Merge branch 'main' of https://github.com/upb-lea/FEM_Magnetics_Toolbox

upb-lea · Apr 28, 2022 · ce6eed3 · ce6eed3
2 parents e8b447b + 4185eb1
commit ce6eed3
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diff --git a/.gitignore b/.gitignore
@@ -41,4 +41,7 @@ femmt/thermal/solver/Group.pro
 femmt/thermal/solver/Parameters.pro
 
 # Used for integration test
-!tests/integration/fixtures/results/result_log_electro_magnetic.json
+!tests/integration/fixtures/results/result_log_electro_magnetic.json
+
+# Example files
+femmt/examples/paper_thermal_validation
diff --git a/CHANGELOG.md b/CHANGELOG.md
@@ -11,6 +11,7 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 
 ### Added
 - conductor material can be chosen from a small material database, used in update_conductors(), e.g. conductivity_sigma=["copper"]
+- isolations for thermal simulation
 
 ### Fixed
 - fix #15: Secondary to Core isolation thickness not working

diff --git a/femmt/examples/ba_examples.py b/femmt/examples/ba_examples.py
@@ -9,18 +9,18 @@ def example_thermal_simulation(geo):
     # The case parameter sets the thermal conductivity for a case which will be set around the core.
     # This could model some case in which the transformer is placed in together with a set potting material.
     thermal_conductivity_dict = {
-            "air": 3, # potting
+            "air": 0.122, # potting
             "case": { # epoxy resign
-                "top": 3,
-                "top_right": 3,
-                "right": 3,
-                "bot_right": 3,
-                "bot": 3
+                "top": 0.122,
+                "top_right": 0.122,
+                "right": 0.122,
+                "bot_right": 0.122,
+                "bot": 0.122
             },
             "core": 5, # ferrite
             "winding": 400, # copper
-            "air_gaps": 3, # aluminium nitride
-            "isolation": 3 # TODO Find material
+            "air_gaps": 0.122, # aluminium nitride
+            "isolation": 0.122 # TODO Find material
     }
 
     # Here the case size can be determined
@@ -91,14 +91,58 @@ def basic_example():
     # Add conductors
     geo.update_conductors(n_turns=[[21], [7]], conductor_type=["solid", "solid"],
                         litz_para_type=['implicit_litz_radius', 'implicit_litz_radius'],
-                        ff=[None, 0.6], strands_numbers=[None, 600], strand_radii=[70e-6, 35.5e-6],
+                        ff=[None, None], strands_numbers=[None, None], strand_radii=[None, None],
                         conductor_radii=[0.0011, 0.0011],
                         winding=["interleaved"], scheme=["horizontal"],
                         core_cond_isolation=[0.001, 0.001, 0.002, 0.001], cond_cond_isolation=[0.0002, 0.0002, 0.0005],
                         conductivity_sigma=["copper", "copper"])
 
     # Create model
-    geo.create_model(freq=100000, visualize_before=True, do_meshing=False)
+    geo.create_model(freq=250000, visualize_before=True)
+
+    #geo.single_simulation(freq=250000, current=[4, 12], phi_deg=[0, 180], show_results=True)
+
+    thermal_conductivity_dict = {
+        "air": 0.0263,
+        "case": {
+            "top": 1.54,
+            "top_right": 1.54,
+            "right": 1.54,
+            "bot_right": 1.54,
+            "bot": 1.54
+        },
+        "core": 5,
+        "winding": 400,
+        "air_gaps": 180,
+        "isolation": 0.42
+    }
+
+    case_gap_top = 0.002
+    case_gap_right = 0.0025
+    case_gap_bot = 0.002
+
+    boundary_temperatures = {
+        "value_boundary_top": 20,
+        "value_boundary_top_right": 20,
+        "value_boundary_right_top": 20,
+        "value_boundary_right": 20,
+        "value_boundary_right_bottom": 20,
+        "value_boundary_bottom_right": 20,
+        "value_boundary_bottom": 20
+    }
+    boundary_flags = {
+        "flag_boundary_top": 1,
+        "flag_boundary_top_right": 1,
+        "flag_boundary_right_top": 1,
+        "flag_boundary_right": 1,
+        "flag_boundary_right_bottom": 1,
+        "flag_boundary_bottom_right": 1,
+        "flag_boundary_bottom": 1
+    }
+
+    geo.thermal_simulation(thermal_conductivity_dict, boundary_temperatures, boundary_flags, case_gap_top, case_gap_right, case_gap_bot, True)
+
 
