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

© 2013 CADFEM GmbH

ANSYS Maxwell: Sensor Applications

- 1 -

Hall Effect

• Velocity、Position

Variable Reluctance

• Velocity、Position

Magnetic Resistance

• Velocity、Position

Flux Gate

• Proximity Sensing

• Navigation

• Velocity、Position

Eddy Current

• NDT（flaw detection)

© 2013 CADFEM GmbH

Maxwell 3D: Example Nonlinear Magnetostatic Analysis

- 2 -

Adaptive meshing for most

automated and precise analysis

Parametrized setup

Extended Postprocessing with fields

calculator

Hall Sensor Permanent

Magnet

Pole piece

IC chip

Cell

Top

Cell

Bot

© 2013 CADFEM GmbH

Simplorer: Example Circuit Simulation

- 3 -

ICA:

EMSSLink1.GAP := 3

EQU

Difference := FLUXM2.FLUX - FLUXM1.FLUX

FLXFLUXM1 FLX FLUXM2CONST

CONST2

Difference

COMP1ECE

EMSSLink1

ROT

ROT_Vw

+

Maxwell 3D LinkMaxwell 3D Link

0.00 100.00 200.00 300.00 400.00 500.00 600.00Time [ms]

0.00

0.02

0.04

0.06

0.08

0.10

0.12

Flu

x [

vs]

0.0000

0.0010

0.0020

0.0030

0.0040

0.0050

Y2

Curve Info Y Axis

FLUXM1.FLUXTR Y1

FLUXM2.FLUXTR Y1

DifferenceTR Y2

COMP1.VALTR Y2

0.00 100.00 200.00 300.00 400.00 500.00 600.00Time [ms]

0.00

0.02

0.04

0.06

0.08

0.10

0.12

Flu

x [

vs]

0.0000

0.0010

0.0020

0.0030

0.0040

0.0050

Y2

Curve Info Y Axis

FLUXM1.FLUXTR Y1

FLUXM2.FLUXTR Y1

DifferenceTR Y2

COMP1.VALTR Y2

Spacing = 3mm

Non Differential Signal Detected

0.00 100.00 200.00 300.00 400.00 500.00 600.00Time [ms]

0.00

0.03

0.05

0.08

0.10

0.13

0.14

Flu

x [

vs]

0.00

0.03

0.05

0.07

0.10

0.13

0.15

0.17

0.20

0.21

Y2

Curve Info Y Axis

FLUXM1.FLUXTR Y1

FLUXM2.FLUXTR Y1

DifferenceTR Y2

COMP1.VALTR Y2

EMSSLink1.GAP := 1

Spacing = 1mm

Differential Signal Detected

Maxwell 3D result（B vs Angle）

© 2013 CADFEM GmbH

Object of Interest

- 4 -

Position Sensor (MR)

Used widely in automotive sector

Low cost

Some sensor parameters

Angular position

Positioning error

Axial

angular

Source: ANSYS

© 2013 CADFEM GmbH

Principle

- 5 -

• Magnetoresistive(MR) sensor element with gear wheel.

• Resistance changes with the angles which the magnetic field which crosses

• the direction of current accomplishes.

• Bridge connection of each resistance.

• No thermal effects.

• No deformation, eddy current effects.

© 2013 CADFEM GmbH

Maxwell: Process

Use Maxwell 3D MagnetoStatic +Optimetrics

Linear permeability for valid parameter.

Variable parameter about a gear rotation angle. Change rotation angle of object to a variable.

Integrate magnetic field intensity of a sensor object. Calculates using a function of Calculator.

Export Design Variation with Workbench Data is manually processed using a function of Table I/O.

6

© 2013 CADFEM GmbH

Maxwell: Simulation Details

Rotation angle of Wheel

Permeability of a deficit part

7

RotAngle

$TeethMur

Magnetize M

© 2013 CADFEM GmbH

Maxwell: Simulation Details

Use of Field Calculator

8

Sens_Fwd Sens_Back

VdvH

VdvH

x

y

/

/tan 1

Qty ・ H ・Scalar ・ Y

Geom ・ Sens_Fwd ・ Integ

Qty ・ H ・ Scalar ・ X

Geom ・ Sens_Fwd ・ Integ

/

Trig ・ Atan

Constant ・PI ・/

Number ・ 180.0 ・*

[Add] → Ang_Fwd

Operation of Calculator.

