© 2011 ANSYS, Inc. September 9, 2014 1

Physics Based System Analysis & Co-Simulation

Scott Stanton Technical Director

Advanced Technology Initiatives

ANSYS, Inc.

© 2011 ANSYS, Inc. September 9, 2014 2

Detailed 3D Multiphysics

Maxwell

Fluent

Mechanical

Simplorer

Software Engineering & System Simulation

Systems V Practices and Owners

System Validation

Sub-System Integ. & Verification

Component Integration

& Verification

Requirements and Specifications

Sub-System Design

System Functional & Architectural Design

Mechanical Electrical Software

Detailed Design & Optimization

Systems Functional Engineering

Functional Allocations

Detailed Architecture Architecture

2

© 2011 ANSYS, Inc. September 9, 2014 3

Model Simulation Result Tool

Requirement Req 23: On request, the valve should close in 500us

X MSWord, DOORS, …

Functional simulation

SCADE System

System simulation

(ODE)

Simplorer using Circuits or VHDL-AMS (Modelica in Progress)

High fidelity physics based

simulation (PDE)

Fluent, Maxwell, Mechanics, Workbench

System Validation

ODE+ROM+Ctrl Close loop validation

Simplorer with SCADE Suite and ROMs from PDE Solvers

500us 0

Pos

true

false t

0

500us

t

Pos

Pmax

Magnetic

t

Pos

0 500us

t

Pos

Pmax

500us

Simulation Driven Product Development

Pmax

Thermal

© 2011 ANSYS, Inc. September 9, 2014 4

Cost of Correcting Defects Throughout the Development Process

Systems Engineering For Dummies, Cathleen Shamieh, ® IBM Limited Edition

© 2011 ANSYS, Inc. September 9, 2014 5

Physical System Simulation

Simulation Synchronizer

Simulink

C/C++

User-defined

Models

Circuits: States:

Electromagnetic

(FEA)

Mechanical

(FEA)

Model Extraction: Equivalent Circuit, Impulse

Response Extracted LTI, Stiffness Matrix

Fluidic

(CFD)

VHDL-AMS Modelica* IF (domain = quiescent_domain)

V0 == init_v; ELSE

Current == cap*voltage'dot;

END USE;

Blocks:

Thermal

(FEA/CFD)

Matlab

Simulink

Co-Simulation

RBD

Maxwell

CFD

*Currently Under Development

© 2011 ANSYS, Inc. September 9, 2014 6

Types of Reduced Order Models – ROMs

Thermal

Magnetic

Electrical

Mechanical

© 2011 ANSYS, Inc. September 9, 2014 7

PExprt

Simplorer

Simplorer

RMxprt

Maxwell

VHDL-AMS

Maxwell

VHDL-AMS

Q3D

© 2011 ANSYS, Inc. September 9, 2014 8

Reduced Order Models (ROMs) for Thermal Systems

© 2011 ANSYS, Inc. September 9, 2014 9

Battery Physics – Thermal

© 2011 ANSYS, Inc. September 9, 2014 10

Battery Thermal Behavior via ROM

• Type 1: Thermal Network

• Careful Calculation and Calibration needed

• Accuracy Compromises

• Type 2: LTI – State Space

• Can be as Accurate as CFD

• No Calibration

LTI t t

Step Input

Step Response

1

© 2011 ANSYS, Inc. September 9, 2014 11

Reduced Order Model for CFD

ROM

Voc = -1.031*exp(-35*(abs(IBatt.V/Vinit))) + 3.685 + 0.2156*(abs(IBatt.V/Vinit)) - 0.1178*(abs(IBatt.V/Vinit))^2 + 0.3201*(abs(IBatt.V/Vinit))^3 + 0.3/30.0*(U1.Temp_block_1-273)

© 2011 ANSYS, Inc. September 9, 2014 12

© 2011 ANSYS, Inc. September 9, 2014 13

Heat dissipated

Discharge curve

Simplorer battery model

CFD battery model

Co-simulation

Co-Simulation between System and CFD

© 2011 ANSYS, Inc. September 9, 2014 14

Nonlinear ROM Extracted from CEM Solver

© 2011 ANSYS, Inc. September 9, 2014 15

Approach Summary

-300.00 -200.00 -100.00 0.00 100.00 200.00 300.00ECE_Iq [A]

-0.25

-0.13

0.00

0.13

0.25

0.38

0.50

me

an

(EC

E_

psi_

d)

