Simulation based design of mechatronic systems

In mechatronic systems basically electromagnetical-, thermal-, mechanical- or fluid -effects and their interactions occur. For the efficient optimal design of those systems it´s essential to take into account those effects. This leads to a reduced number of prototypes and shortens the time to market. As an example for a simulation assisted design procedure, a battery charging system will be optimized. The main part of the charging system, a power frequency transformer and its connected electrical components is analyzed in regard to its electrical and thermal characteristics. The results are compared to measurement on prototypes. The multiphysical simulations of the transformer are based on material parameter, which depend on the temperature and the distribution of the magnetic field. To reduce the power loss of the overall system, the interaction between the power transformer and its connected electrical components, like resistors, inductors or other nonlinear elements is investigated. The energy produced by the loss mechanisms is dissipated by natural convection on the appliances casing. Virtual experiments lead to an optimal geometry of the chasing with regard to price, design and thermal performance.