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Position Sensor Simulation

with
®
ANSYS Maxwell 3D
Dr. Leon Voss (ANSYS Germany)
Jens Otto

PRACE Autumn School 2013 - Industry Oriented HPC Simulations, September
21-27, University of Ljubljana, Faculty of Mechanical Engineering, Ljubljana,
Slovenia

ANSYS Maxwell: Sensor Applications
 Hall Effect
• Velocity、Position

 Variable Reluctance
• Velocity、Position

 Magnetic Resistance
• Velocity、Position

 Flux Gate
• Proximity Sensing
• Navigation
• Velocity、Position

 Eddy Current
• NDT(flaw detection)

-1- © 2013 CADFEM GmbH

Maxwell 3D: Example Nonlinear Magnetostatic Analysis
Hall Sensor
Permanent
 Adaptive meshing for most Magnet
automated and precise analysis
IC chip

 Parametrized setup Pole piece
Cell
Cell Bot
Top
 Extended Postprocessing with fields
calculator

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0040 0.0010 0.03 0.03 0.FLUX TR Y1 TR Y1 FLUXM2.07 0.00 0.VAL COMP1.05 0.GAP Curve Info Y Axis := 1 FLUXM1.00 © 2013 CADFEM GmbH 0. Simplorer: Example Circuit Simulation Maxwell 3D Link EMSSLink1 ICA: EQU Difference := FLUXM2.00 300.00 400.00 200.0000 -3.FLUX Y1 0. 0.FLUX TR FLUXM2.06 0.00 500.0050 0.08 0.0050 EMSSLink1.00 300.0020 Y2 Y2 0.FLUXM1.FLUX Y1 0.06 0.14 0.20 Curve Info Y Axis Curve Info Y Axis FLUXM1.10 0.10 0.0010 0.05 0.FLUX Y1 Spacing = 3mm Spacing = 1mm TR TR FLUXM2.00 Time [ms] Time [ms] .12 0.FLUX EMSSLink1.VAL Y2 0.00 600.04 0.00 600.00 100.08 0.02 0.04 0.VAL TR Y2 TR Y2 0.02 0.00 400.00 0.21 0.GAP := 3 w ROT + ROT_V CONST2 COMP1 ECE CONST FLUXM1 FLX FLX FLUXM2 Difference Maxwell 3D result(B vs Angle) 0.12 0.0040 Y2 0.FLUX FLUXM1.0030 TR Y1 Difference Y2 0.FLUX .00 500.10 Difference Y2 TR TR Flux [vs] COMP1.0030 Flux [vs] Flux [vs] 0.10 Difference TR Y2 Non Differential Signal Detected Differential Signal Detected TR COMP1.00 200.00 0.17 0.0020 0.00 100.08 0.13 0.13 0.15 0.

© 2013 CADFEM GmbH .Object of Interest  Position Sensor (MR)  Used widely in automotive sector  Low cost  Some sensor parameters  Angular position  Positioning error  Axial Source: ANSYS  angular -4.

-5. • No thermal effects. • No deformation. • Resistance changes with the angles which the magnetic field which crosses • the direction of current accomplishes. eddy current effects.Principle • Magnetoresistive(MR) sensor element with gear wheel. © 2013 CADFEM GmbH . • Bridge connection of each resistance.

6 © 2013 CADFEM GmbH .  Export Design Variation with Workbench  Data is manually processed using a function of Table I/O.  Variable parameter about a gear rotation angle.Maxwell: Process  Use Maxwell 3D  MagnetoStatic +Optimetrics  Linear permeability for valid parameter.  Integrate magnetic field intensity of a sensor object.  Calculates using a function of Calculator.  Change rotation angle of object to a variable.

Maxwell: Simulation Details  Rotation angle of Wheel RotAngle  Permeability of a deficit part $TeethMur Magnetize M 7 © 2013 CADFEM GmbH .

Qty ・ H ・Scalar ・ Y Geom ・ Sens_Fwd ・ Integ Qty ・ H ・ Scalar ・ X Geom ・ Sens_Fwd ・ Integ / Trig ・ Atan Constant ・PI ・/ Number ・ 180.Maxwell: Simulation Details Sens_Fwd Sens_Back  Use of Field Calculator  H y dv / V    tan   1   H dv / V   x  Operation of Calculator.0 ・* [Add] → Ang_Fwd 8 © 2013 CADFEM GmbH .

HANDS-ON HANDS-ON-Position-Sensor-Simulation-with Maxwell3D.docx 9 © 2013 CADFEM GmbH .

Workbench: Simulation Process  Efficient use of hardware resources for parameter variations  HPC parallel computation with ANSYS  Types of processing with ANSYS  Example scenario 10 © 2013 CADFEM GmbH .

11 . © 2013 CADFEM GmbH . ANSYS HPC Parametric Pack Time reduction for a parametric study dp4 HPC parametric packs amplify Design points dp3 both solver licenses and HPC One set of Series of dp2 Solver keys licenses allowing you to dp1 without HPC drastically reduce time to Unused Cores innovation Four sets of solver keys or One set of solvers and 94% reduced time 1 x HPC Parametric Pack to innovation + 1 HPC Pack .