 if __name__ == "__main__":
-    pq4040()
+    pq4040()
+    #basic_example()
diff --git a/femmt/examples/basic_example.py b/femmt/examples/basic_example.py
@@ -10,20 +10,18 @@ def example_thermal_simulation():
     # The case parameter sets the thermal conductivity for a case which will be set around the core.
     # This could model some case in which the transformer is placed in together with a set potting material.
     thermal_conductivity_dict = {
-            "air": 3,
+            "air": 0.0263,
             "case": { # epoxy resign
-                "top": 3,
-                "top_right": 3,
-                "right": 3,
-                "bot_right": 3,
-                "bot": 3
+                "top": 0.122,
+                "top_right": 0.122,
+                "right": 0.122,
+                "bot_right": 0.122,
+                "bot": 0.122
             },
             "core": 5, # ferrite
             "winding": 400, # copper
-            #"air_gaps": 180, # aluminium nitride
-            #"air_gaps": 5, # aluminium nitride
-            "air_gaps": 3,
-            "isolation": 3 # TODO Find material
+            "air_gaps": 180, # aluminiumnitride
+            "isolation": 0.42 # polyethylen
     }
 
     # Here the case size can be determined
@@ -64,7 +62,10 @@ def example_thermal_simulation():
     # order for the thermal simulation to work (geo.single_simulation is not needed).
     # Obviously when the model is modified and the losses can be out of date and therefore the geo.single_simulation needs to run again.
     geo.thermal_simulation(thermal_conductivity_dict, boundary_temperatures, boundary_flags, case_gap_top, case_gap_right, case_gap_bot, True)
-    #geo.femm_thermal_validation(thermal_conductivity_dict, femm_boundary_temperature)
+
+    # Because the isolations inside of the winding window are not implemented in femm simulation.
+    # The validation only works when the isolations for the FEMMT thermal simulation are turned off.
+    # geo.femm_thermal_validation(thermal_conductivity_dict, femm_boundary_temperature, case_gap_top, case_gap_right, case_gap_bot)
 
 component = "inductor"
 # component = "transformer-interleaved"

diff --git a/femmt/femmt_classes.py b/femmt/femmt_classes.py
@@ -249,10 +249,8 @@ def calculate_core_volume(self) -> float:
 
             air_gap_volume += np.pi * width**2 * height
 
-        #return (core_height * core_width - winding_height * winding_width - air_gap_area)*
-        print("Core volume calculated:", np.pi*(core_width**2 * core_height - winding_width**2 * winding_height) - air_gap_volume, "|Core volume ansys:", 1.996159905*10**-5)
-        #return np.pi*(core_width**2 * core_height - winding_width**2 * winding_height) - air_gap_volume
-        return 1.996159905*10**-5
+        # TODO Is this right?
+        return np.pi*(core_width**2 * core_height - winding_width**2 * winding_height) - air_gap_volume
 
     def get_wire_distances(self):
         wire_distance = []
@@ -321,7 +319,7 @@ def thermal_simulation(self, thermal_conductivity, boundary_temperatures, bounda
             "wire_distances": self.get_wire_distances(),
             "show_results": show_results,
             "pretty_colors": True,
-            "show_before_simulation": True
+            "show_before_simulation": False
         }
 
         run_thermal(**thermal_parameters)
@@ -3669,7 +3667,10 @@ def generate_hybrid_mesh(self, do_meshing=True, visualize_before=False, save_png
                     gmsh.model.setColor([(2, self.plane_surface_core[i])], 50, 50, 50, recursive=True)  # Core in gray
                 #gmsh.model.setColor([(2, self.plane_surface_air[0])], 0, 0, 0, recursive=True)
                 #gmsh.model.setColor([(2, self.plane_surface_air[0]), (2, self.plane_surface_air_gaps[0])], 181, 181, 181, recursive=True)
-                gmsh.model.setColor([(2, self.plane_surface_air[0]), (2, self.plane_surface_air_gaps[0])], 100, 60, 60, recursive=True)
+                if self.plane_surface_air_gaps:
+                    # only colorize air-gap in case of air gaps
+                    gmsh.model.setColor([(2, self.plane_surface_air[0]), (2, self.plane_surface_air_gaps[0])], 100, 60,
+                                        60, recursive=True)
                 #gmsh.model.setColor([(2, iso) for iso in self.plane_surface_iso_core + self.plane_surface_iso_pri_sec], 100, 100, 100, recursive=True)
                 #gmsh.model.setColor([(2, self.plane_surface_air[0])], 181, 181, 181, recursive=True)  # Air in white
                 for num in range(0, self.component.n_windings):
@@ -4978,7 +4979,7 @@ def femm_thermal_validation(self, thermal_conductivity_dict, boundary_temperatur
         # == Materials ==
         # Core
         k_core = thermal_conductivity_dict["core"]
-        q_vol_core = (losses["Core_Eddy_Current"] + losses["Core_Hysteresis"]) / self.calculate_core_volume()
+        q_vol_core = losses["core"] / self.calculate_core_volume()
         # c_core = 0.007
         c_core = 0
 