Curve Info

mean(ECE_psi_d)ECE_TR_Setup : TransientECE_Id='-300A'

mean(ECE_psi_d)ECE_TR_Setup : TransientECE_Id='-225A'

mean(ECE_psi_d)ECE_TR_Setup : TransientECE_Id='-150A'

mean(ECE_psi_d)ECE_TR_Setup : TransientECE_Id='-75A'

mean(ECE_psi_d)ECE_TR_Setup : TransientECE_Id='0A'

mean(ECE_psi_d)ECE_TR_Setup : TransientECE_Id='75A'

mean(ECE_psi_d)ECE_TR_Setup : TransientECE_Id='150A'

mean(ECE_psi_d)ECE_TR_Setup : TransientECE_Id='225A'

mean(ECE_psi_d)ECE_TR_Setup : TransientECE_Id='300A'

01_Prius_design_IdIq_Symm_ECEECE_psi_d

n1

n2

n3

m1

SimulatorModel=PMSM_DQ_GNurbs

w+

V_ROTB1

© 2011 ANSYS, Inc. September 9, 2014 16

Simplorer Model

0

w+

V_ROTB1

EQU

FML1

S1:=if (Time<=0.01, 1, 0)

R7

R6

R5

R=0.2ohm

R1

R2

R3 L4

L3

L2 n1

n2

n3

m1

SimulatorModel=PMSM_DQ_GNurbsA B C

N

U_MOT

TS1

TS2

TS3

0.00 10.00 20.00 30.00 40.00 50.00Time [ms]

-125.00

-75.00

-25.00

25.00

75.00

125.00

Y1

Curve Info

InducedVoltage(PhA)Imported

InducedVoltage(PhB)Imported

InducedVoltage(PhC)Imported

U_MOT.V_ATR

U_MOT.V_BTR

U_MOT.V_CTR

0.00 10.00 20.00 30.00 40.00 50.00Time [ms]

-200.00

-75.00

50.00

175.00

Y1 [A

]

Curve Info

L2.ITR

L3.ITR

L4.ITR

Current(PhA)Imported

Current(PhB)Imported

Current(PhC)

© 2011 ANSYS, Inc. September 9, 2014 17

Sensor Physics and Behavior via Reduced Order Model (ROM)

© 2011 ANSYS, Inc. September 9, 2014 18

Sub-System Simulation Verify Behavioral Operation

-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 Voltage

© 2011 ANSYS, Inc. September 9, 2014 19

Example: Co-Simulation Magnetic – Pneumatic Force Coupling

0

0

0

0 0

S

+

SM_TRB1

F

F_TRB2

MASS_TRB1

V0=0m_per_sec

S0=0.5mm

M=1gram

F

F_TRB1

Ide

al

STOP

LOWER_LIM=0.01mm

UPPER_LIM=0.195mm

F

F_mag

F

F_Plunger

F

F_spring

SPRING_TRB1

C=333

S+

S_TRB1

VALUE=0.185mm

E1

R1

T1

T2T3

T4

smpl_lift

cfd_force

S1

CTRL=S1

D1

CEM Co-Simulation

CFD Co-Simulation

0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]

0.00

100.00

200.00

300.00

400.00

500.00

Po

sitio

n [u

m]

0.00

0.01

0.02

0.03

0.04

0.05

0.06

Co

il C

urr

en

t [A

]

-20.00

-15.00

-10.00

-5.00

0.00

5.00

10.00

15.00

20.00

Plu

ng

er

Fo

rce

[n

ew

ton

]

02_CoSim_MAgnetic_CFDTransient Switching with CFD ANSOFT

Curve Info Y Axis

Current Current

Plunger Force Plunger Force

Position w. CFD Y3

Position w/o CFD Y3

Simplorer Schematic

© 2011 ANSYS, Inc. September 9, 2014 20

Frequency Dependent ROM

© 2011 ANSYS, Inc. September 9, 2014 21

Inverter Package Model

3 Phase Model

1 Phase Model

3 Phase Model

1 Phase Model

© 2011 ANSYS, Inc. September 9, 2014 22

LCR Extraction + Circuit

LCR Extraction

Simplorer Circuit

State Space Model

Electromagnetics Harmonic Analysis

L – Inductance C – Capacitance R – Resistance

© 2011 ANSYS, Inc. September 9, 2014 23

Parasitics Extraction

Extract the Resistance, Inductance and Capacitance (RLC) parameters of the package by using the Boundary Element Method (BEM)

