EMA - Home | SPDC · 2013-05-24 · • SAE Technical Committee AE-2 Lightning All facets of...
Transcript of EMA - Home | SPDC · 2013-05-24 · • SAE Technical Committee AE-2 Lightning All facets of...
ELECTRO MAGNETICAPPLICATIONS, INCEMA
Full Wave EM Simulation forLightning Protection
Tim McDonald, [email protected]
Phone: +1 (303) 324-7532www.ema3d.com
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Electro Magnetic Applications, Inc.
• Electromagnetic environmental effects simulation andtesting since 1978
• Rod Perala, president, has been with EMA since 1978• Commercial software development and consulting
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
• Over 30 years of softwaredevelopment, consulting,contract R&D
• Lightning Testing
• ESD
• EMC/EMI• Measurement and
Simulation
• F-14, F-18, Pershing II,Space Shuttle, Sikorsky,GPS Multipath, Cargo Lifter
EMA History
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Lightning Testing: Space ShuttleSolid Rocket Booster (SRB)
• EMA designed testgenerators and facilitybuilt in Wendover,Utah
• Tested several SRBcomponents
• Photo shows testing offirst stage
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Lightning Test Facility inWendover, Utah
• Wire gridpeakingcapacitor
• 1 million voltMarxgenerator
• 500 KAcurrent bank
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Static Electricity:Charging of Aircraft by Dust
• Iraqi dust storm• P-Static effects on
aircraft electronicsystems have beenobserved
• EMA• Developed a description of
the dust environment
• Determined charging ratesof dust on aircraft bymeasurement
• Determined dischargecurrents by analysis andmeasurements
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Measurement of Dust Charging ofAircraft Surface Materials
Example test setup Illumination of test sample
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Design and Simulation of AnechoicChambers (Lehman Chambers)
Combination of carbon loadedpyramids and ferrite tiles
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Anechoic Chambers: Comparison ofMeasured and Computed Results
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Triggered Lightning Simulation on 265mlong Airship
Lightning protectionstrips
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.mkV10axE
Electric Field Enhancement FactorsAxial Field
90 kV/m
ELECTRO MAGNETICAPPLICATIONS, INCEMA
Pershing II Accident Investigation
• In 1985, a PII caught fireduring assembly on its mobilelauncher in Germany
• EMA determined the cause tobe static charging of motorcase while inside its steelshipping canister
• An external static dischargeinduced a discharge insidethe propellant with theKevlar motor case
• Demonstrated by extensiveanalysis and full scale testing
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Railroad EM Effects• In 1997, EMA first became involved
in railroad electromagnetic effects• Lightning protection of railroad
signal systemsFaraday cage implementation inside
bungalowsDevelopment of a new arrester
• Interference of power lines withrailroad signal systems
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Civilian Aviation and Emerging TechnologiesEMA has worked on lightning, HEMP, and HIRF qualification ofcivilian aircraft as well as supporting internal prime contractor andgovernment R&D.
EMA TodayLockheed Martin’s Orion EM TeamLightning and space plasma charging effects for returning humansto space beyond low earth orbit.
GMD Ground Based Interceptor TeamMember of incumbent GMD team working on GBI upgradeand maintenance through its lifecycle.
Worldwide Software Sales and TrainingEMA has successful software sales worldwide aiding E3 and EMCengineers in aerospace, maritime, and automotive applications.
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Active Certification/Design Projects(Lightning)
• Super Medium Helicopter
• Regional Jet
• Midsize Business Jet• Two Narrow-body, Medium-
range Jet Airliners (1 active, 1 innegotiation)
• Missile Defense Agency Rocket
• Orion NASA Crew Vehicle
• Low-wing Turboprop Trainer
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EMA Committee Participation
• SAE Technical Committee AE-2 Lightning All facets of aircraft lightning strikes and its effects on aircraft-design, testing, measurement,
procedures, and in-service experience. Rod Perala was on the SAE AE2 from 1981 to 2001, where he helped to develop lightning
qualification waveforms and standards that are in use today. Since 2001, Greg Rigden of EMA has been on the committee and is chairman of the
environment subcommittee to update the lightning environment standards to conform to newresearch results.
• SAE Technical Committee AE-4R HIRF All facets of HIRF effects on aircraft-design, testing, measurement, procedures, and in-service
experience. Rod Perala was on the SAE AE4R from its beginning in about 1986 until about 1996. This committee developed the original environments and certification approaches and test
methods for HIRF certification. EMA also did some specialty tasks for the FAA related to HIRF risk assessment, which resulted
in some FAA technical reports.
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The Lightning Problem
• Design Phase: Need analysis to support system designbefore any testable prototypes exist.
• Certification Phase: Need an experimentally validatedmodel to reduce test costs and ensure viability in allpossible scenarios.
