CAD package for electromagnetic and thermal analysis using finite elements

Flux® 12.2 Release Notes

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Flux® 12.2

Release note

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Flux® 12.2 Release note

Reference Date: December 01th, 2016

Version: Flux 12.2

Introduction The Release Note documents give some useful information on the release of

version 12.2 of Flux. It is a technical document in addition to the New features document installed with Flux at the following path C:\Altair\FluxDocExamples_12.2\UserGuide\English\01_New_Features_12.2.pdf The Release Note describes the version at the time of its release. It gives the essential informations, the limitations, the main improvements, the main fixes, and the main dysfunctions identified, as well as complementary elements of support.

Contents This document contains the following topics:

Topic See Page List of new Features 2 Essential Information 3 Improvements and main fixes 4 Limitations and warnings 9 Known issues 11 Modification of iron losses calculated with Bertotti 13 Improvement the cut plane 15 About external software – supported version 16 About protection and installation 17

About documentation

Concerning the documentation : • The HTML help has been updated for some new features of this 12.2 version. • The documents and examples are automatically installed with the Flux setup

setupWinFlux12.2.exe at the following path : C:\Altair\FluxDocExamples_12.2\UserGuide

• The examples 2D, Skew and 3D are accessible directly in the supervisor (open Flux project and pdf document file).

Flux® 12.2

Release note

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List of new Features

Introduction Here is the list of new features on Flux 12.2 version:

For more details

For more details, please consult the New features document describing all the new features present in this new version. This document is downloadable with the setup of Flux version or consultable at the following path : C:\Altair\FluxDocExamples_12.2\UserGuide\English\01_New_Features_12.2.pdf

Create and manipulate complex 3D geometries

Improved CAD import process with collision detection and correction tools More efficient tools to simplify and repair faces Extrusions along any line Going from 2D to 3D and vice-versa in a few clicks

Analyze dielectric withstand of equipment

New application to study transient electric phenomena Non-linear behavior of materials taken into account Post-processing tools to evaluate dielectric breakdown risks

Go further in transient

Faster solving of 3D transient models of electric machines considering movement

Only store the results you need and save space on your disk Faster post-processing of large models with many time-steps

Go multiphysics and optimize with Altair tools

Coupling with OptiStruct for vibro-acoustics analysis Link with Compose to automate your design studies Optimization available from HyperStudy (Beta) System analysis with Flux-Activate co-simulation (Beta)

Miscellaneous improvements

Better management when continuing a parametric solving in distributed mode

Faster post-processing on cutting-planes Improvement in error messaging

Flux® 12.2

Release note

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Essential Information

Essential information

Here are the essential information about the Flux version 12.2:

Essential information Altair acquired CEDRAT SA, expanding its electromagnetics software portfolio for low frequency simulation and broadening the support for electric and electromagnetic device design. Flux can benefit from the licensing system used for the HyperWorks suite, which is based on HWUs: "HyperWorks Units". Flux 12.2 is not yet integrated into the HyperWorks suite, but already benefits from HWU protection. With this system, the user automatically has access to all HyperWorks software. For Flux 12.2 the user has the possibility to be protected: • either by "Cedrat" protection: FlexNet protection • either "HWU" protection This double possibility of protection should continue for some versions. A new electric application has been added in Flux 12.2, the electric transient application. This application uses the same feature protection as the Steady Stat AC electric application if you use the FlexNet protection system. Flux 12.2 allowed consolidating the robustness of the modeler. The compatibility of python commands on operations made in the modeler between 12.1 version and 12.2 version, is ensured. But the improvement of the algorithm of CAD Import process combined with modification imposed by the change of ACIS version, could introduce some changing of numbering of imported entities. A correction of an issue (7946: formulation of the Bertotti model) done for Flux 12.1 has been canceled in Flux 12.2 because of side effects it created in some cases. (see more detail on the page Modification of iron losses calculated with Bertotti Flux 12.2 takes into account a lot of user feedback, (mainly Flux 12.0 and Flux 12.1 users) and more than 200 issues have been solved in this version. Flux 12.2 is qualified for different OS: • Windows 10 • Windows 8.1 • Windows 7 • Linux Red Hat 5

Disclaimer Altair is not responsible about the database materials data.

This data is given by material manufacturers.

Flux® 12.2

Release note

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Improvements and main fixes

Issue corrections

This new version consolidates the previous version. The main improvements and corrections are listed in the table below. For this version, the consequent number of fixed issues is around 200 issues.

