R.;
Kashikhin, V.V.; Nobrega, A.; Novitski, I.; Rossi, L.; Smekens, D.; Zlobin, A.V.
Design of 11 T Twin-Aperture Nb3Sn Dipole Demonstrator Magnet for LHC Upgrades. Applied Superconductivity, IEEE Transactions. 2012. Volume 22, Issue 3.
www.feacomp.com
Charilaos Kokkinos left CERN in 2013 to found FEAC Engineering, a startup engineering company specializing in simulation-driven product development. FEAC
warmly thanks the project leader of the 11T dipole magnet, Mikko Karppinen.
19
FLUIDTHERMAL
SYSTEMS DESIGN
EXHAUSTIVE
SIMULATION
An exhaust system designer uses multiphysics simulation to reduce
costly iterations by validating designs before testing.
By Matt Butson, Engineering Services Manager, and Ning Cao, Product Design Engineer, Active Exhaust Corp., Toronto, Canada
2014 ANSYS, INC.
20
esigning exhaust systems is complicated by the number of different physical phenomena involved.
Designers must consider airflow inside the
exhaust system and its impact on back
pressure experienced by the engine. The
flow of gas through the exhaust manifold
produces vibrations and noise that the
design must mitigate. The systems temperature must be maintained to maximize
exhaust after-treatment performance and
to minimize impact on both the environment and adjacent vehicle components.
Active Exhaust uses multiphysics simulation to reduce costly iterations by validating designs before testing.
Active Exhaust is a world-class provider of exhaust management systems for
industrial engine and vehicle applications.
The company specializes in sound, emissions and thermal management solutions
for mobile and stationary engine applications ranging from 5 HP to 700 HP.
The companys headquarters in
Toronto, Canada, houses R&D, product engineering and customer support,
as well as its North American manufacturing center, all under one roof. It has
a staff of approximately 275 employees
along with two off-shore joint ventures
in China and India, and warehouse locations in the United States. Active Exhaust
caters its technologies to markets that
include consumer and commercial lawn
care equipment, construction and farming machinery, welders and generators, in
addition to all-terrain, recreation and utility vehicles.
DESIGN VALIDATION
BY TESTING
In the past, the company utilized twodimensional design tools that were developed internally based on existing tube
and muffler elements. The design engineer approximated the design performance using these tools. The accuracy,
documentation and scope of design-ready
geometries were limited. Engine manufacturers must adhere to stringent regulations including those set forth by the
U.S. Environmental Protection Agency and
Department of Agriculture. As a valueadded service, Active Exhaust directly collaborates with various approving bodies to
simplify the process for its customer base.
As a result of uncertainty in design performance, all new exhaust systems have to
undergo lab validation of criteria such as
2014 ANSYS, INC.
21
FLUIDTHERMAL
SYSTEMS DESIGN
parameters arising from the engine operating conditions. ANSYS CFD is then used
to perform a flow simulation through the
exhaust system. This simulation calculates the exhaust system pressure drop
and resulting back pressure at the inlet.
Since the flow is now being simulated in
the actual exhaust geometry, the results
usually correlate quite closely with physical measurements.
The CFD software provides diagnostic
capabilities far beyond what is obtainable
from test results, including velocity and
pressure at every point in the flow path. For
example, an engineer running a flow simulation of a new exhaust system might see a
recirculation zone in the flow path. Aware
that recirculation generally increases the
system pressure drop, he would then make
changes to the geometry of the CFD model,
such as reducing any obstruction or excess
curvature in the main flow path. The engineer would then rerun the simulation to
see if the change eliminated the recirculation zone. If not, the engineer would continue modifying the model geometry until
the recirculation zone was eliminated. This
process often leads to a significant reduction in back pressure. The benefit of using
ANSYS Workbench is that as the geometry
changes, the mesh, setup and solution are
automatically updated, saving time in the
development process.