@@ -5007,11 +5008,11 @@ def femm_thermal_validation(self, thermal_conductivity_dict, boundary_temperatur
         # Setup winding list
         winding_losses_list = []
         for i in range(1, 3):
-            key = f"Winding_{i}"
+            key = f"winding{i}"
             inner_winding_list = []
             if key in losses:
-                for loss in losses[key]["Turns"]:
-                    inner_winding_list.append(loss)
+                for winding in losses[key]["turns"]:
+                    inner_winding_list.append(winding)
             winding_losses_list.append(inner_winding_list)
 
         # Setup materials

diff --git a/femmt/femmt_functions.py b/femmt/femmt_functions.py
@@ -943,10 +943,10 @@ def visualize_simulation_results(simulation_result_file_path: str, store_figure_
     with open(simulation_result_file_path, "r") as fd:
         loaded_results_dict = json.loads(fd.read())
 
-    inductance = loaded_results_dict["Fluxes"]["L_11"][0]
-    loss_core_eddy_current = loaded_results_dict["Losses"]["Core_Eddy_Current"]
-    loss_core_hysteresis = loaded_results_dict["Losses"]["Core_Hysteresis"]
-    loss_winding_1 = loaded_results_dict["Losses"]["Winding_1"]["total_winding"]
+    inductance = loaded_results_dict["single_sweeps"][0]["winding1"]["self_inductivity"][0]
+    loss_core_eddy_current = loaded_results_dict["total_losses"]["eddy_core"]
+    loss_core_hysteresis = loaded_results_dict["total_losses"]["hyst_core_fundamental_freq"]
+    loss_winding_1 = loaded_results_dict["total_losses"]["winding1"]["total"]
 
     print(inductance)
     print(loss_core_eddy_current)

diff --git a/femmt/thermal/solver/Thermal.pro b/femmt/thermal/solver/Thermal.pro
@@ -29,5 +29,5 @@ PostOperation map UsingPost The {
 
   Print[ T, OnElementsOf Total , File thermal_file];
   Print[ influx, OnElementsOf Warm , File thermal_influx_file];
-  Print[ material, OnElementsOf Total , File "material.pos"];
+  Print[ material, OnElementsOf Total , File thermal_material_file];
 }
diff --git a/femmt/thermal/thermal_functions.py b/femmt/thermal/thermal_functions.py
@@ -10,19 +10,15 @@ def calculate_heat_flux_round_wire(power, wire_radius, wire_distance):
     # Power density for volumes W/m^3
     #volume = 2 * np.pi**2 * wire_radius**2 * wire_position_x
     volume = 2 * np.pi**2 * wire_radius**2 * wire_distance
-    ansys_volume = 4.419115371*10**-7
-
-    print("Calculated winding volume:", volume, "|ANSYS winding volume:", ansys_volume)
 
     return power/volume
-    #return power/2*np.pi*wire_radius
 
 def read_results_log(results_log_file_path):
     losses = {}
     if not os.path.exists(results_log_file_path):
         raise Exception(f"Losses file not found {results_log_file_path}.")
     with open(results_log_file_path, "r") as fd:
         content = json.loads(fd.read())
-        losses = content["Losses"]
+        losses = content["total_losses"]
 
     return losses
diff --git a/femmt/thermal/thermal_simulation.py b/femmt/thermal/thermal_simulation.py
@@ -68,7 +68,7 @@ def create_background(background_tag, k_air, function_pro: FunctionPro, group_pr
 