12 . © 2013 CADFEM GmbH . Types of Processing Local Remote 1. Local Pre/Post and Remote Solve Process Geometry Update Meshing Process Boundary Conditions Mapping Solution Process Result Extraction Result Processing 3. All Processes Local Geometry Update Meshing Process Boundary Conditions Mapping Solution Process Result Extraction Result Processing 2. Main Processes Remote Geometry Update Meshing Process Boundary Conditions Mapping Solution Process Result Extraction Result Processing .

13 . All Processes Local Local Remote  Geometry Update  Meshing Process  Boundary Conditions Mapping  Solution Process  Result Extraction  Result Processing . 1. © 2013 CADFEM GmbH .

14 . All Processes Local  All design points are calculated sequentially which means step by step (NO simultaneous processes)  Solution Process:  Update Option: Use application default Local  Design Point Update Process:  Update Option: Run in Foreground Local . 1. © 2013 CADFEM GmbH .

Local Pre/Post and Remote Solve Process Local Remote  Geometry Update  Meshing Process  Boundary Conditions Mapping  Solution Process  Result Extraction Results as rst- file  Result Processing (large) . © 2013 CADFEM GmbH . 2.15 .

2. © 2013 CADFEM GmbH . Local Pre/Post and Remote Solve Process  All design points are calculated sequentially which means step by step (NO simultaneous processes)  Solution Process:  Update Option: Submit to Remote Compute Server Solve Manager  Design Point Update Process:  Update Option: Run in Foreground Local .16 .

Main Processes Remote Local Remote  Geometry Update  Meshing Process  Boundary Conditions Mapping  Solution Process extracted  Result Extraction Results  Result Processing as table (small) . © 2013 CADFEM GmbH . 3.17 .

© 2013 CADFEM GmbH . Main Processes Remote  All design points are calculated sequentially or simultaneously  Solution Process:  Update Option: Use application default Compute Server  Design Point Update Process:  Update Option: Submit to Remote Compute Server Solve Manager  Processing order defined by 3 types of settings (see following slides) .18 . 3.

depending on licensing and RSM settings . g. © 2013 CADFEM GmbH .19 . Main Processes Remote 2nd Type: One Job Each Design Point  Number of jobs is equal to design points  e. 3. 32 design points  32 jobs  Jobs can be processed sequentially or simultaneously.

© 2013 CADFEM GmbH .20 . depending on licensing and RSM setting . Main Processes Remote 3rd Type: Specify Maximum Number of Jobs  Maximum number of jobs is limited  Jobs can be processed sequentially or simultaneously. 3.

Example Simultaneous Processing with ANSYS HPC Parametric Pack  32 core remote compute server machine  1 x ANSYS HPC Parametric Pack  1 x ANSYS HPC Pack  1 x ANSYS Mechanical  100 design points  Geometry parameters + load parameters Recommended Setup .21 . © 2013 CADFEM GmbH .

Example Simultaneous Processing with ANSYS HPC Parametric Pack .22 . © 2013 CADFEM GmbH .

Example Simultaneous Processing with ANSYS HPC Parametric Pack .23 . © 2013 CADFEM GmbH .

24 . Example Simultaneous Processing with ANSYS HPC Parametric Pack Summary  Simultaneous processing enabled by  “Reserved Licenses”  Specified Maximum Number of Jobs: 4  ANSYS HPC Parametric Pack  All geometries are updated locally upfront  4 jobs in process (each job includes 25 design points). enabled by ANSYS HPC Pack  Specified Maximum Number of Jobs < RSM Limiter  Golden Rule . 0 jobs in RSM-Queue  8 cores per job  32 cores in process. © 2013 CADFEM GmbH .

© 2013 CADFEM GmbH .25 .ANSYS Maxwell: Integration into Workbench .

26 . without any centralized bottlenecks. Maxwell 15  Regular DSO: the parametric DSO feature that is available in R13 and earlier versions  Large Scale DSO: parametric DSO that solves variations in an embarrassingly- parallel manner. .DSO Terminology for EM  R14: ANSYS 14. © 2013 CADFEM GmbH .

Additional Function: System Simulation  Motivation:  Include different physical effects  magnetic-thermal / cfd  magnetic-electric circuit  magnetic-mechanic  Use existing (detailed) know how including nonlinearity  Save simulation time  Share data between departments 27 © 2013 CADFEM GmbH .

Maxwell to Simplorer  Exporting Lookup Table  Export as format of Table . 28 © 2013 CADFEM GmbH .LINK Starting Angle – End Angle Result table file : Merged as Complete one round. Export from Parametric Solutions Export from Imported Table 編集 Result table file : ECE .g. Excel)  Reload as Table  Export SML.  Data is manually processed by other tools. (e.

Sensitivity 20.40m 0 -20.00m 40.00m Sensor output Voltage.50u 28.00m VM1.92 0 20.V [V ] 10.V [V] + -2.50 29. VM6.00u 0 20.40m 0 20.00m 40.00u 28.00m Amplified Output. 29 © 2013 CADFEM GmbH .Simplorer: System Simulation (Overview) MRSensor.00 0 -9.00m 40.