Journal of Microwaves, Optoelectronics and Services on Demand

Electromagnetic Applications
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J. Microw. Optoelectron. Electromagn. Appl. vol.10 no.1 São Caetano do
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http://dx.doi.org/10.1590/S2179-10742011000100022 Article

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Analysis of magnetic force production in slider
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actuators combining analytical and finite element
methods How to cite this article

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Antônio Flavio Licarião Nogueira
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Departamento de Engenharia Elétrica Universidade do Estado de Santa Related links
Catarina Joinville, Santa Catarina, Brazil E-mail: [email protected]
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ABSTRACT
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The production of magnetic forces in a magnetic actuator is the focus of
the present analysis. Magnetic circuit analysis is used to investigate the
direction as well as the expected order of magnitude of the force that attracts the armature into the central
portion of a stationary core. A sequence of finite-element based solutions is used to investigate magnetic
saturation and to determine the force-displacement characteristic. The analytical approach is based on the
principle of virtual work and Ampère's law. The force calculations based on numerical field solutions employ the
methods of weighted Maxwell stress tensor and the classical virtual work. The more accurate field-derived
solutions are used to explain the limitations of the analytical calculations. At the end, an alternative approach to
compute the force numerically is proposed. This method is based on the principle of virtual work, but only one
field solution is required.

Index Terms-Energy storage, finite element methods, magnetic circuits, magnetic forces.

I. INTRODUCTION
Calculation of forces and torques from numerical field solutions is often subject to large numerical errors. Any
simplifications made during the modeling of the device, and the numerical approximations assumed during the
solution of the field equations result in field distributions that are, inherently, approximate. The evaluation of
forces and torques invariably involves some kind of numerical differentiation, and this tends to give rise to
errors in the computed forces and torques that are greater than the errors in the potential solutions. A factor
that adversely affects the accuracy of some force calculation methods is the presence of magnetic saturation,
and this should be considered during the choice of the force calculation method.
There is not a single force calculation method able to produce consistent and accurate results across a range of
devices; the geometry of the device and its intended application should thus be considered prior to the actual
modeling and choice of the force calculation method. An initial inspection of the device's geometry can provide
information regarding the nature of the field distribution, and help to identify regions where a greater amount of
field energy is stored, as well as regions where the field solution is more likely to be in error. It is usually
possible, at an early stage, to investigate the direction of the developed forces and torques, and their likely
distributions. The literature documents extensive research into the magnetic forces produced in linear actuators,
as well as into the torques produced by electric motors and other rotating devices [1], [2]. Two of the most
popular types of actuators have cores in the shape of "C" and "E", and are commonly referred to as C-core and
E-core actuators, respectively. C-core actuators have been chosen by Kim, Lowther and Sykulski [3] to evaluate
the accuracy of force computation algorithms developed to determine global forces, as well as force distributions
over the surface of a magnetized body. Magnetic cores in the shape of "E" have been used by Barre et al [4] in
the study of mechanical vibrations and audible noise emitted by industrial inductors. The experiment reported
by Lowther and Freeman [5] to introduce force calculation methods involves force measurements and computer-
based simulations of an EI-core actuator. Many parametric studies of ac contactors consisting of either, EE-cores
[6] or EI-cores [7], are easily found in the literature. Elementary discussions on force development at iron-air
interfaces appropriate to linear actuators may be found in [8].

The aim of the present analysis is to investigate different features that affect the force production of a particular
magnetic actuator. The problem concerns the computation of the global forces acting on a plunger of 16 mm
height and 20 mm depth being attracted into a C-core. The total magnetomotive force is 5.0 kA-turns, and an
outline of the problem geometry is shown in Fig. 1. Only the parts that affect the electromagnetic action of the
slider actuator are presented in the illustration.

