Modern simulan prostedky pro

elektromagnetick, elektronick
a mechatronick systmy

TU Liberec
5.3.2013
ANSYS, Inc.

Tibor Bachorec
SVS FEM s.r.o.
1

March 14, 2013

SVS FEM s. r. o.
analzy,vpoty,instalace,
kolen
a

zstupce
pro R a Slovensko
krochova 42, 615 00 Brno
Tel: +420 543 254 554,5
www.svsfem.cz
Extrmn vkonn zazen za pijateln ceny
https://www.svsfem.cz/content/femworks
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Contents
Introduction
Sensors
Sensor Design Suite
Sensors for Automotive Applications
Hall Sensor
Variable Reluctance Sensor
Magneto-resistive Sensor
Flux Gate Sensor
Eddy Current Sensor
Summary
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Introduction: Sensors
Sensors are electromechanical devices that use magnetic field for sensing
Velocity sensors for antilock brakes and stability control
Position sensors for static seat location
Eddy current sensors for flaw detection

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Component Analysis
Use specific magnetic solvers to understand the basic physics
of the sensor
Vary Geometry, Material Properties, Environmental Conditions
Understand Key Factors that most Significantly affect Performance
Statistical, Monte Carlo, Sensitivity, Design of Experiments
Use Optimization Tools to Refine Design
Quasi-Newton, Genetic, Pattern Search
Create a Model of the Sensor for use in System Simulation

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Introduction: Sensor Design Suite

What is the Sensor Design Suite?
Three independent solutions which can assist engineers in designing
and analyzing electrical machines
Can integrate electromagnetic, circuit, and system engineering using
a common desktop environment
What solutions are provided?
Maxwell 2D/3D: for finite element analysis
Steady State Solvers (DC and frequency domain)
Transient dynamic solution (time domain) handles time-induced eddy
effects

Optimetrics: for design variation and optimization

Can optimize shape, position, and material for a desired response

Simplorer: for complete electrical and mechanical system analysis

System simulation linking with Maxwell Magnetostatic using ECE model
Concentrates on saturation and back-emf effects
Can evaluate design alternatives with parametrics
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Sensor Design Suite

Optimetrics

FEA

FEA
Maxwell 3D

Maxwell 2D
Equivalent
circuits
Co-simulation

SIMPLORER
Hall_Sensor_Model

ICA:

ROT

ROT_V

ANGLE

BX_CELL_BOT

TRIANG1

EQU

BX_CELL_TOP

ECE

Difference:=FLUXM2.FLUX - FLUXM1.FLUX

FLUXM1
CONST2
CONST

Difference

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COMP1

FLX

FLX

FLUXM2

System Analysis
Use System Simulation to understand the Sensors impact on
the whole system
Design a robust sensor using appropriate technology
Dont Over-Design unnecessarily
Consider Variations
MOS1
Controller

RefSpeed

D1

DCMP1

D2

RA := 1

E2

DFW

LA := 9.8m

RefCurrent

KE := 544m

LOAD

J := 4m
FREQ := 60

deg/s -> RPM

Hall_Sensor_Model

D3

GAIN

AMPL := 156
D4
Vbp

ICA:

Vbp

MRSensor

Vop

Vop

ANGLE

BX_CELL_BOT

Vbm

FML_INIT1

TRIANG1

ICA:

EQU

Vpp

ROT
ROT_V

AMP

5V
Vom

RotN

Vom

Vbm

Vpm

VM6 GAIN1

MAX:=-1e36

BX_CELL_TOP

Vin

ECE

Difference:=FLUXM2.FLUX - FLUXM1.FLUX

Encoder

Wheel
AxialSpeed

FLUXM1
CONST2

FLX

FLX

FLUXM2

NEW_MAX

Wheel Mechanical Load

COMP1

A mplif ied Voltage Output

WAIT
CONST

STATE1
Controled Wheele Speed

Difference

Wheele.Speed_RPM

-9.95

990.00

100.00m
Sensed Angle

500.00

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160.00m

Encoder.Angle

346.00

TRANS1

VM6.V [V ]

10.00

TRC := E1.I>MAX

0
0

100.00m

160.00m

100.00m

160.00m

Maxwell

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Maxwell Solution Types

Electrostatic

Static electric fields, forces, torques, and capacitances caused by voltage distributions and
charges. Linear materials only.

