Abstract

An electromagnetic launcher (EML) is a device that allows for the conversion from large amounts of electrical energy to mechanical kinetic energy. At the Kansas City National Security Campus, an EML is currently in use for the purpose of environmental testing. In order to better facilitate simulations-based testing for the EML, design of a complete 3D Multiphysics model of the EML has been proposed. This will include fully coupled mechanical, electrical and magnetic models. A Multiphysics model would allow for the relationship between voltage input to the launcher and mechanical motion output to be better understood in order to better predict launcher performance using simulation. The ultimate goal is to be able to model these three physics environments that are necessary to produce a 10,000G acceleration within a range between 100 µs and .2 in impulse duration. This would allow us to better understand and tailor the input pulse shape as well as improve the force transmissibility by improving the stator and rotor design. This improved performance would allow for the EML to offer more robust environmental testing capabilities, replacing several existing environmental testing apparatuses. The opportunity for simulations-based testing would also be a significant benefit and allow for time and cost savings by reducing requisite physical testing. In order to complete this model, COMSOL Multiphysics software has been selected after a survey of the many design requirements this project would entail. COMSOL software offers complete two-way coupling of the three separate physics systems using a series of special additional design modules and will allow the end product to function as a standalone executable program capable of computing mechanical output data given user-provided electrical input data. This project has been funded as one of KCNSC’s plant-driven research and development projects (PDRD) and is currently under development with completion projected by Q3 of 2021.