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Flux3D coil conductor definition problem.

Hello everyone,

I'm encountering an error when trying to use the "Orient wires of coil conductor regions" feature in Flux3D 2025.0

The error log shows the following:

WIRE1 : On each volume of this region, the number of points on the
input faces must be equal to the number of points of
the output faces and to the number of lines between
the input and output faces.
Please, modify the geometry of each volume of this region
to resolve correctly this problem.
WIRE2 : On each volume of this region, the number of points on the
input faces must be equal to the number of points of
the output faces and to the number of lines between
the input and output faces.
Please, modify the geometry of each volume of this region
to resolve correctly this problem.

As the error message suggests, I have already carefully checked the input and output faces for the volume regions (WIRE1 and WIRE2). I've confirmed that they have the same number of points and edges, but the error still occurs.

Could anyone offer some advice on what else I should check? Any help would be greatly appreciated!

Thank you,

Leon Lin

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Ovando_RBB

Hi there,

It will be worth if you can share a screenshot of the conductor region; to me it looks like your conductor geometry is open and you are trying to apply a "coil conductor" rather than a "solid conductor" in your model and circuit. If that is the case, just delete the "coil conductor" (looks like a cylinder with strands) from your circuit and replace it with a "solid conductor" (looks like a cylinder without strands).

Hope this helps!

Leon Lin

Thanks for your reply.

I want to construct a stranded coil, but it seems Flux 3D does not directly support the creation of helical parts for the coil geometry.

However, the coil I need to model has a more complex geometry, so using a simple cylinder for the volume is not sufficient.

Is there other method for building litz wire(with skin effect and proximity effect)?

Ovando_RBB

Hi there,

Flux is capable analyzing complex geometries; please see Fig. 1.

I believe the issue you're encountering is not having created the infinite box that will represent the volume of air surrounding the coil. In order to do achieve that follow these steps:

Import/create your coil geometry (you did this already with your spiral coil).
Go to the menu on the left search geometry>domain>infinite box, right mouse click and select "new". Proceed to define the dimensions of the volume of air in such a way that the volume of air encloses completely the volume of the coil (see Fig. 2).
Click on the "build volumes" icon in the top menu (Fig. 3).
Create your electric circuit as shown in Fig. 4 using the "solid barrel" symbol (and not the stranded barrel).
Proceed to open your "coil volume region" and proceed to declare it as Type region> solid conductor region (Fig. 5).
Go to the menu at the top physics>assign terminals to solid conductors>assign terminals to solid conductors 2 terminals (completion mode). A new window will poop up (Fig. 6), leave the "external terminals" drop down menu as it is and proceed to click on the "»" arrows for flux to let you chose first the face that is the inlet and afterwards the face that is the outlet.
Create your mesh and solve.

Regarding to the modelling of litz wire; there is a good post from @Nicolas_ABDELNOUR where he goes through two option to model litz wire: 1) as individual conductors (very computationally demanding), 2) as a solid region using stranded equivalent conductors. I am sharing with you the link to the post below.

Hope this comment helps!

https://community.altair.com/discussion/39529/litz-wire-modeling-in-flux-use-a-homogenized-face-region-to-modelize-all-your-coil-conductors-and-save-computation-time

FIG. 1

FIG. 2

FIG. 3

FIG. 4

FIG. 5

FIG. 6

Leon Lin

I appreciate the simulation setup. However, it looks like a solid conductor(not coil conductor) has been implemented. My goal is to simulate a litz wire, so we'll need to adjust for that.

Ovando_RBB

Hi there,

Oh, I understand now; in that case you will need to apply the specific litz wire model resistance value provided by the manufacturer. This is as follows:

Use coil conductor region in your circuit. Add the manufacturer resistance value at the "additional resistance" field (Fig. 1). Afterwards, go to the coil region and deactivate the "compute coil losses" box from the menu shown in Fig. 2. This way Flux will be able to compute the losses in the Litz wire using the litz manufacturer resistance value that you provided.

FIG. 1

FIG. 2

As a reference, find attached an excellent document from New England Wire Technologies, which provides a trustworthy method for estimating litz wire resistance. It may serve as a helpful guide when applying this method.

Hope this comment helps!

LITZ_101_02.pdf

Leon Lin

Drew a helical line, and meshed it.

2. Set up circuit with coil conductor.

3. Assign coil region with detail description(cause I need to considers proximity and skin effects).

4. An error occurred when I checked the physics settings.

The volume Region COIL is a coil conductor region with losses.

It must not include lines with are neither straight lines,

arcs of circle nor helical lines (not implemented case).

This is the issue I'm getting. Any ideas on what I might be doing wrong?

Thanks a lot.