In conjunction with using CFD simulation, Active Exhaust engineers apply ANSYS
Mechanical to analyze the exhaust system
from thermal, structural and acoustics perspectives. The integration between ANSYS
CFD and ANSYS structural mechanics software makes it easy to transfer the internal
temperatures calculated using CFD to ANSYS
Mechanical, where they become inputs for a
thermal analysis that determines the temperatures on the exterior of the exhaust system and identifies the stresses generated by
thermal expansion. ANSYS Mechanical is
also used to validate the structural integrity
of the exhaust system by inputting power
spectral density data from the vehicle. Using
AUTOMOTIVE FLUID-STRUCTURE
INTERACTION (FSI) CONCEPTS,
SOLUTIONS AND APPLICATIONS
ansys.com/82exhaustive
22
Copyright 2014 Intel Corporation. All rights reserved. Intel, the Intel logo, Xeon,
and Xeon inside are trademarks of Intel Corporation in the U.S. and other countries.
*Other names and brands may be claimed as the property of others.
23
FLUIDMECHANICAL
SYSTEMS DESIGN
ortic valve stenosis, a narrowing of the aortic valve, is the most common
type of heart valve disease. It affects about 2 percent of adults aged 65 or
older. Symptoms of this chronic progressive disease include chest pain,
difficulty breathing, and fainting; in some cases, congestive heart failure can
occur if the valve is not replaced.
Surgical aortic valve replacement, which involves open-heart surgery with a heart
lung machine, has been the definitive treatment for aortic valve stenosis for over 40
years. The surgical team replaces the aortic valve with either a mechanical valve or a tissue valve taken from a human donor or animal. The operative mortality of aortic valve
replacement in low-risk patients younger than 70 years is around 2 percent. Long-term
survival following aortic valve replacement is similar to that of patients of similar age
who do not have the condition.
24
25
FLUIDMECHANICAL
SYSTEMS DESIGN
Stress prediction for selected point on the stent helps determine fatigue life of stent.
Simulation predicted the patients blood pressure after valve replacement. The blood
pressure reading was high because the aortic wall was modeled without flexibility.
26
ROBUST ELECTRONIC
SYSTEMS DESIGN
NEAT AS A PIN
Rosenberger leverages mechanical and electrical
simulation to provide a superior alternative to
traditional spring pins for semiconductor testing.
By Frank Schonig, Senior Member, Technical Staff; Sandeep Sankararaman, Electrical Engineer and Steve Fahrner,
FEA Consultant, Rosenberger High Frequency Technology, Fridolfing, Germany.
emiconductor manufacturers use automated test equipment (ATE) to verify that a specific device works before it
is installed in the final product. Todays semiconductors
are very complex devices performing many functions, and ATE
usually tests all, or at least many, of these functions. ATE systems
typically interface with a handler that places the semiconductor
or device under test (DUT) on an interface test adaptor (ITA) with
a socket that makes an electrical connection with connectors
on the DUT. The many required connections between the DUT
and the ATE are normally made with an array of spring pins or
pogo pins consisting of high aspect ratio cylinders loaded with
springs that generate force on the connectors as the DUT and
socket are pressed together.
As the sizes of transistors and other features on semiconductors shrink, it is increasingly difficult to find space for all of the
spring pins needed to make contact with electrical interconnects
on the DUT, particularly when the DUT consists of integrated circuits on undiced wafers. But spring pins or pogo pins cannot
be made much smaller with traditional manufacturing methods. Rosenberger High Frequency Technology has addressed this
challenge by using the LIGA (based on the German acronym for
lithography, electroplating and molding) process, which employs
semiconductor manufacturing methods to accurately build tiny
yet complex mechanisms ones that are much smaller than
the smallest interconnect produced by conventional methods. A
monolithic-compliant interconnect (MCI) produced using LIGA
can have features as small as 10m wide, yet it has dozens of
geometrical features that enhance its mechanical and electrical performance. The LIGA process allows mechanical engineers
the freedom to design pins whose mechanical action is achieved
without compromising electrical performance because it allows
complex geometries in small volumes.