 def create_core_and_air_gaps(core_tag, k_core, core_area, core_losses, air_gaps_tag, k_air_gaps, function_pro: FunctionPro, group_pro: GroupPro):
     heat_flux = core_losses/core_area
-
+    print(heat_flux)
     if air_gaps_tag is not None:
         k = {
             "core": k_core,
@@ -106,6 +106,7 @@ def create_windings(winding_tags, k_windings, winding_losses, conductor_radii, w
                 name = f"winding_{winding_index}_{index}"
                 windings_total_str += f"{name}, "
                 q_vol[name] = calculate_heat_flux_round_wire(winding_losses[winding_index][index], conductor_radii[winding_index], wire_distances[winding_index][index])
+                print(q_vol[name])
                 k[name] = k_windings
                 regions[name] = tag
                 for entity in gmsh.model.getEntitiesForPhysicalGroup(2, tag):
@@ -157,6 +158,7 @@ def run_thermal(onelab_folder_path, results_folder_path, model_mesh_file_path, r
     # Relative paths
     map_pos_file = path.join(results_folder_path, "thermal.pos")
     influx_pos_file = path.join(results_folder_path, "thermal_influx.pos")
+    material_pos_file = path.join(results_folder_path, "thermal_material.pos")
     solver_folder_path = path.join(os.path.dirname(__file__), "solver")
     thermal_template_file = path.join(solver_folder_path, "Thermal.pro")
     parameters_file = path.join(solver_folder_path, "Parameters.pro")
@@ -176,20 +178,21 @@ def run_thermal(onelab_folder_path, results_folder_path, model_mesh_file_path, r
 
     parameters_pro.add_to_parameters({
         "thermal_file": map_pos_file.replace("\\", "/"),
-        "thermal_influx_file": influx_pos_file.replace("\\", "/")
+        "thermal_influx_file": influx_pos_file.replace("\\", "/"),
+        "thermal_material_file": material_pos_file.replace("\\", "/")
     })
 
     # Extract losses
     winding_losses = []
     for i in range(1, 3):
-        key = f"Winding_{i}"
+        key = f"winding{i}"
         inner_winding_list = []
         if key in losses:
-            for loss in losses[key]["Turns"]:
-                inner_winding_list.append(loss)
+            for winding in losses[key]["turns"]:
+                inner_winding_list.append(winding)
         winding_losses.append(inner_winding_list)
 
-    core_losses = losses["Core_Eddy_Current"] + losses["Core_Hysteresis"]
+    core_losses = losses["core"]
 
     # TODO All those pro classes could be used as global variables
     case_dim_tags = create_case(tags_dict["boundary_regions"], boundary_physical_groups, boundary_temperatures, boundary_flags, thermal_conductivity_dict["case"], function_pro, parameters_pro, group_pro, constraint_pro)

diff --git a/gui/femmt_gui.py b/gui/femmt_gui.py
@@ -1275,10 +1275,10 @@ def md_action_run_simulation(self) -> None:
         self.md_loss_plot_label.setMask(pixmap.mask())
         self.md_loss_plot_label.show()
 
-        inductance = loaded_results_dict["Fluxes"]["L_11"][0]
-        loss_core_eddy_current = loaded_results_dict["Losses"]["Core_Eddy_Current"]
-        loss_core_hysteresis = loaded_results_dict["Losses"]["Core_Hysteresis"]
-        loss_winding_1 = loaded_results_dict["Losses"]["Winding_1"]["total_winding"]
+        inductance = loaded_results_dict["single_sweeps"][0]["winding1"]["self_inductivity"][0]
+        loss_core_eddy_current = loaded_results_dict["total_losses"]["eddy_core"]
+        loss_core_hysteresis = loaded_results_dict["total_losses"]["hyst_core_fundamental_freq"]
+        loss_winding_1 = loaded_results_dict["total_losses"]["winding1"]["total"]
 
         self.md_loss_core_hysteresis_label.setText(f"Core Hysteresis loss: {loss_core_hysteresis} W")
         self.md_loss_core_eddy_current_label.setText(f"Core Eddy Current loss: {loss_core_eddy_current} W")

diff --git a/setup.py b/setup.py
@@ -43,6 +43,7 @@
 					  'onelab>=1.0',
 					  'scipy>=1.7.2',
                       'pytest',
+                      'PyQt5>=5.15.6',
 					  ],
     license="GNU General Public License v3",
     long_description=readme + '\n\n' + history,