Magnetostatic

Static magnetic fields, forces, torques, and inductances caused by DC currents, static external
magnetic fields, and permanent magnets. Linear or nonlinear materials.

Eddy Current

Sinusoidally-varying magnetic fields, forces, torques, and impedances caused by AC currents and
oscillating external magnetic fields. Linear materials only. Full wave solver considers displacement
currents. Induced fields such as skin and proximity effects considered.

Transient Electric

Transient electric fields caused by time-varying voltages, charge distributions, or current

excitations. Inhomogeneous and nonlinear materials. The transient electric field simulator
computes time-varying electric fields. Electric potential is the solution quantity.

Transient Magnetic

Transient magnetic fields caused by time-varying or moving electrical sources and permanent
magnets. Linear or nonlinear materials. Induced fields such as skin and proximity effects
considered. Sources can be DC, sinusoidal, or transient voltages or currents. Can use external
schematic circuit.

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Maxwell Desktop
six
windows
Project
Manager
Window

3D
modeler
Window

Properties
Window
Progress
Window

Message
Window

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History
Tree
Window

FEM and Adaptive Meshing

In order to obtain the set of algebraic

equations to be solved, the geometry
of the problem is discretized
automatically into tetrahedral elements
All the model solids are meshed
automatically by the mesher
The assembly of all tetrahedra is
referred to as the finite element mesh
of the model or simply the mesh.

Start
Field Solution

Generate
Initial Mesh

Compute
Fields

Perform
Error Analysis

Has
Stopping
Criteria been
met?
Yes

Stop
Field Solution

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Refine
Mesh

No

Library Structure
3-Tier library structure
System (global) level predefined from Ansoft and ships with new upgrades,
users cannot modify this
User Library to be shared among several users at a company (can be
encrypted)
Personal libraries to be used only by single user (can be encrypted)
Add a new material: Tools > Edit Configured Libraries > Materials
New Interface for Materials Setting shared with RMxprt

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Typical Maxwell 2D/3D Results

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Typical Results for Sensors

Field plot from

Post Processor

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Inductance Variation
vs. Position, External
Field, etc

Simplorer

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Simplorer Overview
Multi-domain, system simulator for designing
high performance systems
Commonly used by the automotive,
aerospace/defense, and industrial automation
industries.
Integrated analysis with electromagnetic
simulation tools (Maxwell, PExprt, RMxprt, Q3D)

Circuits
R1

R2

50

R3

1k

1k

N0002

R4

50

C2

C1

3.3u
3.3u
V0 := 5

12

N0004
N0003

V0 := 0
N0005

Block Diagrams
I_PART_id

Three Basic Simulation Engines:

Circuits
Block Diagrams
State Machines
Analysis Types: DC, AC, Transient

LL := -9

VHDL-AMS Capability

id_ref

P_PART_id

LIMIT

id

GAIN

yd

G(s)

SUM2_6

State Machines
IMP = 0 and RLine.I <= ILOW
SET: CS1:=-1
SET: CS2:=-1
SET: CS3:=-1
SET: CS4:=-1

IMP = 0 and RLine.I >= IUP

IMP = 0
IMP = 0

IMP = 1

IMP = 1 and RLine.I <= ILOW

IMP = 1 and RLine.I >= IUP

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SET: CS1:=-1
SET: CS2:=1
SET: CS3:=-1
SET: CS4:=-1