Improvements Some improvements are listed on the table below.

ID Improvements Modeler: Cut Object

Modification of the algorithm of the geometric operation Cut Object to have a better robustness during a modification cycle (so a parametric study used Cut Object). A new command python is associated.

Modeler: Clean Face Improvement of the Clean Face which allows cleaning locally many configurations with (hole/slot/fillet…)

Modeler: Separate Volume Now it is possible to separate only the desired volumes. The user no longer chooses an object to be separated but a list of volumes.

With the implementation of the modeler and its complex CAD import capabilities, the creation of the enclosing volume of the device generated by the command Complete infinite box can reach its limits. To fix this problem, a specific work has been done on Complete infinite box applied exclusively to a geometry made in the modeler (so a geometry that contains geometric objects).

CAD Import Process In the modeler, the process of CAD import has been improved to make it more robust. New options have been added. The new actions are: • Possibility to detect collisions between Objects • Possibility to separate solids which are independent • Improvement of the simplification of “sliver” faces (done automatically during the

import) • Conservation of color information contained in CAD file

Modeler: Extrusion of faces In 12.2 version, new types of extrusion have been added: • Extrusion along a parameterized path • Extrusion along a path defined by user points

Distributed computation: The possibility of Stop and Continue a solving is available. However some configurations may not be managed.

Continued on next page

Flux® 12.2

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Improvements and main fixes, Continued

Improvements (continued)

ID Improvements Partial storage:

One solution added in 12.2 version is the partial storage in order to reduce the size of the solved project on the disk, while keeping the possibility to post-process the results of these projects. 2 possibilities are given: • Before resolution, define the calculation steps to be saved in the solving scenario • In postprocessing, define the calculation steps to be saved in the solving scenario

Cut Plane: With 12.2 version during the creation of a cut plane, the method to display elements of meshing on this plane has been modified. From 12.2 version, the cutting of the meshes is purely geometric.

Flux - HyperStudy coupling: The HyperStudy to Flux connection allows exploring efficiently the design space of any electromagnetic devices modelled in Flux (motor, actuator, transformer…) The coupling between Flux and HyperStudy is possible with Flux 12.2. It is usable but it is considered for a beta version. Please From Flux, use the command Generate component for GOT-It coupling

Flux - OptiStruct coupling: The coupling between Flux 12.2 and OptiStruct is available and allows : • Allows exporting forces (.bulk file) for OptiStruct

The forces are computed on a support created using the mechanical mesh exported from OptiStruct

• Allows performing a vibro-acoustic analysis (NVH analysis)

Flux - Activate coupling: The coupling with Flux is available in 12.2 version only in advanced mode. It’s a beta version. This connection allows coupling the magnetic with the powerful of a system analysis.

5 application notes have been added on the “Open example” context in the Supervisor (2D): • Linear actuator • Hemoltz Coil • Slot less permanent magnet motor • Brushless Motor - Step Skew • Streamer in an insulator

5 application notes have been added on the “Open example” context in the Supervisor (2D): • IM motor • IPM multilayer magnet motor • Flux barriers SRM motor • DC Motor • Line Start Permanent Magnet Motor

Continued on next page

Flux® 12.2

Release note

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Improvements and main fixes, Continued

Corrections made

Some corrections made are listed in the table below.

Context ID Corrections made

Modeler

8570 In the sketcher (in 2D and in the modeler), now it is not possible to create new points from the data tree, only by the functionalities of the sketcher)

8417 8310 8127

Some improvement about specific configurations of Boolean operation in the modeler

8556 No preview when creating an extrusion of faces in the’ predefined XZ predefined. Fixed in Flux 12.2

8891 8739 8550 8507 8354 8311 6330

…

Improvement of the CAD Import in the modeler. More defaults are automatically detected and corrected or simplified. The “sliver” faces are automatically detected and simplified during the CAD import process.

8574 8203 7793 …

Improvement of the modification of a geometry built with the geometric operation in the modeler

8750 8442 8101 …

Improvement of the conversion of old projects in objects when the modeler is opened after loading the project

8001 7978 7977 7761 8061 9032 …

Improvement of the use of parameters via Modeler for parametric solving

8643 8513 8469 8090 8089 8087…

New algorithm of the cutting of objects in the Modeler

Continued on next page

Flux® 12.2

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Context ID Corrections made

Modeler (continued)

8722 8600 8464 8461 8453 8426 8298 7839 …

Improvement of the management for the Complete infinite box when the geometry is built or imported in the modeler

Overlays 8772 Some update of Speed Import.