© 2013 CADFEM GmbH

HANDS-ON

9

HANDS-ON-Position-Sensor-Simulation-with Maxwell3D.docx

© 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

HPC parametric packs amplify

both solver licenses and HPC

licenses allowing you to

drastically reduce time to

innovation

Time reduction for a parametric study

- 11 -

ANSYS HPC Parametric Pack

dp1

dp2

dp3

dp4

Seri

es

of

De

sign

po

ints

Unused Cores

One set of solvers and 1 x HPC Parametric Pack

without HPC

94% reduced time to innovation

One set of Solver keys

Four sets of solver keys or

+ 1 HPC Pack

© 2013 CADFEM GmbH

Local

- 12 -

Types of Processing

Remote

1. All Processes Local

Geometry Update

Meshing Process

Boundary Conditions Mapping

Solution Process

Result Extraction

Result Processing

2. Local Pre/Post and Remote Solve Process

Geometry Update

Meshing Process

Boundary Conditions Mapping

Solution Process Result Extraction

Result Processing

3. Main Processes Remote

Geometry Update Meshing Process

Boundary Conditions Mapping

Solution Process

Result Extraction Result Processing

© 2013 CADFEM GmbH

Local

- 13 -

1. All Processes Local

Geometry Update

Meshing Process

Boundary Conditions Mapping

Solution Process Result Extraction

Result Processing

Remote

© 2013 CADFEM GmbH - 14 -

1. All Processes Local

All design points are calculated sequentially which means step by step

(NO simultaneous processes)

Solution Process:

Update Option: Use application default

Design Point Update Process:

Update Option: Run in Foreground

Local

Local

© 2013 CADFEM GmbH

Local

- 15 -

2. Local Pre/Post and Remote Solve Process

Geometry Update

Meshing Process

Boundary Conditions Mapping

Result Extraction

Result Processing

Remote

Solution Process

Results

as rst-

file

(large)

© 2013 CADFEM GmbH - 16 -

2. 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

Solve Manager

Design Point Update Process:

Update Option: Run in Foreground

Compute Server

Local

© 2013 CADFEM GmbH

Local

- 17 -

3. Main Processes Remote

Geometry Update

Result Processing

Remote

Meshing Process

Boundary Conditions Mapping

Solution Process

Result Extraction

extracted

Results

as table

(small)

© 2013 CADFEM GmbH

All design points are calculated sequentially or simultaneously

Processing order defined by 3 types of settings (see following slides)

- 18 -

3. Main Processes Remote

Solution Process:

Update Option: Use application default

Design Point Update Process:

Update Option: Submit to Remote

Solve Manager

Compute Server

Compute Server

© 2013 CADFEM GmbH

2nd Type: One Job Each Design Point

- 19 -

3. Main Processes Remote

Number of jobs is equal to design points

e. g. 32 design points 32 jobs

Jobs can be processed sequentially or simultaneously, depending on

licensing and RSM settings

© 2013 CADFEM GmbH

3rd Type: Specify Maximum Number of Jobs

- 20 -

3. Main Processes Remote

Maximum number of jobs is limited

Jobs can be processed sequentially or simultaneously, depending on

licensing and RSM setting

© 2013 CADFEM GmbH

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

Simultaneous Processing with ANSYS HPC Parametric Pack

- 21 -

Example

© 2013 CADFEM GmbH

Simultaneous Processing with ANSYS HPC Parametric Pack

- 22 -

Example

© 2013 CADFEM GmbH

Simultaneous Processing with ANSYS HPC Parametric Pack

- 23 -

Example

© 2013 CADFEM GmbH

Simultaneous Processing with ANSYS HPC Parametric Pack

- 24 -

Example

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), 0 jobs in RSM-Queue

8 cores per job 32 cores in process; enabled by ANSYS HPC Pack

Specified Maximum Number of Jobs < RSM Limiter Golden Rule

© 2013 CADFEM GmbH

ANSYS Maxwell: Integration into Workbench

- 25 -

© 2013 CADFEM GmbH

DSO Terminology for EM

- 26 -

R14: ANSYS 14, 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, without any

centralized bottlenecks.

© 2013 CADFEM GmbH 27

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

© 2013 CADFEM GmbH

Maxwell to Simplorer

28

Exporting Lookup Table

Export as format of Table .

Data is manually processed by other tools. (e.g. Excel)

Reload as Table Export SML.

Export from Parametric Solutions Export from Imported Table

ECE - LINKECE - LINK

編集

Result table file :

Starting Angle – End Angle Result table file :

Merged as Complete one round.

© 2013 CADFEM GmbH

Simplorer: System Simulation (Overview)

29

-20.40m

20.40m

0

0 40.00m20.00m

MRSensor.Sensitivity

Sensor output Voltage.

28.00u

29.00u

28.50u

0 40.00m20.00m

VM1.V [V] + -2.50

-9.92

10.00

0

0 40.00m20.00m

VM6.V [V]

Amplified Output.