IMP = 1

SET: CS1:=1
SET: CS2:=-1
SET: CS3:=-1
SET: CS4:=-1

17

GAIN

GS2

KP := 0.76

Co-simulation with Maxwell and Simulink

Statistical Analysis and Optimization

CONST

UL := 9

SET: CS1:=-1
SET: CS2:=-1
SET: CS3:=-1
SET: CS4:=-1

Multi Domain Design

Transformer
Sensors
Control

Electro Mechanics

Multitude of Domains
Multitude of Tools & Methods
Power Converter

Mechanics

Utility
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Maxwell - Simplorer Link

Solves series of DC solutions using 2D or 3D Magnetostatic Solver
Solve must include limits of Operating Range to be analyzed
FEA Circuit Equivalent imported into Simplorer to couple Electrical and
Mechanical solution

ADVANTAGES
Can modify and re-solve Simplorer simulations quickly
Can simulate design alternatives by using parametrics
DISADVANTAGES
Does not handle time-induced physics such as eddy currents and
magnetic diffusion

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Optimetrics

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Optimetrics Overview

21

Optimetrics enables engineers to determine the best design variation

among a model's possible variations

Create the original model, the nominal design, and then define design
parameters that vary

Optimetrics includes five unique capabilities:

Parametrics: Define one or more variable sweep definitions, each specifying a series of variable
values within a range. Easily view and compare the results using plot or table to determine how each
design variation affects the performance of the design.

Optimization: Identify the cost function and the optimization goal. Optimetrics automatically changes
the design parameter(s) to meet the goal. The cost function can be based on any solution quantity
that can be computes, such as field values, R,L,C force, torque, volume or weight.

Sensitivity: Determine the sensitivity of the design to small changes in variables in the vicinity of a
design point. Outputs include: Regression value at the current variable value, First derivative of the
regression, Second derivative of the regression.

Tuning: Variable values are changed interactively and the performance of the design is monitored.
Useful after performing an optimization in which Optimetrics has determined an optimal variable
value, and you want to fine tune the value to see how the design results are affected.

Statistical: shows the distribution (Histogram) of a design output like force, torque or loss caused by
a statistical variation (Monte Carlo) of input variables.

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Five Unique Optimizers

22

Quasi Newton - This optimizer approximates the gradient of a user-defined cost function in its
search for the minimum location of the cost function. This gradient approximation is only accurate
enough if there is little noise involved in the cost function calculation. The cost function calculation
involves FEA, which possesses finite accuracy.

Pattern Search - This optimizer performs a grid-based simplex search, which makes use of simplices:
triangles in 2D space or tetrahedra in 3D space. The cost value is calculated at the vertices of the
simplex. The optimizer mirrors the simplex across one of its faces based on mathematical guidelines
and determines if the new simplex provides better results. If it does not produce a better result, the
next face is used for mirroring and the pattern continues. If no improvement occurs, the grid is
refined. If improvement occurs, the step is accepted and the new simplex is generated to replace the
original one. Pattern Search algorithms are less sensitive to noise.

Sequential Nonlinear Programming - The main advantage of SNLP over quasi Newton is that it
handles the optimization problem in more depth. This optimizer assumes that the optimization
variables span a continuous space.

Sequential Mixed Integer NonLinear Programming - To be able to optimize on number of turns or

quarter turns, the optimizer must handle discrete optimization variables. The SMINLP optimizer can
mix continuous variables among the integers, or can have only integers, and works if all variables are
continuous.

Genetic Algorithm - The Genetic Algorithm (GA) search is an iterative process that goes through a
number of generations (see picture below). In each generation some new individuals (Children /
Number of Individuals) are created and the so grown population participates in a selection (naturalselection) process that in turn reduces the size of the population to a desired level (Next Generation
/ Number of Individuals).

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Optimization Procedure
Only one model must be set up
Optimization table results may be analyzed
in post-processor
Each simulation replaces multiple buildand-test cycles
Optimetrics finds optimal solution
automatically using user-defined criteria
(cost-function)

Design

Optimize

No

Simulate

Evaluate
OK?
Yes
Manufacture

Fewer solutions may be needed to achieve

optimal solution!

