CAE of Mechatronic Systems I

Prof. Dr. Manfred Kaltenbacher Applied Mechatronics, University of Klagenfurt, Austria http://am.uni-klu.ac.at

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Outline
Introduction to numerical simulation Basics of the Finite Element (FE) method (1D case) Application to electrostatics Vector analysis
Irrotational and solenoidal fields Gradient, divergence, curl

Computational mechanics
Naviers equation Stresses and Strains in an elastic body Plane strain and stress case as well as axisymmetry Material properties FE formulation

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Outline (cont.)
Computational electromagnetics
Maxwells equation Material properties Electromagnetic interface conditions FE for eddy current problems

Computational acoustics
Wave theory of sound Conservation laws and wave equation Plane and spherical waves FE formulation

Advanced topics
Coil modeling (Current / voltage loading) Locking in mechanical thin structures Open domain problems
CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Development Process
The design process

Pure experimental based desin

Definition of concept

Definition of Concept

Design Modification Prototype Fabrication/Test OPT Optimization

CAD

CAA Simulation

No O.K. Yes Fabrication

No

O.K. Yes Prototype Fabrication/Test

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Computer based desin

Development Process (cont.)

Advantages of a computer based design process
Simple variation of material parameters and geometry The impact of variations towards the design goals (e.g., dynamic behavior, signal to noise ration, etc.) can be studied direct on the computer; Possibility of investigating the physical quantities, which are not accessible by experiments (e.g., mechanical stress or magnetic field inside a body)

Drawbacks
Results are based on models, which just can be approximations of reality Material parameters: simulation depend strongly on the material models and the material parameters

Combination of experiments & simulation

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Practical Example
Design of a magnetic valve

Engineering Knowledge

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Practical Example (cont.)

Physical equations
Magnetics:

Engineering Knowledge
Mechanics:

Coupling: electromagnetic force Analytic solution just for simple cases

Mathematics Numerics

Solution by numerical methods, e.g., the Finite Element (FE) method

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Practical Example (cont.)

Simulation and Visualization
Geometric model, discretization (computational mesh) Arising algebraic system of equations quite large (>106 ) Therewith, we need efficient algorithms and parallelization (High performance computing) Post-processing (data steering) and visualization of the computed physical fields on the computational mesh

Mathematics Numerics

Computer Science

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Some Applications
Schematic of a clinical MRI scanner Main magnet

Axis of rotation

Gradient coil

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Some Applications (cont.)

Details of geometric model and computational mesh
Transverse gradient coils Superconducting coils (main magnet)

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Some Applications (cont.)

Minimization of eddy current losses Eddy current losses in the cryostat (W) original system optimized system FE-simulation Measurement

Frequency (Hz)
CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Some Applications (cont.)

Electric power transformer
Goal: Predict Vibrations of transformer tank, caused by Lorentz Forces inside the windings Key Problem: Accurate prediction of winding structure and eigenmodes (mechanical setup)

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Some Applications (cont.)

Electric power transformer
Quarter symmetric model of a single phase

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher

Some Applications (cont.)

Electric power transformer
Eigenmode at 96Hz

CAE of Mechatronic Systems I (2008/2009), Prof. Manfred Kaltenbacher