2-2 Worked Example Eddy Current

OPERA-3d Training Course
2-2 An Eddy Current Worked Example
Version 15 OPERA-3d Training Course

-2
OPERA-3d Training Course November 2011

Induction heating example with ELEKTRA-SS -3
Induction heating example with ELEKTRA-SS
Introduction
This example problem on the course is to calculate the eddy current distri-
bution, loss in the melt (the liquid metal in the bath) and coil impedance of
the induction heating bath shown in Figure 1.6. The bath has rotational
symmetry around its vertical axis, but is supplied by a "racetrack'' style
coil, making it a 3-dimensional problem. . One of the objectives is to com-
Figure 1.6 Induction heating bath
pare the results with a steel bath and a ceramic (non-conducting) bath.

-4
Modelling, Solving and Post-processing
Because of the axisymmetry of the geometry and the "square" racetrack

coil (the straight sections are all the same length and the 90 degree arcs at
the corners are all on the same radius), the minimum symmetry of the prob-
lem is a 45 ``wedge''. However, the facilities to automatically create a
background region, based on the defined geometry in the Modeller, and the
ability of the Post-processor to replicate complete model from the symmet-
ric part (from the description of the background), make it more expedient
to model a 90 section. Figure 1.7 shows the part of the bath that is solved.
Figure 1.7 90 degree section of heating bath
The new features introduced in this example are given below.
Creating the model

Using the SHELL option to create the bath
Using layering to improve modelling of skin-effect
Setting up ELEKTRA analyses
Adding an additional case to an analysis database
Solving the problem

The problem is initially solved using the ELEKTRA-SS module (steady state
a.c. solver including conducting media). Total and reduced magnetic vector

Modelling, Solving and Post-processing -5
potentials are used, although these are set automatically dependent on the
material. The electric scalar potential is also solved in the conducting
regions to ensure current continuity. The results are written to a binary data-
base .op3 file, and the .res file contains the log of the analysis.
The same model is also run in the transient simulation module ELEKTRA-
TR
Getting the answer

New features introduced in the post processing session:
Using the TIME parameter
Displaying eddy currents on surfaces
Reading multiple case solutions

-6
Script
Launch the Modeller

Instructions for starting the OPERA Manager and the OPERA-3d Modeller
can be found at the beginning of the C-Core and Loudspeaker examples
elsewhere in this training course.
Building the bath and melt

The bath and melt are created from two cylinders. The bath cylinder is
modified to create a shell from the outside shape of the cylinder with its top
surface removed. This facility makes a hollow body with a defined wall
thickness from an existing solid body, removing the selected face(s).
Bath cylinder
Select the Cyl- Create a 5 metre radius cylinder with

inder... icon 0 <= Z <= 3. Make it from a Material called
bath with a data storage level of 500

Script -7
Select the Select Cylinder1 and, using the context sensi-

Pick tive menu, select Cell properties (or use
cells... icon Properties => Cell properties from the
menus)
Select the Pick
entity ...
icon
Set the Maximum element size to 0.5
Click on OK
Select the Pick Select the face of Cylinder1 at Z=3 and, using
faces ... the context sensitive menu, select Shell (or
use Operations => Shell from the menus)
icon
Click on Inwards Direction button and set

the Thickness of shell to 0.25
Click on OK.

-8
Melt cylinder
Select the Cyl- Create a 4.75 metre radius cylinder with

inder... icon 0.25 <= Z <= 2.5. Use melt for the Material
and a data storage level of 200
Click on OK
Select the Select Cylinder2 and, using the context sensi-
Pick tive menu, select Cell properties (or use
cells... icon Properties => Cell properties from the
menus)
Set the Maximum element size to 1
Click on OK

Script -9
Improving the discretization

Two materials are to be tested for the bath - ceramic (non-conducting) and
steel. The latter will show considerable skin effect, even at 1 Hz. Conse-
quently, the bath will be subdivided into 4 layers of elements to improve
the representation of the decay of the field and eddy currents. To determine
whether forward or backward layering is needed, the outward normal vec-
tors of the surfaces (forward direction) will be displayed. The effect of the
layering is seen after Model create when additional layers of cells are con-
structed.
Select the Pick Select the side and base outer faces of the bath
faces ... (3 faces in total)
icon
View => Vectors...

Select Face normal. Set the Scale factor
for the vectors to 2
Click on OK
Properties => Face properties ...