There are two types of LIGA processes: X-ray and ultraviolet (UV). In the X-ray LIGA process, a conductive seed layer is
applied to a silicon wafer. Then a photoresist layer is applied
with a spin coat process. The wafer is exposed to high-energy
27
ROBUST ELECTRONIC
SYSTEMS DESIGN
28
VNA
0
-5
1 Gnd
-10
S11 (dB)
2 Gnd
-15
3 Gnd
-20
4 Gnd
-25
5 Gnd
-30
-35
-40
0
2.5
7.5
10
12.5
15
17.5
20
Frequency (GHz)
S11 chart shows return loss of MCI.
29
FLUIDTHERMAL
SYSTEMS DESIGN
Diesel generator
station
Cool Head
Ural Diesel-Motor Works uses multiphysics simulation
to avoid thermal cracking in a cylinder head.
By Dmitry Frolov, Lead Engineer, and Yuriy Abramov, Lead Engineer, Ural Diesel-Motor Works LLC, Yekaterinburg, Russia
30
heads internal geometry and simulate the flow through the cooling jacket. Unnecessary
details were suppressed, and engineers meshed the fluid region using tetrahedral elements with an inflation layer near the wall for accurate resolution of the boundary layer.
Engineers opened the mesh in ANSYS CFX computational fluid dynamics (CFD)
software and assigned properties for the fluid and boundary conditions. They simulated the flow through the cooling jacket, looking for areas where fluid velocity is
low. This low velocity restricts heat transfer from the head to the cooling water and
causes excessive temperatures that can, in time, reduce reliability. Next, engineers
applied temperatures from experiments to the CFD model and reran the simulation
to generate temperature fields throughout the inside walls of the cylinder head.
THERMALSTRESS SIMULATION
The team returned to the original CAD model in ANSYS Workbench and used it to
create a structural model in ANSYS Mechanical finite element analysis (FEA) software. Automatic contact detection capabilities were used to identify and configure contacts in the model. Mechanical loading was applied to the model, first by
initiating contact of components that mate with the cylinder head and pretension
of bolts used to hold the head to the block and other components. Engineers then
used ANSYS Workbench coupling to apply temperature fields (determined by the
CFD simulation) for use in ANSYS Mechanical to calculate the thermal stresses
associated with these temperatures. Engineers selected the models inside faces
and applied the temperature fields generated in the CFD simulation as temperature loads. The last step was applying the pressures generated during the engines
working cycle. In the early stages, engineers generated several load cases based on
different phases of the engine cycle, but later they determined that they could save
time by using only the highest load case.
ANSYS Mechanical calculated the mean stresses and amplitude of stresses from
the complete loading applied to the head. The calculated stresses were higher than
the yield strength of the aluminum material. Engineers had clearly identified the
root cause of the cracking problem.
Ural Diesel-Motor Works engineers then worked to address the problems
uncovered by simulation. They decided to change the head material to a grade
of cast iron, which has a considerably higher yield strength than aluminum.
Engineers modified the cooling system to address the low-velocity flow areas
revealed in the earlier CFD simulation. They reran the CFD simulation and generated temperature fields for the modified head, then imported these temperature
fields into ANSYS Mechanical.
SHAPE OPTIMIZATION
Because cast iron is heavier than aluminum, the team needed to change the heads
geometry to reduce its weight. Engineers used the ANSYS shape optimization module to redistribute the material in the cylinder to reduce mass to a minimum while
maintaining stiffness above a defined minimum value. The output of shape optimization is a contour plot that shows where material can be removed with the least
impact on overall stiffness.
Engineers were limited in the changes they could make because they needed
to maintain interfaces with mating parts. However, they were able to substantially reduce the heads weight using the shape optimization tool. The weight of
the resulting design is somewhat higher than the previous aluminum head but still
2014 ANSYS, INC.
31
FLUIDTHERMAL
SYSTEMS DESIGN
GTAM Solution
Final Part
Engineers realized 70 percent mass reduction while minimizing strain energy (maximizing stiffness) using GTAM.
