B&W Fe802d - Rev - D

STATUS CLIENT DOC NO
CONCEPT INDEPENDENT R&D FE800D

REVISIONS
REV DESCRIPTION CHECK ENG DATE
A DRAFT SM SM 11/01/15
B RESTART AC ANALYSIS SM SM 12/01/15
C B&W PICTURES SM SM 14/01/15
D STEALLUS X CONCEPT SM 16/01/15
SM TRANSDUCER ENGINEERING
DATE PHUKET, THAILAND
dd/mm/yy
steve.mowry@ymail.com
3 CHECKER
S. MOWRY 14/01/15 B&W 800 SERIES DIAMOND DUAL MAGNET WOOFER
2 ENGINEER MOTOR ASSEMBLY TOPOLOGY WITH STEALLUS X
S. MOWRY 16/01/15 TOPOLOGY CONCEPT WOOFER SIMULATION REPORT
1 DRAFTER SIZE TYPE CLASS DOC NO REV
S. MOWRY 16/01/15 LETTER LF REPORT FE800D D
PAGE 1 of 36
1. SCOPE
This document summarizes the simulation results for the B&W 800
Series Diamond Dual Magnet Motor Assembly Topology. The
geometry was approximated by studying B&Ws transducer
sectional illustrations et al. The principal engineering tool used
was Vector Fields OPERA 2d. B&Ws R&D also uses OPERA.
Then proprietary voice coil emulating command files were used
within Nonlinear DC Static and Restart AC Steady State Harmonic
Finite Element Models.
2. OBJECTIVE
Document and report on the simulation of the 800 Series
Diamond Dual Magnet Motor Assembly Topology.
Figure 1. Illustrations of the B&W 800 Series Diamond Dual Magnet Woofers
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steve.mowry@ymail.com LETTER LF REPORT FE800D 2 D
3. NONLINEAR DC FEA SIMULATIONS
3.1 BH CURVES:
Figure 2. Room Temperature BH curve of Annealed 1010 AISI Steel
Figure 3. N38SH Magnet BH Curves with Red Load Line

3.2 VOICE COIL
Figure 4. Voice Coil Model
3.3 DC SIMUALATION CONTOUR PLOTS
Figure 5. Simulation of |B| (T)

Figure 6. Simulation of Bradial within the Voice Coil section only at x = 0
Figure 7. Simulation of Bradial within the Voice Coil section only at x = 7mm

Figure 8. Simulation of Bradial within the Voice Coil section only at x = -7mm
Figure 9. Simulation of the DC Flux Distribution Lines

Figure 10. Simulation of the Relative Permeability
Figure 11. Simulation of |Baxial| within the Magnets only

3.5 SIMULATED VOICE COIL SWEEP
Figure 12. Simulation of Bl(x) and b(x)
4. ENGINEERS COMMENTS
This motor seems well designed and implemented. The operating point
is high with a Permeance Coefficient of 1.5 that is illustrated in red in
figure 3. This motor is robust and looks okay to above 150C. BETA
was simulated at more than 50 N2/W, which is high for a woofer of this
size. The symmetric topology paid off with symmetric flux linkage with
respect to displacement.
My concerns are related to ease of assembly or lack thereof. Assembly
seems to be difficult at best. The powerful Neo magnets must be
magnetized before assembly. Their directions of magnetization are
opposed. Another concern is that even statically with the voice coil at
the rest position, a bit of anti-flux links to the voice coil. This can be
seen in figures 6 thru 8 as the minus Bradial value at the voice coil section
height extremes. Finally, the voice coil is cantilevered with a long
bobbin. As time passes and the suspension relaxes, I am concerned
about rocking modes. One could have positioned the spider at the rear
and implemented mid-motor topology with complementary suspension,
surround and spider.
This anti-flux linkage should help to control displacement somewhat but its
onset seems too soon and is within the linear operating range. Then the
thought of what if this topology was used to implement an under-hung voice
coil and a much thicker gap plate or coin between the two magnets.
MAGNETIC
ANTI-GAP
PRIMARY
MAGNETIC
GAP
MAGNETIC
ANTI-GAP
Figure 13. Sectional Illustration of the 800 Series Diamond Woofer

Motor Assembly Topology
One could have used thicker magnets with a smaller magnet OD and
voice coil ID. This would leave more room for a larger spider. Then the
anti-flux would work just to help control displacement, while not reducing
linearity due to any anti-flux linkage within the zero to |Xmax|
displacement range. With a smaller voice coil ID, the wind height could
then be increased without a mass or impedance penalty. The surface
would remain about the same too. Thus any thermal impact should be
secondary.