Mesh

7956 7583 Bad surface mesh with 12.2 for a sphere. Fixed with Flux 12.2

8872 Now the extrusive mesh in rotation works from a sketch created in the modeler

8213 Manages the mesh of lines and faces when a line is in contact with several faces

8592 Correction of the completion mode to structure Faces for mapped mesh

Physics- Solving

7891 Now, on a 3D project "no exist" points outside the domain are not taken in account by the check

8726

When the distributed computations from GOT-It and Flux were overlapped. The issue occurred when the distributed jobs from GOT-It involves the solving of a scenario where the option "Distributed computing" is activated. Fixed in Flux 12.2.

8260 Improvement of the solving when static initialization is used in a steady state AC magnetic coupled with Transient Thermal with a FTS file.

7402 8501

Improvement the robustness of the adaptive solving containing mechanical set, sliding, …

8259 The Variation of number of turns is now taken into account in a solving scenario if the non-meshed coil is linked to the circuit

8631 In this case, it was impossible to solve this 3D transient magnetic project with airgap surface regions. It was a problem of duplication of airgap surface region. Fixed with Flux 12.2

Continued on next page

Flux® 12.2

Release note

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Context ID Corrections made

Post-processing

8609 8459 8416 7469 7078 6963 5144 4148 3347 3118

Acceleration of the creation and the postprocessing of a cut plane Now the cut plane is based on the geometry (and no longer on the mesh)

8120

Correction of the Excel Export used on different Macro available with Flux (command : Workbook.createWorkbook) The concerned versions are : ExportAreaAverageValue.PFM, MacroScreening.PFM

8321 Update the macro "RunEfficiencyMapWithLdLqData" which did not work on Flux 12.1 because of the Jython update done

8468 Problem of permutation label when I permute the abscissa in a 3D curve. Fixed in Flux 12.2

8494 Now it is possible to create a support in Vibro-acoustic context even if no mechanical set is defined

8440 In the vibro-acoustic context, now the scaling of a 2D curve is automatically done

Flux® 12.2

Release note

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Limitations and warnings

Limitations The list of principal limitations (and warnings) of the 12.2 version is

presented in the table below.

ID General limitations The number of characters in the Flux formula (formula editor) is limited to 80.

5452 The number of circuit component is limited to 10000 (circuit) The names of Flux folders and Flux projects should not contain accents, blank

character, specific characters such as '%', ... Flux accepts the following characters: "+-./0123456789ABCDEFGHIJKLMNOPQRSTUVWXYZ_abcdefghijklmnopqrstuvw&xyz~"

ID 12.2 new features limitations

Modeler: The simplification of hyper-tangencies command does not exist. Several functionalities can be used to “break” a hyper-tangency, such as Boolean operations, object cut, … However in Flux 12.2 , the algorithm of mesh has been improved to limit the creation of too many nodes in the zone of hypertangency

Modeler: A preview is available for all functionalities of the modeler in Construction except for the defeaturing, reference plane, reference line, reference point and chamfer on summits The preview is not available if an object has been submitted to one or more operation.

Modeler: The graphic representation of a spline line is divided in 27 segments. This is a limitation of Flux today. So if you have a spline having a lot of turns, you may obtain a bad graphic representation, but the definition of lines, faces and volumes will be right. For example if you use the helicoidal extrusion you may see a poor graphic representation.

Modeler: It is not possible to de-feature several objects at once. Please proceed with one object at a time.

Modeler: With this Flux 12.2 version, the old method to describe the geometry is always available in the standard geometry context. But if you begin to use the modeler to describe your geometry, we advise you to continue and finish with the modeler. Theoretically, the two methods are compatible but we cannot guarantee multiple interactions between these two methods of geometry description.

Modeler: The modeler context authorizes the superposition of entities (unlike standard geometry context of Flux). You must check upon exiting the modeler that your geometry is assembled (without superposition entities). To do this please use the Assembly operation Boolean

Modeler: Use mandatory a reference line as axis of rotation to apply a geometric operation of rotation of objects to ensure thereafter the parametric solving.