32
ROBUST ELECTRONIC
SYSTEMS DESIGN
Balance
of Power
transformer winding that allows a variable number of turns to be selected in discrete steps. By varying the turn ratio of
the transformer, its output voltage can
be controlled. Hyundai Heavy Industries
Co. Bulgaria (Hyundai) builds tap changers for its own and others' transformers.
The company manufactures oil-immersed
power transformers and tap changers for
power substations, thermal power plants,
hydro-electric power plants and industrial enterprises throughout the world. Its
products have been validated consistently
in tests by independent laboratories.
Hyundais compact design and dependable technical parameters reduce transformer weight and cost. The company
is among the worlds leading producers
of tap changers, with more than 50,000
units produced so far.
DESIGN METHODS
In the past, Hyundai engineers used a
combination of stand-alone analysis
tools and physical testing to design transformers and tap changers. Engineers
applied simulation tools to analyze various aspects of the equipments electrical,
thermal and structural design. However,
they performed each type of analysis separately without considering interrelated
effects. For example, the electromagnetic
simulation was not tied to the thermal
and structural analysis; it was not possible, for example, to determine thermal
33
ROBUST ELECTRONIC
SYSTEMS DESIGN
Hyundai reduced
engineering costs by
up to 5 percent. It
expects to achieve
up to 15 percent
cost reduction in
the future through
multiphysics
simulation.
34
The company conducts seismic analysis of power transformers to ensure that equipment functions
reliably in earthquake-prone areas. Equivalent stress in horizontal direction: response spectrum
analysis (left) and modal analysis (right)
35
ADVANCED MATERIALS
SYSTEMS DESIGN
Getting Around
in
Style
36
DESIGN INTEGRATION OF
ADVANCED LIGHTWEIGHT
COMPOSITE MATERIALS
AND THE CHALLENGES OF
MULTI-FUNCTIONALITY
A N SYS .CO M /8 2 st y l e
37
ADVANCED MATERIALS
SYSTEMS DESIGN
KTM X-BOW, from sketch to prototype in just 18 months, thanks to a cross-functional team approach
38
The ultralight carbon frame weighs only 1,600 grams without sacrificing
performance or aesthetic design.
39
ROBUST ELECTRONIC
SYSTEMS DESIGN
Simulation@Work
KEEP THE
NOISE DOWN
ANSYS electronics tools work together to solve coupled power integrity and signal integrity problems
in designing robust electronic systems.
By Cornelia Golovanov, Senior Engineer, LSI Corporation, Allentown, U.S.A.
40
physical chip layout and easily checked for problems, such as missing vias and poorly connected decoupling capacitors, before the
simulation was run. They used the schematic to probe nodes and
add stimulus and models to the system setup. Sentinel-SSO allows
for simulation with native transistor models of I/O buffers, providing a one-time qualification of chip I/O models.
EVALUATING THREE PACKAGE DESIGNS
The engineering team created three different package models
in SIwave; each included full and compact models of a package
mounted on a PCB model. These models accounted for all data bit,
address bit and control bit lines as well as PDN and PLL supply coupling and the characteristics of the system-level ground. Engineers
extracted the S-parameter touchstone format model from each
model and plugged it into Sentinel-SSO.
Package 1 was based on the original package in which the PLL
positive supply voltage (VDDPLL) was a separate supply, with two
ANSYS ADVANTAGE Volume VIII | Issue 2 | 2014
41
ROBUST ELECTRONIC
SYSTEMS DESIGN
The PLL supply separated from the 1.8 V analog supply was included in
the layout extraction.
42
ADVANCED MATERIALS
SYSTEMS DESIGN
SEALING
THE DEAL
Pacific Northwest National Laboratory leveraged simulation to develop an optimized method for inspecting sealed
containers in verifying nuclear arms control treaties.
