topic Re: Coating / Insulation layer for a 3d bent busbar in Fusion Design, Validate & Document Forum

Coating / Insulation layer for a 3d bent busbar

Anonymous — Tue, 27 Apr 2021 19:05:49 GMT

Hello,

I am trying to add a 2mm insulation layer to a 3d busbar that has bents in different 3d dimensions but I can find the tools that serve that purpose.

I tried using the offset and the thicken command but I keep getting the error:

"The body could not be repaired after deleting faces ..."

The first image shows a sample of what I'm try to do and the second image shows the 3d bent busbar that I am trying to add insulation to. I imported the 3d bus bar as an .stl file.

Re: Coating / Insulation layer for a 3d bent busbar

jhackney1972 — Tue, 27 Apr 2021 18:59:22 GMT

You will get a better and more relevant answer if you attach the model you want to cover. If you do not know how to attach your Fusion 360 follow these easy steps. Open the model in Fusion 360, select the File menu, then Export and save to your hard drive. Then use the Attachments section of a forum post to attach it.

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Tue, 27 Apr 2021 19:06:56 GMT

I attached the .stl file as suggested

Re: Coating / Insulation layer for a 3d bent busbar

TheCADWhisperer — Tue, 27 Apr 2021 19:43:47 GMT

@Anonymous wrote:
I attached the .stl file as suggested

STL is rubbish - doesn't it look poor quality to you too?

You will need native *.f3d geometry.

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Tue, 27 Apr 2021 19:45:46 GMT

what I am really asking for is how to add the insulation layer not the quality of the drawing

Re: Coating / Insulation layer for a 3d bent busbar

TheCADWhisperer — Tue, 27 Apr 2021 19:48:38 GMT

@Anonymous wrote:
what I am really asking for is how to add the insulation layer not the quality of the drawing

Oh, in that case I will let someone else jump in here.

Re: Coating / Insulation layer for a 3d bent busbar

TrippyLighting — Wed, 28 Apr 2021 12:22:22 GMT

What @TheCADWhisperer is telling you is the the input geometry is garbage ( I completely agree) and that is the reason you cannot work with the normal Fusion 360 modeling tools.

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Mon, 03 May 2021 01:01:10 GMT

Thank you guys @TheCADWhisperer and @TrippyLighting.

The software I am using to produce the busbar is Ansys Maxwell.

I can't export the f3d file from that software. The formats I can export are shown in the attached image.

kindly advise

Re: Coating / Insulation layer for a 3d bent busbar

TrippyLighting — Mon, 03 May 2021 01:03:56 GMT

.STEP is the right format, assuming that thit actually does not export faceted geometry.

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Mon, 03 May 2021 01:04:39 GMT

Thank you for the fast reply.

How do I proceed after that?

should I offset the faces by 0mm and then thicken them as new bodies ?

Re: Coating / Insulation layer for a 3d bent busbar

TrippyLighting — Mon, 03 May 2021 01:06:29 GMT

That could work, but let's get past eth export/import first 😉

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Mon, 03 May 2021 01:12:00 GMT

I opened the exported .stp file in fusion 360 and tried to offset and thicken but still didn't work.

attached is an image for reference

Re: Coating / Insulation layer for a 3d bent busbar

TrippyLighting — Mon, 03 May 2021 01:14:07 GMT

Export the .f3d file and attach it to the next post. It's getting late in this part of the world so I might look at it in the morning.

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Mon, 03 May 2021 01:17:51 GMT

Thank you so much for your support.

I attached it as requested.

Re: Coating / Insulation layer for a 3d bent busbar

TrippyLighting — Mon, 03 May 2021 01:28:33 GMT

What is the ultimate goal of this exercise?

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Mon, 03 May 2021 01:34:18 GMT

The ultimate goal is FEA thermal simulation in Ansys.

So what I am doing now is adding insulation for the first busbar which is a winding in a medium voltage induction machine, then I will replicate over the other windings. After that, I will assign different materials and check the effect of each material on the performance of the machine.

Re: Coating / Insulation layer for a 3d bent busbar

TrippyLighting — Mon, 03 May 2021 01:37:28 GMT

My recommendation is to redesign the geometry with the native tools in Fusion 360. The input geometry is pretty terrible. even in STEP format. How was this created, to begin with?

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Mon, 03 May 2021 01:39:26 GMT

This shape is automatically generated by an Ansys package called RMxprt.

how easy is it to redesign it?

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Mon, 03 May 2021 16:21:00 GMT

Is there an easy way to replicate the shape in fusion 360 ?

Re: Coating / Insulation layer for a 3d bent busbar

Anonymous — Mon, 03 May 2021 22:13:31 GMT

I have replicated the design in fusion 360 but can't figure out how to add the 2mm insulation.

Attached is the file.

@TrippyLighting @TheCADWhisperer kindly advise