Modeler: Don’t use the import Flux Object for a 3D project in Flux 3D, privilege the CAD import

Continued on next page

Flux® 12.2

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Limitations and warnings, Continued

Limitations (continued)

Distributed computing: No distribution : • in multiphysics context • with co-simulation with another software • with Linux OS • for Skew projects • if adaptive time step • if adaptive solver • if transient initialization by file

Adaptive solving in 3D: The adaptive solver doesn’t work with : • mapped mesh or extrusion mesh, • linked mesh on internal volumes and faces (entity on the edge of a periodicity can be

(and have to) mesh by this way…), • variation on a parametric geometric and a variation of the position of a mechanical

set, • automatic cut on mesh.

Partial Storage The option ONE OUT OF is available only for transient parameter (time or position of mechanical set

Flux® 12.2

Release note

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Known issues

Principal known issues

The list of principal “Known issues” of the 12.2 version is presented in the table below (as well as the “Bypass solutions” when they exist)

ID Summary

On Linux system, when Flux is launched via a remote pc, Flux is not opened and a Java message is returned. Java is unable to determine the size of the font. Bypass: With Linux, use Flux with virtual pc or real pc.

9135 Load a macro after a motor overlay gives a graphical error Bypass 1: load and run the overlay + save project + load and run the macro Bypass 2: load the macro + load and run the overlay + run the macro

8992 Flux crashes if you close the supervisor during the solving process

8558 In this MH3D project, the resistance of a non-mesh coil is not taken into account in the electrical circuit.

8341 Issue concerning insulator face region on symmetry surface. A problem concerning a geometry with symmetry and periodicity. When a face region is assigned to a face localized on a symmetry surface, the project is impossible to solve.

8254 When a project is being solved in batch mode, the button "stop current solving" does not work (the solving continues). The bypass is to create by hand the STOP file in the working directory.

8124 Problem of mesh with 180° arc line (problem of periodic mesh) Bypass : split arc in 2 arc of 90° (you can use the cut object of the modeler)

8099 Problem of CAD Import with certain file with format .STEP and .IGES

7926

In this 2D magnetostatic project, the same sensors created before and after solving give different results. It is the particular case of punctual sensors linked to a region with mobile mechanical set.

7832 Import Flux Object of a 3D project is not managed By pass : export in a SAT file and then import the SAT file (but the parametering is lost)

7301 There are some regions (solid conductor and thermal conducting region) without materials. Flux do not detect this problem.

7080

If we create a volume region with impedance surface type, Flux create face regions corresponding to this volume regions. If a user associate a sensor to this face regions, and want later to delete results and re-launch the calculation flux reset the sensors, and delete the face regions impedance surface type.

5703

Thermal application: The value of the injected power is not available in the postprocessing part. The calculation of power on “Thermal conducting region with heat thermal source” is proposed (Active power), but the result is invalid (= not implemented). Bypass solution: use the integral computation mode in the advanced menu in 2D: face integral of dHeatV on the face region (integration in the domain depth) in 3D: volume integral of dHeatV on the volume region

Continued on next page

Flux® 12.2

Release note

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Known issues, Continued

Principal known issues (continued)

ID Summary

5448

Magnetic application / kinematic coupling: Impossible to pilot ANGPOS parameter value from GOT-It because of the (°) symbol in the parameter comment. Bypass solution: The symbol (°) in the ANGPOS parameter comment has been replaced by (deg). This correction has been implemented in Flux v.11.1.0. For projects created with anterior versions, the (°) symbol in the parameter comment remains. To avoid the problem with “old” projects, it is needed to rename twice the mechanical set (step1: rename ROTOR to ROTOR1; step2: rename ROTOR1 to ROTOR).

5101 2D Steady State Thermal application: In the case of axi-symmetric domain, do not use point region of Imposed temperature type: the results cannot be guaranteed.

4640 2D Electrostatics application: With mechanical set (multi-static kinematic mode), it’s not possible to compute the torque

4167 In skew Transient Magnetic, user can't use line region to represent airgap in 2D multi layers

3818

3D Steady State AC Magnetic coupled with Transient Thermal application: Post-processing with “volume density of Laplace’s force” (dFLapV / dFLap2wV) is not possible

Bypass: Computation with the formula: dvBJFvL ∫ ∧=

3816

3D Steady State Thermal application with: • a region of the following type: “Conducting region with heat source” • the heat source is described by a formula that depends on temperature ⇒ the temperature dependence is not taken into account Bypass : 1) Continuation of the solving process: iterate on one step of the scenario, after several iteration the results converge on the good results. 2) Create a material with a function which has a law which depend on the temperature, to make the system nonlinear and to make more iterations

3145 Impossible to solve a 3D Steady State AC Electric project with a face region of the type "Thin dielectric and no conducting region". Bypass: Use a volume region instead of the face region.