The type of slider actuator shown in Fig. 1 is less popular, and its analysis is more difficult than that of the
actuators containing armatures that are essentially external to the stationary core. In the latter class of
actuators, when the armature moves towards the stationary core, the stored magnetic energy in the air gap
regions always increases. In the slider actuator, when the plunger moves in towards the coil, the stored energy
in the region between the plunger and the coil becomes smaller, whereas the energy stored in the two
overlapping gaps increase. A curious feature of this particular actuator is that the useful, net force attracting the
plunger is actually produced by the leakage field in the actuator's window rather than the field in the
overlapping gaps.

The present study starts with an inspection on the direction and magnitude of the force developed in the slider
actuator. This is followed by the planning of the finite element model, especially in its aspects concerning the
sequence of static solutions that simulate the displacement of the movable part.

Three force calculation methods are employed in the analysis of the computer-based problems: (i) virtual work;
(ii) Maxwell stress tensor; (iii) weighted Maxwell stress tensor. Under their classical formulations, the first two
methods can be applied for the force evaluation of practically any device [9]. In the following, the basis of the
first two methods are used in the analytical development, whereas the third one is used to compute force values
from the finite element solutions. The method of weighted Maxwell stress tensor is recognized for producing
accurate and consistent force predictions, and one of its major advantages is its adequacy to the analysis of
magnetically saturated devices. The mathematical formulation of this method is presented in [10].

II. ANALYTICAL CALCULATIONS

A. Direction of the force

Consider a closed surface placed in the air region surrounding the magnetic plunger, as shown in the illustration
of Fig. 2. The total magnetic force acting on the body may be found through the integration of the Maxwell field
stresses in the air space over this surface [11]. In two dimensions, the surface of integration becomes a contour
of integration. In this particular analysis, it is assumed that the magnetic parts are highly permeable. The two
short gaps crossed by the segments a-b and f-g are the regions where the H-field is more intense, more uniform
and where a considerable amount of the system's energy is stored. If each gap is viewed as a magnetic dipole,
it becomes clear that attractive forces are developed in both gaps. The attractive force transmitted to the
plunger through the face a-b acts in the +y direction, whereas that transmitted through the face f-g acts in the
-y direction. Due to the symmetry of the structure, these two forces cancel.

Yet considering the short length of the overlapping gaps, and the resulting uniformity of the H-field, it is may be
expected a negligible contribution of the fringing fields to the force transmitted through faces b-c and e-f. In
addition, the faces indicated by a-i, i-h and h-g may be considered remote regions where the H-field is also
negligible. The force acting on the face c-e should then be considered. The field distribution in the actuator's
window is very difficult to determine analytically, although not numerically. With the aid of the idealized flux
lines that appear in the illustration, it is possible to observe that part of the magnetic flux emerging from the
upper limb of the stationary core bends towards the front edge of the plunger and strikes the air-iron interface
at right angles. On the left hand side, close to the coil, a smaller proportion of the magnetic flux crosses the air
region in the -y direction, but gives no contribution to the developed force. As a result of the attractive force
represented by the bending flux lines that cross the faces c-d and d-e, and observing the symmetry of the
structure with respect to a horizontal line that bisects the device, it becomes clear that the vertical components
of the forces pulling the upper and lower halves of the front edge in opposite directions, cancel. Therefore, the
net force that tends to move the magnetic plunger is wholly accounted for by the horizontal components of the
force density in the -x direction. In other words, the net force can be simply calculated by numerical integration
of the force densities along the faces c-d and d-e.

B. Magnitude of the force

To estimate the order of magnitude of the force by the method of virtual work, it is assumed magnetic linearity
in a way that the system's coenergy can be approximated by its stored magnetic energy. In addition, it is
assumed the presence of uniformly developed magnetic fields in two adjacent air-filled regions, namely the
actuator's window and the overlapping gaps. The essence of this simplified approach is the assumption that the
change in the system's energy with movement is mainly confined to these air regions that are "deformed" by
the movement.

