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
VelocityPosition

Variable Reluctance
VelocityPosition

Magnetic Resistance
VelocityPosition

Flux Gate
Proximity Sensing
Navigation
VelocityPosition

Eddy Current
NDTflaw detection)

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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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 Simplorer: Example Circuit Simulation
Maxwell 3D Link
EMSSLink1
ICA: EQU

Difference := FLUXM2.FLUX - FLUXM1.FLUX

EMSSLink1.GAP := 3

w
ROT

+ ROT_V

CONST2 COMP1
ECE
CONST
FLUXM1 FLX FLX FLUXM2
Difference

Maxwell 3D resultB vs Angle

0.12
0.0050
EMSSLink1.GAP
Curve Info Y Axis := 1
FLUXM1.FLUX Y1

Spacing = 3mm Spacing = 1mm

TR

TR
FLUXM2.FLUX Y1
0.10 Difference
TR Y2

Non Differential Signal Detected Differential Signal Detected

TR
COMP1.VAL Y2 0.0040

0.08 0.14 0.21

0.12
0.0050 0.20
Curve Info Y Axis
Curve Info Y Axis
FLUXM1.FLUX
FLUXM1.FLUX TR Y1
TR Y1
FLUXM2.FLUX
TR
FLUXM2.FLUX
Y1
0.13
0.0030 TR Y1
Difference Y2 0.17
0.10 Difference Y2 TR
TR
Flux [vs]

COMP1.VAL
COMP1.VAL TR Y2
TR Y2 0.0040

Y2
0.06 0.10
0.15

0.08

0.13
0.0030
Flux [vs]
Flux [vs]

0.08
0.0020

Y2
Y2

0.06
0.10

0.04 0.0020
0.05 0.07
0.04

0.05

0.0010
0.02 0.03
0.0010
0.03
0.02

0.00
0.00 100.00 200.00 300.00 400.00 500.00 600.00
0.0000
-3- 0.00
2013 CADFEM GmbH
0.00 100.00 200.00 300.00 400.00 500.00 600.00
0.00
Time [ms] Time [ms]
Object of Interest
Position Sensor (MR)
Used widely in automotive sector
Low cost

Some sensor parameters

Angular position
Positioning error
Axial Source: ANSYS
angular

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Principle

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.

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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.

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Maxwell: Simulation Details
Rotation angle of Wheel RotAngle

Permeability of a deficit part

$TeethMur

Magnetize M

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Maxwell: Simulation Details Sens_Fwd Sens_Back

Use of Field Calculator H y dv / V

tan
1
H dv / V
x

Operation of Calculator.
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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HANDS-ON

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

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Workbench: Simulation Process
Efficient use of hardware resources for parameter variations
HPC parallel computation with ANSYS
Types of processing with ANSYS
Example scenario

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 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

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 Types of Processing

Local 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

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 1. All Processes Local

Local Remote

Geometry Update

Meshing Process

Boundary Conditions Mapping

Solution Process

Result Extraction

Result Processing

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 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 Local

Design Point Update Process:

Update Option: Run in Foreground Local

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 2. 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)

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 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 Compute Server
Solve Manager

Design Point Update Process:

Update Option: Run in Foreground Local

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 3. Main Processes Remote

Local Remote

Geometry Update

Meshing Process

Boundary Conditions Mapping

Solution Process

extracted Result Extraction

Results
Result Processing as table
(small)

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 3. 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)

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 3. Main Processes Remote

2nd Type: One Job Each Design Point

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

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 3. Main Processes Remote

3rd Type: Specify Maximum Number of Jobs

Maximum number of jobs is limited

Jobs can be processed sequentially or simultaneously, depending on

licensing and RSM setting

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 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

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 Example

Simultaneous Processing with ANSYS HPC Parametric Pack

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 Example

Simultaneous Processing with ANSYS HPC Parametric Pack

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 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), 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

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ANSYS Maxwell: Integration into Workbench

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DSO Terminology for EM
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.

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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

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Maxwell to Simplorer
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

Result table file : ECE - LINK

Starting Angle End Angle Result table file :

Merged as Complete one round.

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Simplorer: System Simulation (Overview)
MRSensor.Sensitivity
20.40m
0
-20.40m
0 20.00m 40.00m

VM1.V [V] + -2.50

29.00u

28.50u

28.00u
0 20.00m 40.00m
Sensor output Voltage.
VM6.V [V ]
10.00

-9.92
0 20.00m 40.00m

Amplified Output.
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