By Mark Jones, Senior Research Engineer, Pacific Northwest National Laboratory, Richland, U.S.A.
43
ADVANCED MATERIALS
SYSTEM DESIGN
Simulated impedance signatures for family of metal spheres inside closed metal container
5 mm
25 mm
44
Plot shows an overlay of measured and simulated coil impedance for different types of solid
metal spheres placed inside a closed container. The stainless steel container has double-walled
construction and insulation material between inner vessel and overpack. Simulation results closely
matched experiments.
demonstrated the ability to differentiate between components from different weapons programs inside sealed metal storage containers. This method also can be used to discriminate
between different chemical forms of concealed nuclear materials, since some nuclear materials are metals that are electrical conductors and others are oxides that are electrical insulators,
and these materials interact differently with a magnetic field. ANSYS Maxwell was instrumental in helping to enable an efficient simulation-based methodology for designing optimized
coils to determine the contents of sealed containers.
Reference
Verification Technology Research and Development Needs, U.S. Department of State Bureau of Arms Control,
Verification and Compliance, Office of Verification and Transparency Technologies, Washington, D.C.,
April 24, 2012.
100 Hz
500 Hz
1,000 Hz
2,000 Hz
3,000 Hz
45
ROBUST ELECTRONIC
SYSTEMS DESIGN
COOL DESIGNS
FOR REMOTE
DESKTOP ACCESS
Teradici improves PCoIP zero client design by optimizing enclosure cooling with ANSYS Icepak.
By Steve Dabecki, Director of Silicon Engineering, and Kevin Betts, Principal Engineer,
Teradici Corporation, Burnaby, Canada
46
PCB copper traces for the PCoIP zero client modeled in ANSYS Icepak shows the substrate with
die as a heat source, two DRAM devices, a flash device and an audio codec device.
47
ROBUST ELECTRONIC
SYSTEMS DESIGN
48
SUMMARY
ANSYS Icepak and its parameterization
capabilities proved extremely useful to
determine different design options of
a zero client enclosure, including the
best approaches to minimize device
temperature and enclosure surface
temperature. Icepak successfully modeled the complex heat flows in the system, including the heat transfer of the
PCoIP processor (primary heat source)
from the die through the substrate and
onto the PCB, as well as the heat transfers through the enclosure. Simulation
helped to quickly analyze different
enclosure orientations and venting
options.
Teradici recognized the benefits
of ANSYS technology in developing best
practices to design a functional enclosure for the PCoIP zero client. Developing
reasonable correlation between the 3-D
printed model and the simulation presented an enticing opportunity to expand
efforts to design smaller, more-efficient
device enclosures.
Reference
www.teradici.com/zeroclient
49
ANALYSIS TOOLS
Departments
FAST, ACCURATE
SIMULATIONS
FOR FUEL
COMBUSTION
APPLICATIONS
The acquisition of Reaction Design broadens the ANSYS simulation offering with industry-leading chemistry
solvers to advance clean engine and fuel technologies.
By Bernie Rosenthal, CEO, Reaction Design
50
Number of
Components
Hydrogen/CO
n-Alkanes
iso-Alkanes
1-Ring Aromatics
2-Ring Aromatics
cyclo-Alkanes
Olefins
Oxygenated Fuels
10
Gasoline
Diesel
Jet Fuels
or FT Fuels
Natural or
Synthetic Gas
Biofuels or
Additives
The Model Fuel Library features more than 40 validated fuel component models.