A cross-sectional view of the device is shown in Fig. 3. The height lw of the window is 20 mm, and the length lg
of each overlapping gap is 2 mm. The depth of the device is z=20 mm, and all parts of the actuator are
considered longitudinally uniform. In this illustration, a is a constant and denotes the maximum distance the
plunger can move into the cavity; the variable x is measured from left to right and represents the distance
between the coil's right edge and the plunger's front edge. According to this, the amount of overlap is d=a-x. In
the following development, Δx denotes the positional displacement associated with the classical virtual work
method. The selection of the positional displacement defines the sequence of perturbed system solutions used
to obtain, either a single force estimate or a force-displacement characteristic. In the illustration of Fig. 3, the
variable Δx may be interpreted as the small amount of "deformation" in the air-filled regions caused by the
plunger movement in the -x direction.
The derivation assumes no change in the mean value of the flux density B of the air-filled regions at two
consecutive positions. Therefore, the density of magnetically stored energy does not change with movement,
and the change in stored energy is expressed in terms of the volumes of air of each adjacent region, before and
after the displacement.

Let Ew denote the magnetic stored energy in the volume of air, Vw, of the stator window. For a mean flux density
2 -7
Bw in the window region, the density of magnetic stored energy is (Bw) /2µ0, and µ0=4πx10 H/m is the
magnetic permeability of free space. The corresponding magnetic stored energy is

Similarly, let Eo denote the magnetic stored energy in the volume of air, Vo, of one overlapping gap. For a mean
2
flux density Bo in the gap region, the density of magnetic stored energy is (Bo) /2µ0. The corresponding stored
energy is

After a short displacement Δx of the plunger in the -x direction, the width of the window decreases from x to
(x-δx), and its volume decreases from xlwz to (x-δx)lwz . The width of the overlapping gap increases from d to
(d+δx), and its volume increases from dlgz to (d+δx)lgz .

The energy difference δE is calculated taking into account the reduction in the volume Vw of the window, and the
simultaneous increase in the volume of the two overlapping gaps. After some algebraic manipulations, one gets

According to the principle of virtual work, an estimate for the force, Fx, can be obtained by the ratio of the
energy difference δE with respect to the small positional displacement δx,

The closed contours C1 and C2 that appear in the illustration of Fig. 4 are used in the calculation of the magnetic
flux densities in the actuator's window and overlapping gaps. If the magnetic field intensity H is assumed to be
negligible in the magnetized parts of the contours, application of Ampère's law along the contour C1 gives an
estimation for the flux density Bw in the actuator's window,
In a similar way, integration along the contour C2 gives an estimation for the flux density Bo in each of the two
gaps,

An estimate for the order of magnitude of the force can now be obtained. Based on the flux densities computed
by (5) and (6), the magnitude of the force calculated by (4) is 62.8 N. In a later section, this force value will be
contrasted with the force-displacement characteristic.

In practical terms, the accuracy of this simplified approach is mainly related to the geometrical dimensions of
the actuator, to know: i) the distance a between the coil's right edge and the rightmost edge of the C-core; ii)
the width d of the overlapping gaps, as indicated in Fig. 3. For larger widths, the approximations to the
distributions of flux density given by (5) and (6) become less accurate. This loss of accuracy clearly affects the
calculation of parameters like the forces calculated by (4). Fortunately, most magnetic actuators produce motion
over a limited range, and the method gives results of sufficient accuracy for many practical purposes.

III. FINITE ELEMENT MODEL

Numerical field solutions have been obtained using the two-dimensional Cartesian magnetostatic processors and
solver of the simulation software FEMM [12]. To permit two-dimensional analysis, the actuator is considered
longitudinally uniform and long enough so that end effects are negligible. The solutions are obtained for the
magnetic vector potential A which, in a two-dimensional analysis, is assumed entirely z directed. It is then
possible to work simply with a scalar distribution A which denotes the longitudinal component of the vector A.
The nonlinear magnetization characteristic of the M-36 steel represents the behavior of the material that forms
the magnetic parts. First-order triangular finite elements are employed in all computations. The boundary
conditions are homogeneous Dirichlet; the condition A=0 is applied to a remote circular boundary whose radius
is 40 cm and represents approximately 6 times the leading dimension of the device [13].