Example for two conductors

© 2011 ANSYS, Inc. September 9, 2014 24

Definition of Inverter package circuit

Bus Bar

IPM Gate Drive

Simplorer

Q3D Extractor

© 2011 ANSYS, Inc. September 9, 2014 25

Output switching waveform with considered extracted parameter

Device Model + Parasitic parameter : Switching ON/OFF

Surge and ringing waveform

© 2011 ANSYS, Inc. September 9, 2014 26

Cable Design Automation

Phase A

Phase B

Partition

Phase C

Armor

Outer Jacket

Hydraulic Tubes

© 2011 ANSYS, Inc. September 9, 2014 27

ANSYS Approach: Process Compression

1.00E-006 1.00E-005 1.00E-004 1.00E-003 1.00E-002 1.00E-001 1.00E+000 1.00E+001 1.00E+002F [MHz]

-75.00

-65.00

-55.00

-45.00

-35.00

-25.00

-15.00

-5.00

3.65

S (

dB

)

Simplorer_SmatrixS11 and S21Curve Info

dB20(S11)Imported

dB20(s21)Imported

Design Inputs Post-Processing

• Fully Automated • Maxwell or Q3D

• Graphical Matrix Reduction • Parameter Extraction • Project accessible in Maxwell

or Q3D for field overlays or workbench coupling

• Template Driven Input

Analysis stage requires some expertise and training Automate analysis for better accessibility in engineering and the field

Analysis

Python/(Esterel) Scripting

© 2011 ANSYS, Inc. September 9, 2014 28

Cable Design Kit – Post-Processing

• User Friendly panel to define Cable Connections

• Matrix reduction performed for Impedance and Admittance matrix

• Sequence Parameter Calculation of resulting matrix is 3x3

Reduced Admittance Matrix

Sequence Parameters

Matrix Reduction

© 2011 ANSYS, Inc. September 9, 2014 29

Model Verification: Test Circuit Generation

Define S parameters in Simplorer using Output Variables and reference power meters

All 1ohm reference termination resistors

1OhmSpars 0

0

0 0

Circle1_A Circle1_B

R1 R2E1

W

+

WM1

W

+

WM2

With power on the input side, S11 and S21 are obtained (a1 ≠ 0, a2 = 0) If desired to obtain S22 and S12 (a2 ≠ 0, a1 = 0) place a power source on the secondary side, shorting the supply on the primary.

a1 a2

b1 b2

+ +

- - V1 V2

I1 I2

Make power meter orientation consistent with current flow references

(Positive in)

© 2011 ANSYS, Inc. September 9, 2014 30

Model Verification: Frequency Domain

• Compare Circuit AC Sweep to Field Simulation

1 meter Works for Long or Short Length Low or High Frequency

DC 100MHz

© 2011 ANSYS, Inc. September 9, 2014 31

Separate CM/DM Voltage by LISN

Waveform ＣＭ Voltage: Vcm ＤＭ Voltage: Vdm

Common Mode Voltage(Vcm) , Differential Mode Voltage(Vdm)

© 2011 ANSYS, Inc. September 9, 2014 32

FFT: Waveform changes to Frequency domain

Common Mode Nose is over the CISPR regulations

© 2011 ANSYS, Inc. September 9, 2014 33

Mechanical ROM

© 2011 ANSYS, Inc. September 9, 2014 34

Simplorer – Model Order Reduction

1. Simplorer - ANSYS Mechanical Link

• Reduced Order Model from ANSYS to Simplorer (State-space)

From ~45,000 equations to 18 states and 6 terminals (Rotational and translational for each DOF)

© 2011 ANSYS, Inc. September 9, 2014 35

Four Masses with Four Rotational DOFs: Free Simulation

Rotational Torque source

1Nm Torque

© 2011 ANSYS, Inc. September 9, 2014 36

4DOF: Free Simulation Results

Simplorer

ANSYS Mechanical

© 2011 ANSYS, Inc. September 9, 2014 37

Simplorer – RBD Co-Simulation

© 2011 ANSYS, Inc. September 9, 2014 38

Embedded Software SCADE Suite

Battery CFD - Fluent

P.E. Simplorer Characterization

IGBT CFD Icepak

Electric Motor CEM Maxwell

Sensor CEM Maxwell

A to D VHDL-AMS Simplorer

Q3D L,R,C

ANSYS Mechanical FEA

Temperature profile Current profile

© 2011 ANSYS, Inc. September 9, 2014 39

Thank You