51
ANALYSIS TOOLS
Time to Solution
TRADITIONAL CFD
GENERATE
MESH
SETUP
CALIBRATE
SPRAY
SOLVE
EXPORT
ANALYZE
FORTE
GENERATE
MESH
SETUP
CALIBRATE
SPRAY
SOLVE
ANALYZE
FORT delivers dramatic reductions in time to solution over conventional CFD approaches.
components greatly increase the accuracy of results across a wide range of operating conditions and fuel types without negatively impacting time to solution, measured as the total
wall clock time an engineer experiences from simulation setup through completion of analysis of the visualized results. The Reaction Design products address traditional bottlenecks
in the simulation process by offering easy-to-understand, wizard-like graphical user interfaces to ease the setup, solve and analyze steps of the simulation process, and incorporate
mathematical solver technologies with the appropriate level of physics and chemistry detail
to ensure accuracy.
INDUSTRY-LEADING PRODUCTS
CHEMKIN, the gold standardfor modeling gas-phase and surface chemistry, was born at
the Sandia National Laboratories in the 1980s as a set of command-linedriven codes that
describe the complex series of molecular-level chemical reactions that take place during fuel
combustion. These led to the development of a suite of detailed-kinetics reactor models that
use idealized representations of reacting flows. In time, the 0-D and 1-D flow approximations became the workhorse of fundamental combustion research. CHEMKIN also became an
important educational tool in chemical engineering, mechanical engineering and chemistry curricula. The detailed approach to gas-surface reactions led to wide use of CHEMKIN for
materials processing studies, such as chemical vapor deposition or plasma etching in microelectronics chip manufacturing.
In 1997, Reaction Design became the exclusive developer and licensor ofCHEMKIN technology. CHEMKIN evolved into commercial-quality software that enables engineers and scientists to develop a comprehensive understanding of chemical processes and kinetics and
to quickly explore the effects of design variables on performance, by-products production,
and engine or process efficiency. Using CHEMKIN, researchers are able to consider thousands of chemical species and tens of thousands of reactions for wide ranges of processes and conditions. The advanced solvers developed for CHEMKIN enable fast, accurate
simulation of underlying detailed chemical and ignition behaviors, cutting combustion simulation times from days to hours or hours to minutes for complex models with large
mechanisms. The speed and accuracy of these simulations allow designers to test alternative system configurations and inputs to optimize for performance, efficiency and emissions
compliance virtually, before moving to the prototype stage of their development program.
Reaction Designs ENERGICO simulation package brings the power of detailed kinetic
modeling to combustion system design for applications such as gas turbine combustors, burners for boilers and furnaces, and flares and incinerators. ENERGICO uses CFD
simulation to help create accurate chemistry models of a system to meet the challenges
of emissions reduction and combustion stability for energy production and related
References
[1] Union of Concerned Scientists: Cars, Trucks, and Air Pollution,
www.ucsusa.org/clean_vehicles/why-clean-cars/air-pollution-and-health/cars-trucks-air-pollution.html
52
Improve
reliability.
Avoid unplanned
downtime.
www.QuestIntegrity.com/SFFS
Email: [email protected]
A TEAM Industrial Services Company
53
ANALYSIS TOOLS
A FOUNDATION FOR
COLLABORATION
Multiphysics simulation in ANSYS Workbench powers system-level analysis and helps shorten design cycles.
By Guy Barnes, Lead Technical Services Engineer; Zoran Dragojlovic, Technical Services Engineer;
and Jared Harvest, Senior Technical Services Engineer, ANSYS
54
Geometry of example electrical power supply device. These devices must meet several
specific standards for electrical emissions, heat output and noise level before they can be
made available for sale to the public.
HFSS simulation predictions show electromagnetic fields radiating from the initial thermal
venting configuration. The proposed design fails to meet FCC specifications in a 3-meter
emissions test because the peak values are too high.
55
ANALYSIS TOOLS
to prevent overheating. For example, the original vent configuration operating at a power consumption of 6 Watts
keeps the internal temperatures under the target of 110
degrees C while running a fan at 3,500 RPM. With smaller
vent openings, the fan speed must be increased to 4,600
RPM to stay below the same target temperature. Using HFSS
in conjunction with Icepak, thermal and EMI engineers can
work together to find a solution to their joint design goals.