-10
Create 4 layers each 0.0625 metres deep using

the Geometry layering method
Click on OK
Boundary Condition Definition and Symmetry

Because one quarter of the device is being modelled, the boundary require-
ments are such that the symmetry of the field is implied. The symmetry will
be imposed along the YZ and ZX planes and on both of these planes the
magnetic field will be tangential and the electric field will be normal.
OPERA automatically converts this desciption of the field into the appro-
priate magnetic vector potential boundary conditions.
The outer boundary of the model will be spherical and will be 4 times
larger than the radius of the largest dimension in the model. In the far-field,
default boundary conditions are used.
Before defining the model symmetry and boundary conditions, the type of
simulation to be performed should be defined, as not all symmetries are
valid for some analysis modules.
Model = > Analysis type => ELEKTRA Steady State

Model => Model symmetry ...

Script -11
Using the pull down menu, set the Shape of background to Sphere and the
value of R in Spherical Scale Factors to 4. Set the Reflection in coor-
dinate planes to be Tangential magnetic for the YZ and ZX planes
Click on OK
The model body can now be created. This will add the background region
of air, enforce the symmetry and the layering.
Model => Create Model Body
Two views of the model body showing the overall model and the layering in
the bath
Define the Conductors

The conductor is a racetrack coil surrounding the bath. Although the finite
element mesh boundary conditions imply the symmetry of the model, the
complete coil description for the entire device must be given to ensure that
values of Hs are computed correctly.

-12
The racetrack conductor is created with its local Y-axis equivalent to the
global Z-axis. Consequently, it is necessary to access 3 of the tabs used in
defining the racetrack conductor before accepting the definition.
Select the The cross-section of the coil is 0.25 x 2.25 and it is positioned such that its
Racetrack closest distance to the wall of the bath is 0.5. Its base is at the same height as
the base of the melt.
icon
After completing the dialog, go to the Further Options dialog

Script -13
The Current density is 2 x 106 and the Tolerance for the Biot-Savart cal-
culation is 1 mT. Set the Drive label to d1. This will be used when the
model is later run in transient mode. In Local coordinate system 2, set the
origin to (0,0,0) and all three Euler angles to 90 (degrees)
Click on OK
Generating the Mesh
Surface meshing Creation of the finite element mesh is performed in two stages. All surfaces
of the model are meshed with triangles initially. After the surface mesh is
complete, the volume mesh of tetrahedra can be created.
Model -> Generate surface mesh

-14
Set the Target maximum mesh element size

to 5
Click on OK
Volume meshing Using the surface mesh on the faces of each cell, the volume mesh for each
cell is generated in turn.
Model -> Generate volume mesh

Use the default tolerance.
Construction of the volume mesh may take up

to a minute and results in a mesh with about
41,000 elements (the exact number will
depend on the computer hardware in use).
Create ELEKTRA-SS Database File
Material The analysis will initially be run using a steel bath assuming properties of
properties relative permeability = 5 and electrical conductivity = 2.2 x 106 S/m. At a
frequency of 1 Hz, this gives a skin depth of about 0.15 metres. However,
the wall thickness of the bath is 0.25 metres - so not much flux (and hence
induced current) is expected to penetrate to the melt.
The properties of the melt are relative permeability = 1 (because steel

becomes non-magnetic above its Curie temperature) and conductivity =
40,000 S/m.
Model -> Set Material Properties

Script -15
Highlight the material called bath and set the Relative permeability to 5
and the Conductivity to 2.2 x 106.
Click on the Apply button

Highlight the material called melt and set the Relative permeability to 1
and the Conductivity to 4 x 104.
Click on OK to apply the setting and exit the dialog
Analysis data The only data that needs to be changed from default values for the ELE-
KTRA-SS analysis is the frequency of operation.
Model => ELEKTRA Steady State Settings

-16
In the Analysis frequencies section, click on the Change button
Highlight the 50.0, set the New frequency value to 1 and click on Replace
Click on OK to accept the change

Script -17
Review the final settings of the ELEKTRA-SS Analysis Data dialog
Click on OK
Create the OP3 The file name for the analysis database is bath.op3 and the model has been
file constructed in SI units (length unit is metres, current density is in A / sq.
m). The title is optional
Model => Create Analysis Database