5. RESTART NONLINEAR AC FEA SIMULATIONS
MATERIAL ELECTRICAL CONDUCTIVITY
NdFeB MAGNET 0.7 x 106 (1//m)
AISI 1010 STEEL 7.0 x 106 (1//m)
Table 1. Material Properties
Figure 14. A 0.5 (A) AC Current is applied to the Voice Coil (~ 1 W)

Figure 15. Simulation of the Induced Current Density Amplitude (A/m2) @ 50 Hz

Figure 17. Simulation of the AC Flux Distribution lines @ 50 Hz

Figure 19. Simulation of the Induced Current Density Amplitude @ 50 Hz, x = 7mm

Figure 21. Simulation of the AC Flux Distribution lines @ 50 Hz, x = 7mm

Figure 23. Simulation of the Induced Current Density Amplitude @ 50 Hz, x = -7mm

Figure 25. Simulation of the AC Flux Distribution lines @ 50 Hz, x = -7mm
Figure 27. Simulation of Le(x,0.5A) @ 1.0 kHz
Figure 28. Simulation of AC Bl (x,0.5A)

Although the inductance seems a bit high it is linear and symmetrical.
The AC flux modulation is reasonable and again linear and symmetrical.
The linear and symmetrical inductance and AC flux linkage should map
into lower distortion than other nonsymmetrical single ended (Rice-
Kellogg) motor geometries and topologies.
7. ALTERNATIVE WOOFER CONCEPT

157mm
160mm
Figure 29. Sectional Illustrations of the 800 Series Diamond Woofer

Assembly and a STEALLUS X Concept Woofer Assembly
DIAPHRAGM
ASSEMBLY
MODULE
SPIDER-
TERMINATED
VOICE COIL
MODULE
WITH SIMPLE
SHIM GAUGE
HARD-PART
MODULE
Figure 30. Exploded Section and Top View Illustrations of STEALLUS X

Concept Woofer Assembly

8. NONLINEAR DC FEA SIMULATIONS
Figure 31. Voice Coil Models

Figure 32. Simulation of |B| (T)
Figure 33. Simulation of Bradial within the Voice Coil section only at x = 0

Figure 34. Simulation of Bradial within the Voice Coil section only at x = 7mm
Figure 35. Simulation of Bradial within the Voice Coil section only at x = -7mm

Figure 36. Simulation of the DC Flux Distribution Lines
Figure 37. Simulation of the Relative Permeability

Figure 38. Simulation of |Baxial| within the Magnets only
Figure 39. Simulation of Bl(x) and b(x)

9. RESTART NONLINEAR AC FEA SIMULATIONS
Figure 40. A 0.5 (A) AC Current is applied to the Voice Coil (~ 1 Wpeak)


Figure 45. Simulation of the AC Flux Distribution lines @ 300 Hz in Free Air




Figure 54. Simulation of Le(x,0.5A) @ 1.0 kHz
Figure 55. Simulation of AC Bl (x,0.5A)

The STEALLUS Topology is not new and I did not invent it. It seems to
have been patented more than 50 years ago. The application was filed
in 1962. However, there were no Neo magnets back then.
www.freepatentsonline.com/3201529.pdf
I published a two part discussion of the STEALLUS Topology in Voice

Coil magazine in 2007 to share my R&D results and concepts and to
encourage interest in development.
www.pearl-hifi.com/06_Lit_Archive/14_Books_Tech_Papers/Mowry_Steve/Steallus_Motor_Design.pdf
Then in 2010 the Neo magnet crisis hit the market.