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Sensors for Automotive Applications

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Hall Effect Sensor

For speed control
Determine flux passing through
3D Hall effect sensor
Rotate sensor and vary gap

Gap between pole piece

and target wheel
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Permanent
magnet
Pole piece

Hall
sensors
IC chip

Rotate about the Z axis through one

half of a tooth, or 30 degrees.

Hall Effect Sensor

Flux in Hall effect sensor can be
determined by integrating B(normal)
on a surface

Field in IC and
Hall sensor

Field in permanent magnet

& pole piece
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Hall Effect Sensor Meshing Tips

Sensor Air Box

Required for Proper Meshing

Target Air Box

Required for Proper Meshing

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Differential Hall Sensor

Gap between
pole piece and
target wheel

Target Wheel

Hall IC
Cell Bot

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Pole Piece

Cell Top
Permanent
Magnet

ave = Bx dAcell_face
diff = ave1 ave 2

Hall Sensor - Parametric Results

Average top and bottom flux vs. angle
Spacing = 1, 2, and 3mm

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Hall Sensor - Simplorer Simulation

Maxwell
3D Link
EMSSLink1
EQU

ICA:

Difference := FLUXM2.FLUX - FLUXM1.FLUX

EMSSLink1.GAP := 3
+

ROT
ROT_V

CONST2
CONST

COMP1
ECE

FLUXM1

FLX

Difference

Use The ECE Link Element

Library to Import the Maxwell 3D Component Model

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FLX

FLUXM2

Hall Sensor - System Simulation

Spacing = 3mm
Differential signal is too small
0.12
0.0050
TR
TR

0.10

TR
TR

Curve Info
FLUXM1.FLUX

Y Axis

FLUXM2.FLUX

Y1

Difference
COMP1.VAL

Y1

Y2

0.0040

Y2

0.08

Y2

Flux [vs]

0.0030

0.06

0.0020
0.04

0.0010
0.02

0.00

0.0000
0.00

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100.00

March 14, 2013

200.00

300.00
Time [ms]

400.00

500.00

600.00

Hall Sensor - System Simulation

Spacing = 1mm
Differential signal is detected
0.21

0.14

TR

0.13

TR
TR
TR

Curve Info
FLUXM1.FLUX

Y Axis

FLUXM2.FLUX

Y1

Difference
COMP1.VAL

0.20

Y1

0.17

Y2
Y2

0.15

0.10

Flux [vs]

0.13

Y2

0.08
0.10

0.07

0.05

0.05
0.03
0.03

0.00

0.00
0.00

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100.00

March 14, 2013

200.00

300.00
Time [ms]

400.00

500.00

600.00

Variable Reluctance Sensor

For speed control by determining output voltage
Consider varying flux linkage vs. time due to fringing, nonlinear
materials, and speed of rotation
Coil
Permanent
magnet

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Pole piece

Variable Reluctance Sensor

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Variable Reluctance Sensor

Output voltage vs. time

Finite element
model
(equivalent
circuit)

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Angle vs. Time

Magneto-resistive Sensor
For speed control of gear wheel
Resistance changes with the angles
which the magnetic field which crosses
the direction of current accomplishes

Use Maxwell to determine average magnetic

field angle:
In Simplorer, look-up table of vs. rotation
gives resistance
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Magneto-resistive Sensor
Input Parameters
Rotation angle of Wheel
Permeability of missing tooth

RotAngle

$TeethMur

Magnetize M

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Magneto-resistive Sensor
Output Parameters
The Angle of magnetic field on sensor part
H y dv / V
= tan
H dv / V
x
1

Sens_Fwd

Field Calculator Operation:

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
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Sens_Back

Magneto-resistive Sensor
Exporting Lookup Table
Export as format of Table
Data is manually processed by other tools (e.g. Excel)
Reload as Table
Export SML
Part for One round is copied
Export from Parametric Solutions

Export from Imported Table

Result table file :

30[deg] and 15[deg]
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ECE - LINK

Result table file :

Merged as Complete one round.