-18
Set the Database to bath.op3 and use the pull

down menu for Units to select SI
Click on OK
Adding a second An alternative material for the bath will also be examined. The steel bath
case will be replaced by a high temperature ceramic material. In an ELEKTRA
analysis, only magnetic and conducting properties of the material are used
- that is, dielectric properties are ignored. This is generally a reasonable
assumption when the wavelength of the electromagnetic field is much
longer than the dimensions of the structure. Consequently, the non-con-
ducting, non-magnetic ceramic will have identical properties to air as far as
ELEKTRA is concerned.
Model => Set Material Properties

Script -19
Highlight the Material called bath and click on the Set to air button
Click on Cancel to exit the dialog
The second case can be added to the existing database bath.op3. Adding
multiple cases to a database where the mesh remains unchanged is useful
for reducing the data storage requirements. The mesh is only stored once.
Model => Add Simulation to Analysis Database

Give the database name and add any additional comments
Click on Prepare and solve to run both cases consecutively
Monitoring progress
The program reports when major stages of the analysis are complete and
the amount of CPU and elapsed time used at each stage.
When the analysis is complete, select the Post-Process button on the

Solver Window to launch the Post-Processor with the database pre-loaded
and the solution for case 1 (the steel bath).
Whilst the analysis is being carried out, a window will be visible showing
progress of the analysis. A second advantage of multiple cases in the same
database can be seen. The Biot-Savart field calculations to compute the

-20
right hand side of the equations remain unchanged between the two cases.
Consequently, these values can be recovered from the first calculation, sav-
ing computer time.

Post Processing -21
Post Processing
Viewing the model

The field and flux density can be displayed similarly to the TOSCA results.
To examine the induced current density the components JZ, JY, JZ and
JMOD are used.
Initially the basic model will be displayed, then the conductor will be
removed to enable the fields and currents on the bath to be seen more
clearly.
When the Post-processer starts, the user has

the option to select a different case if a multi-
case database exists.
Click on Cancel to retain case 1

Select the The Conductors are de-selected by first high-
Select... lighting the Label Conductors and then press-
ing the Remove from selection button.
icon
Click on Select and Refresh

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View the magnitude of the current density (JMOD) over the surface of the
model.
Select the 3D Using the pull-right arrow, set the Field com-
display icon ponent to Jmod
Click on OK

Post Processing -23
This display can be further enhanced by adding vectors of the induced cur-
rent onto the display.
Select the 3D Select the Vectors button and using the pull-
display icon right button set the Vector to J with a Scaling
factor of 2 x 10-7
Click on OK
The distribution of current density displayed is the in-phase component.

(The current in the coils is of the form Re : I ei ( t ) ,where is the phase
angle - for the in-phase component = 0 ). The solution is expressed as a
complex value in the form a + ib . The in-phase component is the real part
of this solution.
To examine the imaginary part of the solution the user requests results at
TIME=90 i.e. 90 around the a.c. time cycle.
Alternatively, the variables RJX, RJY, RJZ, IJX, IJY and IJZ are available,
which are the real and imaginary components of Jx, Jy and Jz respectively.
So the currents can be recalculated at a different AC time as follows:
Select AC Set the Angle round AC cycle to 90

time button
Click on OK

-24
Select the This will leave the same settings for the con-
Refresh icon tour component and the vectors
It can be seen from these 2 displays that the largest eddy current densities
are in the steel and not much current is flowing in the melt.
To view the eddy current in the melt, the scale of the contour display can
be changed or the bath material can be removed. The second of these
options is used
Select the Highlight Volumes => Materials => bath and

Select icon click on Hide selection
Click on Make Selection

Post Processing -25
Select the 3D Set the Scaling factor for the Vector to 5 x

display icon 10-5
Click on OK
Compute the inductance

The inductance is computed from the stored energy of the system.
Select the Accept the default setting. This gives the time
Energy, average energy over one cycle
power and
force icon
By default the integral is carried out over all

materials so simply press Integrate.