A. Simulation of movement

A sequence of static solutions is used to obtain the force-displacement characteristic of the slider actuator. In
this sequence, the plunger moves 11 mm in the -x direction. The initial position represents an overlap of 1 mm,
and the final position represents an overlap of 12 mm. The plunger movement is simulated using the artifice of
material re-identification to change materials and their properties in problems representing successive positions
[14].

IV. RESULTS
A. Flux densities

The flux plot presented in Fig. 5 is used to illustrate the general pattern of the solutions. The plot refers to the
configuration of the slider actuator where the overlapping gaps are 4 mm wide. At this position, the energy
storage in the two overlapping gaps is approximately 1% larger than that in the window region. With the aid of
this plot it can be observed that the field in the two overlapping gaps is essentially uniform, and this is mainly
due to the short length of these gaps, namely 2 mm. There is also a component of the total flux that avoids the
overlapping gaps and crosses the magnetic plunger. This leakage field is completely symmetrical with respect to
a horizontal line that bisects the device and does not contribute to the force production.
The plot reveals that, in the region of the actuator's window, there is no uniform developed field. The
distribution of these flux lines is in accordance with the theoretical predictions made in the earlier analytical
development. On the left hand side of the window, the magnetic flux crosses the space between the upper and
lower limbs more or less vertically. Close to the front edge of the plunger one can observe an increasing
concentration and inhomogeneity of the field, especially near the upper and lower corners of the plunger; close
to the tips, flux lines bend towards the nearer side of the stationary core with a relatively small radius of
curvature. The main contribution to the net force is due to the stresses in these regions.

Inspection of the numerical values of flux densities is made with the aid of the horizontal contour that appears in
Fig. 5, in red color. This contour is defined from left to right, starts very close to the coil, and crosses the
window and the upper gap. The variations of flux densities along this contour are presented in the graph of Fig.
6. The curve in blue color represents the flux distribution in the upper sector of the window's region. This is
followed by the curve in red color that represents the flux distribution in the middle of the upper gap. Both
curves have been obtained from the potential solution that represents overlapping gaps of 4 mm width. The
solid horizontal line represents the estimate Bw=0.314 T, calculated by (5) for the flux density in the window's
region. The dashed horizontal line represents the estimate Bo=1.571 T, calculated by (6) for the flux density in
the overlapping gaps.

Observation of the characteristics presented in Fig. 6 confirms the earlier predictions related to the general
pattern of the field distributions, i.e. the uniformity of the field in the short gaps and the inhomogeneity of the
field in the upper portion of window's region.

The analytical calculations based on Ampère's law ought to be compared with the more precise values obtained
from the finite element solution. In the window's region, the analytical estimate is Bw=0.314 T. This value is
clearly underestimated, and represents only 58% of the mean value of the curve shown in blue color, namely
0.538 T. In the overlapping gap, the discrepancy between the analytical and numerical estimates is not so
severe. The analytical estimate is Bo=1.571 T, and this value is only 8.6% larger than the mean value of the
curve shown in red color, namely 1.447 T.
B. Stored energy and saturation

Variations of the magnetically stored energy in the window's region and overlapping gaps with the respect to the
amount of overlap are presented in the graph of Fig. 7.

Observation of the two characteristics that appear in Fig. 7 reveals that when the plunger moves in the -x
direction, the amount of energy stored in the window's region decreases. Simultaneously, it can be observed a
much more pronounced increase in the amount of energy stored in the two air gaps. The energy stored in the
coil's region decreases only 3.6% over the simulated excursion, and the change in the energy stored in the
external leakage fields is negligible.

Inspection of magnetic saturation has been made by comparing the values of stored energy and coenergy. The
difference in the values of energy and coenergy indicates the presence of magnetic saturation in the magnetic
parts of the actuator. Presented results show that saturation effects only become significant for larger overlaps;
when the overlap increases from 10 to 12 mm, the relationship between the values of coenergy and energy
rises rapidly from 11 to 15.4%. When saturation is present, a considerable number of force calculation methods
must be disregarded, and these include, e.g. some linearized approaches based on the virtual work principle
[15]. This is not the case of the method employed here to obtain the force-displacement characteristic, i.e. the
weighted Maxwell stress tensor method [10]. This method has proved to be adequate for extracting accurate
and consistent force predictions from imperfect numerical field solutions, and its formulation does not include
any simplifications regarding magnetic linearity.

