Simulation is more than Software

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Optimized product development through coupled field and system simulation
The optimization of mechatronic systems should not be done, as in the past, by considering the individual components in isolation; rather, a simulation of the complete system behavior is necessary.

Multiphysics simulation of mechatronic systems

Branch : Electrical engineering/electronicsSpecialist field: Multiphysics, System simulation

In a system consisting of several components in different physical domains, the demands for low wear and low energy consumption cannot be translated into design requirements at a glance. Simulation provides valuable support here.

Summary

Task

To ensure the longest possible service life, wear in the system must be kept low even with many millions of switching cycles. In addition, low energy consumption and efficient development must be ensured.

Solution

With Ansys Simplorer the co-simulation of different physical domains is possible as well as the coupling with fast behavioral models, which are obtained from field simulations by model order reduction. Due to the short simulation times it is possible to calculate many design variants and to optimize them by using Ansys optiSLang.

Customer benefits

By using the system simulation, a configuration was found for the relay under investigation that ensures safe operation with minimal bounce, even under the influence of manufacturing tolerances. Due to the considerably reduced energy consumption an increased lifetime was achieved.

Project Details

Task

Electromagnetic relays are mechatronic systems consisting of electromagnetic and mechanical components. These components must meet a variety of requirements. To ensure the longest possible service life, wear in the system must be kept low even with many millions of switching cycles. In addition, low energy consumption must be ensured. The power input in a relay may be low, but accumulated over the multitude of relays used, the energy consumption should not be underestimated. Another goal is to keep development costs low, for example by reducing the number of prototypes and experimental investigations. However, the demands for low wear and low energy consumption cannot be translated into design requirements at a glance in a system consisting of several components in different physical domains.


Customer Benefit

By using the system simulation, a configuration was found for the relay under investigation that ensures safe operation with minimal bounce, even under the influence of manufacturing tolerances (Fig. 2). Compared to the original configuration, the power converted in the arc - which is the main reason for the wear of the electrical contacts - is reduced by 60% and the drive power by 20%. This results in an increased service life with reduced energy consumption. In addition, the experimental search for an optimal system configuration can be usefully supplemented or even replaced by targeted simulations.


Solution

The optimization of such systems should not be done, as in the past, by considering the individual components in isolation; rather, a simulation of the complete system behavior is necessary. With Ansys Simplorer the co-simulation of different physical domains is possible as well as the coupling with fast behavioral models, which are obtained from field simulations by model order reduction. Furthermore, controller structures and state machines can be implemented, as well as digital elements and block models for electrical, mechanical, thermal, acoustic and hydraulic components. Due to the short simulation times it is possible to calculate many design variants and to optimize them by using Ansys optiSLang. A guarantee of the correct functioning of the component, considering the manufacturing tolerances, can be examined specifically with a sensitivity study (Figure 1).


Product Area Manager

Products applied in the project