-26
The value of energy that is calculated is the time average stored energy and
power, over the whole problem space (including symmetry replications).
Both take the form W = A + B cos ( 2t + C ) and the time-average part is (A).
Then the inductance can be calculated from:
2W e
Induc tan ce = -----------2- Henrys, where We is the stored energy in the system.
I rms
The peak mmf applied to the coil is 1.125 x 106 Ampere-turns, specified by
the user in the Modeller (X-section = 2.25 x 0.25, density = 2 x 106). We
shall assume this is produced by a coil of 90 turns carrying 12500 Amps
(peak).
The expression for the inductance can be calculated within the software
simply by setting up a new variable and using the system variable energy
which was calculated above.
Select User Double click on Constants => Type variable name and type #inductance.
variable Tab to the Expression field and enter 2*energy/(12500/sqrt(2))**2. Tab to
calculator Description and enter Inductance for steel.
button
A further tab computes the value of the Expression
The inductance is about 113 mH. Click on Close

Post Processing -27
Reading multiple case files

The solution has been examined for the steel bath. Results at other frequen-
cies, different material properties etc (or different output times for transient
solutions) are stored as separate cases in the .op3 file. The second case for
the ceramic bath can be loaded and examined by simply selecting simula-
tion number 2 in the Load Another Simulation dialog box.
Select the Load Select simulation 2

Another Sim-
ulation icon
o
Click on Load and Refresh
In this simulation, the eddy currents in the melt are much larger so the scale
of the vectors needs to be reduced.
Select the 3D Set the Scaling factor for the Vector to 3 x

display icon 10-6. Click on OK
Any of the previous calculations can be repeated for the second case. For
example, Figure 1.8 shows the calculation for the inductance.
Figure 1.8 Calculation of inductance for case 2

-28
The inductance has increased by 35%. The bath and melt are acting simi-
larly to the secondary winding of a transformer. When the bath is made of
steel the eddy current reaction field is stronger than when the eddy currents
are only induced in the melt for the ceramic bath case.
Exit the Post Processor

The post processor is closed down by using File => Exit.

Running an ELEKTRA-TR Simulation -29
Running an ELEKTRA-TR Simulation
ELEKTRA-SS solves the electromagnetic diffusion equation assuming

that all quantities vary sinusoidally with time at the same frequency. This
leads to a complex solution where the solution at any angle in the AC cycle
can be found from a combination of the real and imaginary parts.
ELEKTRA-TR has been developed to model non-sinusoidal time varia-

tion. However, it can also be used to examine models where the excitation
is sinusoidal but the resultant currents and fields are non-sinusoidal
because of non-linear effects or initial "switch-on" transients.
The induction heating model with the ceramic bath will be simulated dur-
ing the first 2 cycles of the AC excitation to examine these switch on
effects.
Setting up the simulation

Return to the Modeller. If the Modeller session has already been closed,
start it again and load the bath.opc model using the file Open button .
ELEKTRA-TR ELEKTRA-TR has 2 options for time-stepping through the transient anal-
data ysis - a fixed time-step or an adaptive time-step. In this simple example, a
fixed time-step will be used. Adaptive time-stepping allows the user to
select the accuracy to which the solution will be calculated. The time-step
will be reduced or increased to achieve the required level of accuracy.
Although ELEKTRA-TR solves the transient equation at each time-step

(whether fixed or adaptive), it only writes a solution into the .op3 database
at times requested by the user.
Model => Analysis Type => ELEKTRA Transient

Model => ELEKTRA Transient Settings

-30
The fixed time-step to be used is 50 milliseconds - that is 20 steps through each

1 Hz cycle. Set Fixed time step to 0.05
Click on Change in Output times

Output of results will be at 0.25, 0.5, 1.25, 1.5 and 2.0 seconds. Set the
New output time to 0.25. Click on Add

Running an ELEKTRA-TR Simulation -31
Repeat this process for values 0.5, 1.25, 1.5 and 2.0
Click on OK
The ELEKTRA-TR data is now complete.
Click on OK
If the model was re-loaded from the .opc file, it has returned the material
properties of the bath to steel. Adding a case to an existing .op3 database
does not create a new .opc file. Repeat the instructions to set the bath mate-
rial to air as shown in Adding a second case on page -18.

-32
Drive function The drive function specifies how the excitation of a coil, circuit component
or boundary condition varies with time. The Drive Label of the coil was
set to d1 which will be assigned as a sinusoidal drive at 1 Hz with 0 degrees
phase lag.
Model => Set Drive Properties

Highlight d1, set the Drive Type to Sine, the Frequency to 1 and the Phase
angle to 0
Click on OK
Running the The analysis could use the same bath.op3 database as for the steady state
Analysis AC simulations. However, for this exercise, a new database will be cre-
ated. Repeat the instructions Create the OP3 file on page -17 to make a
new database called bath_transient.op3.
When the analysis is complete, launch the Post-processor by clicking on

the Post-Process button in the Solver Window.

