Example #9 Integrated Magnetics Example Designing a new 42-volt automotive power system requires knowledge of components, electronics and controls. It has become a truly multi-disciplinary engineering task. Ansoft's Electromechanical System Design Suite is a powerful combination of software simulation technology including electromagnetics, circuits, block diagrams, state machines, and specialized design programs which allow an engineer to successfully design and analyze a complete 42V system from start to finish.

Open PExprt Modeler [PEmag] application This example shows how to setup and solve an Integrated Magnetics model, which has windings on all three core legs. Note: In the Maxwell Projects panel, create a PEmag project instead of a PExprt project. Integrated Magnetic models cannot be generated from PExprt

Select File/New for a new project Opening PEmag from Maxwell Control Panel, a new project is opened by default

Note: Only EE, EI, UU and UI cores are valid for Integrated Magnetics Select E25/10/6 core from Ferroxcube library Un Ferroxcube library, select E25/10/6 and drag the core on the “cross section area” to assign it Note: Only EE, EI, UU and UI cores are valid for Integrated Magnetics

Double click on core element in library tree to edit Edit core properties and select “Double 2D” Double click on core element in library tree to edit

Select winding strategy “1 layer concentric” from Ferroxcube library On Ferroxcube windings tab, drag the “1 layer concentric” winding strategy and drop it on the “cross section area” to assign it

Select winding strategy “3 layer concentric” from Ferroxcube library On Ferrocube windings tab, drag the “3 layer concentric” winding strategy and drop it on the “cross section area” to assign it

Assign AWG20 wire to each layer of “3 Layer Concentric” winding strategy Select 3 Layer Concentric Drag AWG20 wire and drop it on the layer to assign it

Assign 14 turns to each layer Right click on each layer symbol to edit properties and assign 14 turns

Drag the AIR_200um insulator and drop it on the layer to assign it Assign “AIR_200um” insulator to the insulator layer of “3 Layer Concentric” winding strategy Drag the AIR_200um insulator and drop it on the layer to assign it

Right click on the layer to edit properties and change to 12.5mm high Assign 12.5 mm to the layer height Right click on the layer to edit properties and change to 12.5mm high

Connect layers as shown in the picture Use “Connections/Add” to add connections to both winding A and winding B

Assign AWG18 wire to the layer of “1 Layer Concentric” winding strategy and assign 11 turns to the layer Click on 1 Layer Concentric winding Drag AWG18 wire and drop it on the layer to assign it Right click on the layer to edit properties and assign 11 turns

Use “Connections/Add” to add connections Connect layers as shown in the picture Use “Connections/Add” to add connections

Information for each core leg appears Select “Current Design” tab Information for each core leg appears

Select “Winding Setup [Left Leg]” Click on winding setup for each leg to list Available Winding Setups under Available Elements

Select “1 Layer Concentric” from the available elements list Click on Winding setup [Left Leg] and then 1 Layer Concentric to assign it

Repeat the two previous steps for the right leg Click on Winding setup [Right Leg] and then 1 Layer Concentric to assign it

Select 3F3 core material from Ferroxcube library Drag 3F3 core material and drop it on the “cross section area” to assign it Click on “OK” when the Al dialog appears Click on “OK” when the Core Properties dialog appears

The Magnetic Component Definition is done and ready for modeling Click on “2D” button to generate the model Model should take approximately 8 minutes to be generated

Results Choose Results / FEA Based (2D) / FEA Based Results (2D) to view calculated parameters for the Pemag model

Results: Small Signal test available Use “Results\Using the model\Small Signal Test” or click on toolbar button to define the tests

Viewing Maxwell 2D Project Choose Modeler / FEA Based Modeler (2D) / Maxwell 2D link / Eddy Current to open the Maxwell 2D project

Note: In Simplorer, the model can be inported using the Interface6 library and the PExprt element. Note: The nodes of the model are clearly named in the model netlist and in the model symbol

Open “EE_Integrated” example Note: Different bobbins can be assigned to each core leg Open “EE_Integrated” example

Open “EI_Integrated_Planar” example Note: Planar Integrated can also be defined Open “EI_Integrated_Planar” example