C. Force calculations

The variation of the force along the simulated excursion is shown in the graph of Fig. 8. The numerical force
estimates have been obtained from the finite element solutions employing the methods of weighted Maxwell
stress tensor and the classical virtual work.
The single force estimate calculated analytically by (4) is 62.8 N. In fact, force values vary substantially along
the simulated excursion, as shown in the graph of Fig. 8. However, all that is expected from the simplified
analytical approach is an estimate for the order of magnitude, and this estimate may be considered satisfactory
for many practical purposes. When compared with the predictions by the weighted tensor method, the numerical
error is 4.5% when compared to the peak force, and 9.8% when compared to 57.19 N, the mean value of the
force-displacement characteristic.

A close observation of the characteristic marked with circles shows that, when the overlap width is 4 mm the
force reaches its maximum value, namely 60.12 N. This maximum value occurs at the plunger's position where
the amount of energy stored in the force producing region has just become smaller than that stored in the small
gaps. This helps to explain why further increases in the overlap width actually lead to a reduction in the
developed force. In other words, for overlaps greater than 4 mm, a greater proportion of the system's energy
will be stored in the air-filled regions that give no contribution to the production of force.

V. ALTERNATIVE FORCE CALCULATION APPROACH

The force production in the actuator is intimately related to the change in the magnetic energy stored in the
non-magnetic parts of the device. The total energy Et of the actuator has three major components: i) a constant
component Ec associated with the coil; ii) a component Ew associated with the window's region; and a
component Eo associated with the two overlapping gaps. In this way, the force can be calculated only in terms
of the variation of the energies Ew and Eo with respect to displacement.

According to the illustration of Fig. 3, the variable x denotes the width of the actuator's window,

whereas the width of the overlapping gaps is (a-x). The attractive force can be expressed as where a is a
constant and denotes the maximum distance the plunger can move into the cavity.

Each of the two energies Ew and Eo represents a fraction of the total energy Et. Each fraction can be determined
as the ratio of the flux crossing the region with respect to the total flux.

For the field solution where the amount of overlap is 4 mm, the total flux Φt is 0.536 mWb. The flux crossing the
window's region is 0.221 mWb and represents a fraction fw=0.2094. The flux crossing the overlapping gaps is
0.123 mWb and represents a fraction fo=0.2298.

The total stored energy is 1.550 J. The energy stored in the window's region can be computed as

The energy stored in the overlapping gaps is

The magnitude of the force computed from (7) is 60.80 N. This value compares very well with that calculated by
the weighted tensor method, to know 60.12 N. It is worth noting that the latter calculation has been performed
in a completely different way. This excellent agreement between magnetic force predictions by different
approaches suggests consistent and completely satisfactory force estimates for most practical purposes.

VI. CONCLUSIONS
The device under analysis is a type of slider actuator containing a movable plunger that is attracted into the
interior region of a stationary C-core. The discussion shows one way to investigate the direction of the
developed force using a surface-integration method. A simplified analytical approach that combines the principle
of virtual work and Ampère's law is used to investigate the magnitude of the force. This approach represents a
useful method to figure out the order of magnitude of developed forces and can be applied quickly and easily.
The artifice of material re-identification has allowed the use of a single finite element model to simulate the
plunger's movement. The field-derived distributions of flux densities and stored energies in different regions
show good agreement with the theoretical predictions made in the initial analytical development. The force-
displacement characteristic is consistent with the physical understanding of the device in its aspects related to
energy storage and force production. The study of force production based on the proportions of magnetic energy
stored in different regions of the device brings considerable insight into the subject, and should be of value to
people working with electromagnetic engineering education, as well as to designers working with device's
performance prediction.

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th
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