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Virtual Prototyping by Multiphysics

Simulations at CSEM

Dr Ivar KJELBERG

Systems Engineer & Senior Project Manager, CSEM sa, Neuchâtel (CH)

VPE Symposium,

Rapperswil, 2012, Apr 19

© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 1

Overview

• Some words about CSEM sa

• Importance of Virtual Prototyping & Simulations

• Different types of Modelling

• What is needed for Modelling: People, Software, Data & Interfacing

• Model Testing, Validation, and Verification

• Model Reduction and Model Interfacing to next Modelling level

• Some examples of Multiphysics Simulations at CSEM

• Conclusions

CSEM

the Swiss platform

for transfer in

micro-technology

Our mission:

Development and transfer of micro-

technologies to the industrial sector

– in Switzerland, as a priority –

in order to reinforce its competitive

advantage

• Cooperation agreements with

established companies

• Creation of start-ups


Federal contributions

29%

Cantons 11%

CTI 12%

EU projects 12%

Other public projects

5%

Industrial income

31%

• Incorporated, not-for-profit Research and Technology Organization

(RTO), supported by the Swiss Government

• A public-private partnership

• 31 % public

• 69 % private

• Key figures (2010)

• Revenues ~ CHF 70 mio

• Employees ~ 400

16% Swiss Confederation (EPFL)

15% Neuchatel (city and canton)

69% Private organizations

share

hold

ers

CSEM at a glance

Centre Suisse d’Electronique et de Microtechnique SA


CSEM’s technology programs


• MEMS

• Ultra-low-power integrated

systems

• Systems

• Surface engineering

technologies


Closer to industry …



CSEM’s national network

Our strategic research partners

Universities

Universities

of applied sciences


CSEM’s European network

At European Level – HTA Heterogeneous Technology Alliance

Dresden, Berlin, München

Empl. 1’600

Turnover : 220 M€

Clean room : 8450 m2

Division Recherche Technologique

Grenoble

Empl. 1’400

Turnover : 191 M€

Clean room : 8’000 m2

Neuchâtel

Empl. 400

Turnover: 50 M€


Espoo, Oulu

Empl 2’700

Turnover : 217 M€



Research

Development and integration of technologies

Transfer to industry

Production and commercialization

CSEM’s positioning

European

Allies EMPA, PSI

EPFL, ETHZ

Universities

Industrial partners

Spin-off, Start-ups


Virtual Prototyping by Multiphysics Simulations at CSEM


Virtual Prototyping & Simulations are essential at CSEM

• As technology and systems developers, virtual prototyping and detailed

simulations is a mandatory task to all our activities: before we start to

prototype, as well as to optimise further before we start to manufacture

• With the very diverse activities at CSEM, modelling and simulations cover:

• Micro-electronics & -optics production technologies,

• Galvano, chemistry etching, plasma, material depositing, … processes

• ASIC electronic design, and extensive software testing, also before fab

production launch

• MEMS and Silicon (mechanics) machining technologies,

• MEMS behaviour and integration simulations (structural, vibrations,

thermal, ACDC, RF, micro-fluidics …)

• Full Systems simulations at (multi-) physical and component level

• …


Types of Modelling

• I distinguish classes of modelling:

• Physics detailed models

FEM: i.e. ANSYS®, NASTRAN®, MARC®,

COVENTOR®, COMSOL Multiphysics®,…

Analytical: Maple®, Mathematica®,

Numerical: Matlab®, Scilab®,…)

• Systems (block) models

Simulink®, SciLab®, … or

Modelica® based: MapleSim®,

SimulationX®, Dymola® …

See also www.modelica.org

Narrowing down on modelling definitions

From: “Introduction to Modelling and Simulations of Technical and Physical Systems

with Modelica”, by P. Fritzson, IEEE-Wiley, 2011, ISBN: 978-1-118-09245-9

® Registered Trademarks

by respective commercial

software suppliers


And many other specific types of Modelling

• CAD & CAM modelling

• Data acquisition modelling

• Electronics circuit modelling

• FPGA modelling

• Proprietary tools for automation and PLCs modelling

• Optics ray tracing modelling

• Company specific custom codes

• etc.

• Important question: How to get all these models to link to each other

flawless, and in a simple manner ?

A standard interfacing mean is missing, today !


What is needed for efficient (Multi-)Physics Simulations?