If increasing the fan speed is not an option, the EMI engineer could try different venting shapes or even incorporate
an optimization approach to address both thermal and EMI
criteria.
Once the electromagnetic effects and heat transfer have
been taken into account, the aero-acoustics must be considered. Modifying the vent design and increasing fan speed
addressed EMI and thermal needs, but these changes may
affect the acoustic noise that the device emits during its
operation. Consumers will not accept a noisy fan running
in their home or workspace, so devices that use fans as part
of thermal management have to operate at low noise levels.
ANSYS Fluent can answer questions about noise levels via
aero-acoustic CFD analysis. The sound-pressure level (SPL)
amplitudes over the range of frequencies audible to humans
are derived from pressure fluctuations at a receiving point
located in the fan inlet region that is just outside of the casing. The original design was predicted to generate less than
50 decibels (dB) of noise at audible frequencies, which is low
enough to blend into background noise in an average home.
With the modified vent configuration and resulting higher
fan speed, the peak sound pressure level of 56 dB occurs
at the frequency of 311 Hz. This is comparable to conversational speech at a distance of 1 meter.
During device operation, the turbulent fluctuations of
pressure interact with the solid surfaces of the fan, casing
and electronic components, turning them into sources of
acoustic noise. A special Fluent utility can be used to generate 3-D contour plots of noise sources inside the device
for a given range of frequencies. This can aid the design
process by identifying the regions with high values of SPL.
For example, the core turbulent region generated by the fan
interacts with the fan blades and the large electronic components placed near the fan. This interaction results in elevated noise levels in the region between the fan and the two
components. Addressing this issue requires further design
changes.
Through this example of an electrical power supply,
simulation with the multiphysics capabilities available in
ANSYS Workbench allows engineers to evaluate numerous
physical aspects of virtual design variations without the
56
laborious process of having to build and test every one of them. By using a simulation-driven process, engineering teams are enabled to work together more cohesively and accelerate development of new technology. When time to market is so
critical, companies cannot afford design failures that appear late in the process.
With a suite of industry-leading solvers working together under the same hood,
ANSYS Workbench offers the ability to analyze multiple physics from the overall
system level, allowing critical issues to be identified early in the design stages and
enhancing the product development process.
HIGH-PERFORMANCE ELECTRONIC
DESIGN:
PREDICTING
ELECTRONIC
DESIGN:ELECTROPREDICTING
MAGNETIC
INTERFERENCE
ELECTROMAGNETIC
INTERFERENCE
ansys.com/82foundation
ansys.com
OPTIMIZATION IN ELECTRONICS
THERMAL MANAGEMENT USING
ANSYS ICEPAK AND ANSYS
DESIGNXPLORER
ansys.com/82foundation2
ANSYS
Workbench
enables analysis
of multiple
interacting
physics, allowing
critical issues
to be identified
early in the
design stages.
With the modified vent configuration and resulting higher fan speed, the peak sound pressure level of 56 dB (blue line) occurs
at a frequency of 311 Hz. This is comparable to conversational human speech at a distance of 1 meter.
Fluent results showing spatial distribution of acoustic noise sources driven by near-wall turbulent fluctuations of local air pressure, including vortex
core regions colored by eddy viscosity (left) and sound pressure level at 500 Hz (right)
57
ANSYS, Inc.
Southpointe
275 Technology Drive
Canonsburg, PA U.S.A. 15317
Send address corrections to
[email protected]
Winners demand the best. Ferrari would know. It has one of the best
racing records the world over.
Using ANSYS simulation technology, Ferrari is realizing its product
promise by optimizing critical aspects of its race cars, like brake cooling
systems and full-body aerodynamics, to better handle the twists and
turns of the racing world.
Sounds like Ferrari is in the drivers seat.
2014
ANSYS, INC.
ANSYSrealize
ADVANTAGE
Volume
VIII | Issue
1 | 2014
Visit
ANSYS.COM/Ferrari
to learn how simulation software can help you
your
product
promise.
58