Post-processing an ELEKTRA-TR solution -33
Post-processing an ELEKTRA-TR solution
The same type of post-processing calculations as for ELEKTRA-SS can be

performed for each simulation result stored in the bath_transient.op3 data-
base. The database contains 6 simulations at the output times 0.0, 0.25, 0.5,
1.25, 1.5 and 2.0 seconds. Figure 1.9 shows the dialog offered to the user
when the Post-Processor is launched.
Figure 1.9 Dialog showing simulations in database
The only difference in post-processing ELEKTRA-TR is that the values of

the solution at each output time are real not complex. Eddy current density
values have been computed from the time differential of the magnetic vec-
tor potential (and the spatial gradient of the electric scalar potential), which
are also stored in the database.
Figure 1.10 through Figure 1.13 show the eddy currents in the melt at 0.25,
0.5, 1.25 and 1.5 seconds respectively. Since this is a sinusoidal drive, 0.25
and 1.25 seconds correspond to the in-phase and 0.5 and 1.5 seconds to the
quadrature parts of the solution - that is, the real and imaginary parts of the
complex ELEKTRA-SS solution. It can be seen that the current density
patterns at 0.25 and 1.25 are very similar, and 0.5 and 1.5 are also very sim-
ilar. Also the 0.5 and 1.5 patterns are very similar to the imaginary part of
the case 2 ELEKTRA-SS solution in bath.op3 (see page -27). This indi-
cates that there are very few switch-on transients and the ceramic induction
heating bath is close to steady state performance even in the first cycle.

-34
Figure 1.10 Eddy current density at 0.25 seconds

Post-processing an ELEKTRA-TR solution -35

-36

2-2 Worked Example Eddy Current

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OPERA-3d Training Course

2-2 An Eddy Current Worked Example

Version 15 OPERA-3d Training Course

OPERA-3d Training Course November 2011

Induction heating example with ELEKTRA-SS

Figure 1.6 Induction heating bath

Version 15 OPERA-3d Training Course

Modelling, Solving and Post-processing

Because of the axisymmetry of the geometry and the "square" racetrack

Figure 1.7 90 degree section of heating bath

The new features introduced in this example are given below.

Creating the model

Solving the problem

OPERA-3d Training Course November 2011

Getting the answer

Version 15 OPERA-3d Training Course

Launch the Modeller

Building the bath and melt

Select the Cyl- Create a 5 metre radius cylinder with

OPERA-3d Training Course November 2011

Select the Select Cylinder1 and, using the context sensi-

Click on Inwards Direction button and set

Version 15 OPERA-3d Training Course

Select the Cyl- Create a 4.75 metre radius cylinder with

Set the Maximum element size to 1

OPERA-3d Training Course November 2011

Improving the discretization

View => Vectors...

Version 15 OPERA-3d Training Course

Create 4 layers each 0.0625 metres deep using

Boundary Condition Definition and Symmetry

Model = > Analysis type => ELEKTRA Steady State

OPERA-3d Training Course November 2011

Model => Create Model Body

Define the Conductors

Version 15 OPERA-3d Training Course

After completing the dialog, go to the Further Options dialog

OPERA-3d Training Course November 2011

Generating the Mesh

Model -> Generate surface mesh

Version 15 OPERA-3d Training Course

Set the Target maximum mesh element size

Model -> Generate volume mesh

Construction of the volume mesh may take up

Create ELEKTRA-SS Database File

The properties of the melt are relative permeability = 1 (because steel

Model -> Set Material Properties

OPERA-3d Training Course November 2011

Click on the Apply button

Click on OK to apply the setting and exit the dialog

Model => ELEKTRA Steady State Settings

Version 15 OPERA-3d Training Course

In the Analysis frequencies section, click on the Change button

Click on OK to accept the change

OPERA-3d Training Course November 2011

Review the final settings of the ELEKTRA-SS Analysis Data dialog

Model => Create Analysis Database

Version 15 OPERA-3d Training Course

Set the Database to bath.op3 and use the pull

Model => Set Material Properties

OPERA-3d Training Course November 2011

Click on Cancel to exit the dialog

Model => Add Simulation to Analysis Database

Click on Prepare and solve to run both cases consecutively