• The software user’s personal skills to understand the simulations performed

• The adapted software tool(s)

• The geometry and CAD data and extensive data exchange availabilities

• The detailed material data base and material knowledge: material detailed

dependency on temperature, pressure, magnetic field strength, damping …

• But also the same user’s ability and willing to actively participate to:

• To verify and validate the models via simple analytical or numerical

analysis

• Test by prototyping the models, or parts of the models

A “model” (a simplified representation of reality), is to be used, ̶ NOT to be believed !


How to best cover Multi-Physics Systems Simulations ?

• Check software tools ability to perform true multiphysics Simulations under

the same software environment, with simple and efficient interfacing means.

• Do NOT choose a

• For Multi-Physics, do select an “open” software

“BlacBox” SW Data in Results (?) out

“Open” SW Data in

Results out Equation example taken from COMSOL Multiphysics®


Some “public” examples of Multiphysics Simulations

at CSEM


Silicon’s conquest of the watchmaking industry

Examples of technology transfer Silicon (anisotropic crystal) spirals

1996 2002 TODAY

Development & Integration

Transfer & Industrialization


Spherical reaction wheel – rotor, with 728 magnets and 20 stator

coils, and rotor in magnetic levitation

• With 728 magnets on spherical rotor (Ø180 mm) and 20 fixed stator coils,

• Rotor in magnetic levitation

• Excellent agreement between measurements FEM and analytical simulations

Examples of COMSOL Multiphysics Simulations from CSEM Neuchâtel (L. Rossini)


Transient capacitor discharge into a MEMS heater

• Embedded Spice model for

driving circuit, conduction, radiation

and convective cooling

100 µs time span

MEMS size: 300x200x100 µm3

Examples of COMSOL Multiphysics Simulations from CSEM Neuchâtel


Water boiler heating, heat source at bottom

• Heater (10kW) at bottom of 600 litre water tank, natural convection

• Nice convective turbulence pattern displayed in animation mode

• After 24 minutes T = 9.5 °C after 2 hours => T = 17 °C



Water boiler heating, heat source at top

• Heater (10kW) at top of 600 litre water tank, natural convection

• Little heat exchange lower down due to low heat diffusivity of water

• After 24 minutes T = 29.5 °C after 37 minutes => T = 44 °C



Simulation of alternating flow air heat-exchanger

• Air heat exchanger with alternating flow, air temperature drop and storage

and recovery efficiency optimisation for 4 alternating cycles

• Air flow, + solid material and gas heat exchange



Flexible guidance systems with very high resolution

mechanisms

SOFIA (Stratospheric Observatory for Infrared Astronomy)

Activation of a secondary mirror on an airborne telescope

• SiC Mirror Ø 350 mm

• Displacement ± 3 mm, resolution > 1:32’000 (bandwidth > 100 Hz)

Scientific instrumentation

http://upload.wikimedia.org/wikipedia/en/7/74/Dlr_logo1.png


SOFIA Airborne IR Telescope M2 drive mechanism

• Stress analysis of deformed M2 mirror guiding flexures

• CAD model view Reduced FEM solid model



Thermo-Fluid-mechanical modelling

Examples of COMSOL Multiphysics Simulations from CSEM Alpnach (G. Spinola Durante)


Accurate calculations of resistive path



Diffusion-driven packaging model



Thermal circuit model



Microfluidic model



CONSLUSIONS

• Advanced Multi-Physics Simulations are readily available today with the new software

developed over the last decade

• Multi-Physics Modelling requires high level skills from the user, and a regular use of the

tool, but allows then to rapidly build very complex models (days ̶ versus months a

decade ago)

• Correct and extensive knowledge of the material property data is essential

• Easy CAD and data exchange allows rapid update of the model with minimal effort for

verification and validation

• The most important for successful modelling is to verify and validate the models, as

well as to perform critical prototypes and tests, this remains the users responsibility

• The prices of such software are affordable also to SME’s

• Consultancy services can also be readily found on the market (but check the skills of

the provider for YOUR model needs)

• Multi-Physics FEM tool is the physicist and systems engineers best “sandbox”

Thank you for your attention!

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Virtual Prototyping by Multiphysics Simulations at … · Virtual Prototyping by Multiphysics Simulations at CSEM ... Virtual Prototyping by Multiphysics Simulations at CSEM ... chemistry