Magneto-resistive Sensor

-15[deg] Magnetic Flux Density B

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-13[deg] H vector near sensor.

Magneto-resistive Sensor
Parametric results vs. rotation
Shows results for missing tooth

-15[deg] ~ 15[deg]
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-30[deg] ~ 30[deg]

System Model with Sensor

10

Rb
Sensor

MRSensor.Sensitivity

PHI0 := -30

180.0/PI

20.40m
0
-20.40m

600 rpm

Angle_bck_OUT
dRb := cos(INPUT[0]*PI/180.0)^2
dRf := cos(INPUT[1]*PI/180.0)^2
VAL[0] := Rz + dRz* dRb

EQUBL

20.00m

40.00m

VAL[1] := Rz - dRz * dRb

10

RotAngle_IN

RotN

RotN

Angle_fwd_OUT

VAL[2] := Rz + dRz * dRf

VAL[3] := Rz - dRz * dRf

Vbp

MRSensor

Vop

Vop

Vpp

AMP

5V

Vom
Vbm

E1

10

Sensitivity

CONST

Vbp

10

dRfact

Vom

Vbm

Vpm

V
R1

VM6
Vbp

VM1.V [V] + -2.50

R2

Vop

29.00u
28.50u

R3

Vom

Vbm

28.00u
0

20.00m

R4

40.00m

Sensor output Voltage.

Vbp
R14

VM6.V [V]
10.00

184k

R3

OPV54

1k

1k

1k

30k
+

Vop

R1
1k

R13
OPV51

100k

0
Vom

-9.92
20.00m

40.00m

R4
Vbm

Amplified Output.
2011 ANSYS, Inc.

R9

R15

100

R5

1k

100k

42

R2

R16 Vpp

OPV55

March 14, 2013

Vpm

System Model for Speed Control

speed
MOS1
Controller

RefSpeed

D1

DCMP1

D2

Speed

RA := 1

E2

DFW

NError

GAIN

GAIN

GAIN

KP := 16.66667m

KP := 1

RefSpeed

LIMIT1

SUM

IError

TPH1

LIM IT

INTG

UL := 20

THRES1 := -2.5

LL := 0

THRES2 := 2.5
VAL1 := -1

CONST

M
LOAD

LA := 9.8m

RefCurrent

KE := 544m

CONST := 16.66667

VAL2 := 1

KI := 2

Current
GAIN

KP := 1

J := 4m
FREQ := 60

deg/s -> RPM

D3

GAIN

AMPL := 156
D4
Vbp

Vbp

MRSensor

Vop

Vop

ICA:

Vpp

Vbm

FML_INIT1

AMP

5V
RotN

Vom
Vom

Vpm

Vbm

VM6GAIN1

MAX:=-1e36
Vin

Encoder

Wheele
AxialSpeed

NEW_MAX

Wheele Mechanical Load

Amplified Voltage Output

WAIT

STATE1
Controled Wheele Speed

Wheele.Speed_RPM

-9.95

1.05k

100.00m
Sensed Angle

500.00

0
0

100.00m

160.00m

100.00m

Angle
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2011 ANSYS, Inc.

160.00m

Encoder.Angle

346.00

TRANS1

VM6.V [V]

10.00

TRC := E1.I>MAX

March 14, 2013

160.00m

Fluxgate Sensor
For static position indication
A fluxgate sensor contains a small
core designed to be easily saturated
Inductance is affected by the
magnitude of an external field
created by drive coil
The value of inductance can change
by 10 times or more
This circuit provides an output
voltage that is proportional to the
magnitude and the direction of an
externally applied field.