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The Lightning Problem
• The lightning levels are specified for the entiresystem
• There are no test levels for individual elements• Lightning effects depend on current distribution in
the entire system
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However . . .
• The system may not yet exist for testing
• If it does exist, full-scale lightning testing is expensive
• Full-scale testing is complicated by the ground plane and returnconductor system effects (ARP 5583 requires additional simulationsupport to full-scale testing)
• A limited set of attachment scenarios can be practically assessed• Design changes after the test are a problem
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Status Quo Approaches
• Use the test results of a previous project• Use poorly-suited analytical methods with a great
deal of margin
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Status Quo IssuesUse the test results of a previous project:
• The materials (use of composites) and bonding designmay be significantly different between designs
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Current Generation ofComputational Electromagnetics
• Mature codes (continuously under developmentsince 1978 and applied to hundreds of systems)
• Optimized for system level electromagneticsincluding lightning in complex systems
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Simulation Work FlowOriginal CAD
drawing
From Mech. Eng. Designers
CEM CADEnvironment
Imports CAD formats
3D CEM
Solves down to20 mm resolution
Harness Sim.
Transients/levels atpins/interfaces
CouponTesting
Experimental testlevels by analysis
ActionableResults
• Actual Transient Levels• Model Validation• Design Requirements• Tailored Test Levels• Design Evaluation• Certification Support
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Composite Materials
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• Complex material modeling challenges with individualcomposite layers and interaction with fasteners
ELECTRO MAGNETICAPPLICATIONS, INCEMA
Understanding Composite TestCoupon Properties
• EMA has developed methods to measure individual layeranisotropic conductivity properties
• A simulate-measure-simulate approach ensures a completeunderstanding of current distribution in each couponscenario
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Experimentally ValidatedApproach
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Representing Composite Joints inSimulations
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Validation
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• EMA has achieved a successful validation of simplified boxes• This lowers the cost versus a full wing validation and allows for use of
simulation results in certification
ELECTRO MAGNETICAPPLICATIONS, INCEMA
EMA Validation Heritage
• EMA has been doing this since one of the first composite fueltanks was placed in SAAB Gripen Fighter
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Validation Heritage
• MD-80 Simulation Compared to Test Data• High degree of correlation allowed for IEL
certification of MD-90 by simulation
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Recent Validation
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Fuel System validation Object
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Results
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Integrated Harness Simulation
• Lightning: MHARNESS gives transients at the pinlevel. Necessary for accurate results.
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Simulation Platform Size
• EMA3D integrated with MHARNESS is available as acluster version to operate in parallel over many nodes
• Extremely efficient scaling on computational clusters• Successfully used to simulate entire aircraft and large
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Lightning Redistribution
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Current on Ribs
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Pipe and Cable Currents
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Wind Turbine Simulation Example
CAD imported from STEP format
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Cables
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
New Cables in EMA3D CAD
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FDTD Cartesian Mesh (50 mm)
Meshing operation takes < 5 minutesAll materials are steel
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Cable Cross Section
Cable 1 Cable 2 Cable 3
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
EMA3D Cable Cross Section Tool
EMA3D has the uniquecapability of Co-simulatingwith a full-featuredTransmission Line Solver
•Ability to quickly calculatethe accurate capacitance andinductance matrix for cablecross-section•Easy drag and drop cablecross section tool
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Material Library
EMA3D includes built-in sampleproperties for standard types ofcables•Diameter•Resistance•Transfer impedanceparameters
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Computational Simulation
CEM simulation completed in about two hours•Gradual permittivity scaling speeds up time-domainsimulation by a factor or more than ten•Built-in parallel simulation capabilities allow for speedup over 100 times on multi-core workstations andcomputational clusters
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Magnetic Field Slice Probe
LightningChannel
Log of H-field normal to page is proportional to color47
ELECTRO MAGNETICAPPLICATIONS, INCEMA
Current Density Animation
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Source Waveform
•The first case will be the standard 200 kA Component AWaveform 1 (~ 5 μs peak, slow fall)
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Waveform 1 Overall Cable BundleCurrent
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Waveform 1 Individual PinCurrent
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Waveform 1 Individual Pin Voltage
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DC Simulation
Gradual permittivity scaling allows for a time-domaincalculation of a ramp up to DC as described.•Simulation completed in a little over an hour•Impossible to complete with other time-domain solvers
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Ramp to 800 A DC SimulationResults: Pin Currents
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Summary
• Computation electromagneticsis critical for model complexsystem design and verification
• New simulation techniquesinteroperate with CAD
• Mature validation heritagemeans that the results can betrusted
• Applicable to wind turbinesand related systems
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ELECTRO MAGNETICAPPLICATIONS, INCEMA
Contact us with any questions!
Tim McDonald, PhD11 October [email protected]
Phone: +1 (303) 324-7532www.ema3d.com
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