2819 Mechanical losses due to friction coefficient are not taken into account in the power balance computation. Bypass: Do not forget to take them into account.

Flux® 12.2

Release note

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Modification of iron losses calculated with Bertotti

Introduction A correction of an issue 7946 done for Flux 12.1 has been canceled in Flux

12.2 because of strong impact of the iron losses on the efficiency.

Formulation In transient magnetic, iron losses calculated with Bertotti’s formula is :

Equation 1 : (Note that in Flux documentation, Bm is Bmax)

The problem In rotating electrical machine, flux density close to magnets is constant. Iron

losses are mainly losses by hysteresis, the first term of the equation 1. Up to the 12.1 version, the losses by hysteresis term were wrong because Bmax was too high. An issue was opened (I7946) and Bmax has been modified in Bmax – Bmin. But, in the case of some specific configurations, on the stator part of electrical machine for example, iron losses value are now strongly underestimated with this method. This is a side effect of this correction.

Go back in Flux 12.2

Because of strong impact of the iron losses on the efficiency, it was chosen for the 12.2 release to go back on this issue. With this new version 12.2, hysteresis iron losses will be identical to the 12.0 release

Continued on next page

Flux® 12.2

Release note

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Synthesis Here is a synthesis:

Bertotti’s losses : hysteresis part in W/kg

Flux density shape versus time

Flux 12.0 and 12.2 Flux 12.1

Comment Iron losses (W)

Iron losses (W)

1.551 1.551 In this case, without constant component, user don’t meet any kind of problem.

1.551 0.051

For his type of signal, due to the constant component, Bmax is too high. With the 12.1, using Bmax - Bmin give more accurate result of iron losses close to the rotor magnet.

1.551 0.051

For this type of signal, with the Bmax – Bmin value under evaluate the iron losses. With the 12.1, the algorithm doesn’t detect the crossing by 0 value. A very tiny step have to be set to detect it.

Note : A specific FAQ “Why Flux 12.1 (or higher version) is giving a different result on iron losses computed with Bertotti method than in previous version?” was written on this subject.

Flux® 12.2

Release note

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Improvement the cut plane

Introduction With 12.2 version during the creation of a cut plane, the method to display

elements of meshing on this plane has been modified. From 12.2 version, the cutting of the meshes is purely geometric.

Flux 12.1.1 Flux 12.2

Example 1

eExample 2

Flux® 12.2

Release note

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About external software – supported version

External programs

The use of external programs can be achieved with the versions listed in the table below.

Flux OS

Flux functionality External software Supported version

Supported OS Win64 Lin64

Flux 12.2 coupling

Matlab/Simulink*

Version 2013a

64 bits

Flux 11.2

Version 2014b Flux 12.0

Version 2015b Flux 12.1

Version 2016b 64 bits Flux 12.2

GOT-It Version 3.0 64 bits

CDE Version 2.1

32 bits (can be installed in a 64 bits to exchange with Flux and Got-It)

Import Speed files (2D) Speed 64 bits

Flux® 12.2

Release note

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About protection and installation

About FlexNet protection

The new functionalities contained in the version 12.2 don’t need new features. The new electric transient application use the same feature as the Steady State AC Electric application.

About HWU protection

Since the 12.2 version, it is possible to use the HyperWorks Units as protection system The HWUs count is split into 2 parts: • GUI = description of geometry+ mesh + physics + postprocessing of

results • Solver = computation of the model All the applications are covered.

HWU for Flux 3D and Flux Skew

For Flux 3D (and Flux Skew), the HWU licensing system is the same as all HyperWorks solvers: • GUI = 21 HWUs • Solver = 25 HWUs

HWU for Flux 2D

For 2D users exclusively, the offer has been adapted. There is no GUI / Solver distinction. By default, the user has access to all applications and with 15 HWUs.

About installation

The setup specific to the documentation is integrated on the main setup of Flux. Since Flux 11.2, documents and examples are automatically installed with the main setup of Flux.

About installation - CDE

The Cedrat Distribution Engine tool (CDE) allowing distributing computations, is installed automatically with the main setup of Flux.

Graphic cards It is necessary for the proper functioning of our software that the driver of the

graphics card is as up-to-date as possible. In our experience a "Windows Update" is not sufficient, it is essential to install the latest driver supplied by the manufacturer of the card. Eg for NVIDIA: http://www.nvidia.com/Download/index.aspx?lang=en-us