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Drive Coil

Core

Fluxgate Sensor
Typical Flux Gate Sensor Applications include:
Proximity Sensing
Magnetic Field Measurement (Navigation, Geomagnetics)
Speed & Position Sensing
Sensor has Linear Response Characteristic

Arrows
Indicate
Magnetization
Direction

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Fluxgate Sensor Basics

Sensor is Driven Between Linear and Saturated Regions of the B-H Curve

Typical B-H Curve

2

1.5

Saturated Region
- Low Inductance

B (T)

0.5

0
-8.0E+05

-6.0E+05

-4.0E+05

-2.0E+05

0.0E+00

2.0E+05

4.0E+05

6.0E+05

-0.5

Saturated Region
- Low Inductance

-1

-1.5

-2

H (A/m)
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Arrows
Indicate
Magnetization
Direction

8.0E+05

Parametric Analysis

Linear Region
Curve Shifts Due
To Influence of
External Field

Saturated
Region

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System Analysis
Fluxgate_Sensor_1

Waveform
Distortion caused
by traversing the
B-H Curve

R1
oi_p

E1
oi_m

External Field Source

Bz

E2
EMF := 0

Sensor Current Response to a 2.5V, 100kHz Sinusoid

Current (A)

Positive and
Negative Areas are
Equal

20.00m
10.00m

-10.00m
-20.00m
80.00u

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85.00u

90.00u

Time (s)

95.00u

100.00u

Sinusoidal Response
External Field Shifts Curve Positively or Negatively

Current (A)

Positive and Negative Areas are No Longer Equal

Force = 3.72N
Time (s)
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Current (A)

Square Wave Response

Time (s)
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Differential Configuration
System Simulation

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Differential Results
Differential Sensor Response
External Field For Sensor 2 Changes from 0G to 2G at 2ms
Output Voltage Shifts Downward to Reflect the Change

Differential Flux Gate Sensor System Output Voltage

2.50
2.49
2.48
2.47
2.46
2.45
2.44
2.43
2.42
2.41
2.40
1.00e-003

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2.00e-003

3.00e-003

4.00e-003

Eddy Current Flaw Sensor

Current density for unflawed and
flawed cases very different
Flaw changes stored energy, and
thereby affects mutual inductances of
coils

Determine differential voltage between

two coils based on mutual inductance
Differential voltage calculated by:

Voc = I driver N1 N 2 ( Ld pu1 Ld pu 2 )

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Eddy Current Sensor

For flaw detection in
structures without altering
the physical makeup of that
structure
Eddy Current Probes are
based on the principle of
artificially creating induced
current in the target material,
from which we are able to
detect if any defect is present

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Description of the Task

This is a multi-parametric Eddy Current problem
Goal: sweep the probe at every location on the pipe
and reconstruct cartography of the flux patterns
Comparing simulated and tested results allows
testers to have a better understanding of the
measurements taken in the field

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Description of the Task

The tested device is a pipe made of Inconel
= 1.001
= 970,000

22 mm

Skin depth:

100kHz = 1.6mm
600kHz = 0.6mm

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1.3 mm thick

Description of the Task

The vertical slot crack blocks all the
induced current. This crack should
be easy to detect
The horizontal surface crack only
alters current paths. This crack is
more difficult to detect
Will the probe be able to detect the
signal due to the surface crack ?

10 mm

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Description of the Task

Pick up
Coils

Source
Coil

The Probe works at 2 frequencies: 100 kHz and 600 kHz

We need to solve each problem twice
Note: this is not the exact geometry used by customer
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Solve twice with same mesh

Maxwell set up:

59

1.

Solve the design with the crack

as vacuum

2.

Duplicate the design

3.

Change material property of

crack to inconel (to remove the
crack) in the second design

4.

Solve the second design without

adaptive meshing, importing
final mesh from original design

2011 ANSYS, Inc.

March 14, 2013

Results
Induced Currents

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2011 ANSYS, Inc.

March 14, 2013

Summary
Introduction to Sensor Design Suite
Several examples of sensors were given including:

Hall, VR, Magneto-resistive, Flux Gate, and Eddy Current

These were used for speed, position and flaw sensing
Both component and system level simulations were necessary to
understand the coupling interaction and complete performance of most
sensors

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2011 ANSYS, Inc.

March 14, 2013

Dkujeme Vm za pozornost !

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2011 ANSYS, Inc.

March 14, 2013