www.warren-news.com/neodymium.html
Now with respect to figure 39, that contains the results of two virtual
voice coil sweeps, the coil used in the B&W 800 Series simulations and
a new 4-layer Al magnet wire coil. Mass, resistance and wind height are
the same but the 4-layer coil has more turns. The key here is to
understand b in terms of physical parameters of the gap and the coil.
( Bl( x) )
2
( x) = N 2 /W
Re
l
Re =
S wire
S ( Bl( x) )
2
( x) = wire
l
( x) = lS wire B( x) 2
( x) = Volwire B( x) 2
Where s is the electrical conductivity (1/W/m); S is the cross section (m2)
and Vol is the volume of conductor (m3).
Now it is well known that Aluminum is a more efficient coil material than
copper. This can be shown by a simple ratio of Conductivity/Density,
where M is the figure of merit.
M = Electrical Conductivity/Mass Density (m2/W/kg)
MCu = 60 x 106/8960 = 6696
MAl = 35 x 106/2700 = 12962
However with typical motors, the B field decreases with increasing coil
width and thus gap width. With regards to the STEALLUS X Topology,
the magnetic gaps are quasi-infinite and obviously gap width is not a
design consideration.
Both of the transducers that were analyzed were concepts and not fixed
designs. In the case of the B&W 800 Series Diamond, the transducer
was a generalized approximation meant to help understand B&Ws Dual
Magnet Woofer Motor Topology. Whereas in the later case, the
STEALLUS X woofer concept was intended as a response to concerns
regarding the B&W woofer topology. These include but are limited to
the following.
1. Manufacturability
HARD PARTS ASSEMBLY ONLY B&W STEALLUS X
NUMBER OF PARTS 7 6
NUMBER OF DIFFERENT PARTS 6 3
NUMBER OF INTERFACES 6 5
TOTAL 19 14
2. Long cantilevered voice coil bobbin and possible rocking modes
The STEALLUS X topology facilitates a much shorter voice coil bobbin
and eliminates any chance of the voice coil winding rubbing. The short
bobbin and 2 x spider make the chance of any rocking mode issue a
remote possibility. Furthermore, as theSTEALLUS X coil is heated during
operation the ID increases and if any contact does occur between the
motor and voice coil assembly, the aluminum bobbin should protect the
windings from damage.
3. Suspension linearity
STEALLUS X is intended to operate within the linear displacement range
of the suspension. The anti-magnetic DC flux coil linkage should control
maximum displacement with only mild pull-up from the spiders and or
surrounds. This extends suspension life and long term suspension
performance. Using 2 x spider inherently increases effective spider
robustness. This also reduces the probability of spider failure.
Personally, I felt that perhaps my discussion of the STEALLUS in 2007
in Voice Coil had an effect on the designer of the B&W Dual Magnet
Motor Topology. However, my opinion is that they missed an
opportunity. With regards to performance and manufacturability,
STEALLUS is simply (pun intended) hard to beat.
Note: The STEALLUS and STEALUS X motors differ in that the X
indicates that the spacer or gap plate between the magnets is ferrous
(typically low carbon annealed steel), whereas the STEALLUS motor
uses a nonferrous material such as non-ferritic stainless steel for the
spacer. STEALLUS X facilitates smaller magnets and a higher relative
DC operating point and thus reduces cost with just a modest loss in AC
performance.
Serious questions, comments, or concerns can be sent to Steve
Mowrys attention at steve.mowry@ymail.com.
Steve Mowry 18 January 2015


B&W Fe802d - Rev - D

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CONCEPT INDEPENDENT R&D FE800D

Figure 2. Room Temperature BH curve of Annealed 1010 AISI Steel

Figure 3. N38SH Magnet BH Curves with Red Load Line

SM TRANSDUCER ENGINEERING SIZE TYPE CLASS DOC NO PAGE REV

Figure 4. Voice Coil Model

3.3 DC SIMUALATION CONTOUR PLOTS

Figure 5. Simulation of |B| (T)

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Figure 9. Simulation of the DC Flux Distribution Lines

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Figure 11. Simulation of |Baxial| within the Magnets only

Figure 12. Simulation of Bl(x) and b(x)

Figure 13. Sectional Illustration of the 800 Series Diamond Woofer

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Table 1. Material Properties

Figure 14. A 0.5 (A) AC Current is applied to the Voice Coil (~ 1 W)

SM TRANSDUCER ENGINEERING SIZE TYPE CLASS DOC NO PAGE REV

SM TRANSDUCER ENGINEERING SIZE TYPE CLASS DOC NO PAGE REV

Figure 18. Simulation of the AC Flux Distribution lines @ 300 Hz

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Figure 28. Simulation of AC Bl (x,0.5A)

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7. ALTERNATIVE WOOFER CONCEPT

Figure 29. Sectional Illustrations of the 800 Series Diamond Woofer

Figure 30. Exploded Section and Top View Illustrations of STEALLUS X

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Figure 31. Voice Coil Models

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Figure 37. Simulation of the Relative Permeability

Figure 39. Simulation of Bl(x) and b(x)

Figure 41. Simulation of the Induced Current Density Amplitude (A/m2) @ 50 Hz

Figure 43. Simulation of the AC Flux Distribution lines @ 50 Hz

SM TRANSDUCER ENGINEERING SIZE TYPE CLASS DOC NO PAGE REV

SM TRANSDUCER ENGINEERING SIZE TYPE CLASS DOC NO PAGE REV

SM TRANSDUCER ENGINEERING SIZE TYPE CLASS DOC NO PAGE REV

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Figure 55. Simulation of AC Bl (x,0.5A)

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I published a two part discussion of the STEALLUS Topology in Voice

Then in 2010 the Neo magnet crisis hit the market.

Steve Mowry 18 January 2015

SM TRANSDUCER ENGINEERING SIZE TYPE CLASS DOC NO PAGE REV

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