Sensors for Automotive Applications - ANSYS Customer Portal … · 2011-01-21 · © 2010 ANSYS,...
Transcript of Sensors for Automotive Applications - ANSYS Customer Portal … · 2011-01-21 · © 2010 ANSYS,...
© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary
Sensors for Automotive Applications
Mark ChristiniLead Application Engineer
Zed (Zhangjun) TangLead Application Engineer
ANSYS, Inc.
© 2010 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary
Contents
• Introduction• Hall Sensor• Variable Reluctance Sensor• Magneto-resistive Sensor• Flux Gate Sensor• Eddy Current Sensor • Summary
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Introduction
• 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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System Analysis
• Use System Simulation to understand the Sensor’s impact on the whole system– Design a robust sensor using appropriate technology– Don’t Over-Design unnecessarily– Consider Variations
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Hall Effect Sensor
Gap between pole piece and target wheel
Rotate about the Z axis through one half of a tooth, or 30 degrees.
• For speed control• Determine flux passing
through 3D Hall effect sensor
• Rotate sensor and vary gap
Permanent magnet
Pole piece
Hall sensors
IC chip
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Hall Effect Sensor
Field in permanent magnet & pole piece
Field in IC and
Hall sensor
• Flux in Hall effect sensor can be determined by integrating B(normal) on a surface
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Hall Effect Sensor – Meshing Tips
Sensor Air BoxRequired for Proper Meshing
Target Air BoxRequired for Proper Meshing
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Differential Hall Sensor
Gap between pole piece and target wheel
Target Wheel
Permanent
Magnet
Pole
Pie
ce
Cell Top
Cell Bot
Hall IC
21
cell_face
aveavediff
xave dAB
ϕϕϕ
ϕ
−=
= ∫
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Hall Sensor - Parametric Results
• Average top and bottom flux vs. angle• Spacing = 1, 2, and 3mm
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Hall Sensor - Simplorer Simulation
ICA:
ink1.GAP := 3
EQU
Difference := FLUXM2.FLUX - FLUXM1.FLUX
FLXFLUXM1 FLX FLUXM2CONST
CONST2
Difference
COMP1ECE
EMSSLink1
ROT
ROT_Vω +
Maxwell 3D LinkMaxwell 3D Link
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Hall Sensor - System Simulation
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
Flux
[vs]
0.0000
0.0010
0.0020
0.0030
0.0040
0.0050
Y2
Curve Info Y AxisFLUXM1.FLUX
TR Y1
FLUXM2.FLUXTR Y1
DifferenceTR Y2
COMP1.VALTR Y2
• Spacing = 3mm• Differential signal is too small
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Hall Sensor - System Simulation
• Spacing = 1mm• Differential signal is 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
Flux
[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 AxisFLUXM1.FLUX
TR Y1
FLUXM2.FLUXTR Y1
DifferenceTR Y2
COMP1.VALTR Y2
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Variable Reluctance Sensor
Permanent magnet
Coil
Pole piece
• For speed control by determining output voltage• Consider varying flux linkage vs. time due to fringing, nonlinear
materials, and speed of rotation
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Variable Reluctance Sensor
Finite element model
(equivalent circuit)
Output voltage vs. time
Angle vs. Time
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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: α
– In Simplorer, look-up table of α vs. rotation gives resistance
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• Input Parameters– Rotation angle of Wheel– Permeability of missing tooth
RotAngle
$TeethMur
Magnetize M
Magneto-resistive Sensor
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• Output Parameters– The Angle of magnetic field on sensor part
Sens_Fwd Sens_Back
⎟⎟
⎠
⎞
⎜⎜
⎝
⎛=
∫∫−
VdvH
VdvH
x
y
/
/tan 1α
Qty ・ H ・Scalar ・ YGeom ・ Sens_Fwd ・ Integ
Qty ・ H ・ Scalar ・ XGeom ・ Sens_Fwd ・ Integ
/
Trig ・ Atan
Constant ・PI ・/Number ・ 180.0 ・*
[Add] → Ang_Fwd
Operation of Calculator.
Magneto-resistive Sensor
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• 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
Part for One round is copied
Result table file : ±30[deg] and ±15[deg] Result table file :
Merged as Complete one round.
Magneto-resistive Sensor
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-15[deg] Magnetic Flux Density B
-13[deg] H vector near sensor.
Magneto-resistive Sensor
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• Parametric results – α vs. rotation• Shows results for missing tooth
-15[deg] ~ 15[deg] -30[deg] ~ 30[deg]
Magneto-resistive Sensor
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RotN
Vom
Vop
Vbm
Vbp
ω +
MRSensor
E1
PHI0 := -30
Vbm
Vbp
Vpm
Vpp
Vom
Vop +
-+
V
AMP
VM6
600 rpm
5 V
-20.40m
20.40m0
0 40.00m20.00m
MRSensor.Sensitivity Sensor
RotAngle_IN
Vbp
Vbm
Vop
Vom
CONST
R1
R2
R3
R4
EQUBL
10
Rb
10
dRfact
10
Sensitivity
10
RotN
dRb := cos(INPUT[0]*PI/180.0)^2dRf := cos(INPUT[1]*PI/180.0)^2VAL[0] := Rz + dRz* dRbVAL[1] := Rz - dRz * dRbVAL[2] := Rz + dRz * dRfVAL[3] := Rz - dRz * dRf
180.0/PI
Angle_fwd_OUT
Angle_bck_OUT
Sensor output Voltage.
28.00u
29.00u
28.50u
0 40.00m20.00m
VM1.V [V] + -2.50
Vop
Vom
Vpp
Vpm
R1
1k
R2
1k
+
-
OPV54
R9
100k
R4
100k
Vbp
Vbm
R3 1k
R5 1k
+
-
OPV51R13
1k
R14 184k
R15 100
+
-
OPV55R16
30k
-9.92
10.00
0
0 40.00m20.00m
VM6.V [V]
Amplified Output.
System Model with Sensor
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RotN Vom
Vop
Vbm
VbpMRSensor
Vbm
Vbp
Vpm
Vpp
Vom
Vop +
-+
V
AMP
VM6
VinEncoder
LOAD
M
ICA:
E2
FREQ := 60AMPL := 156
DCMP1
RA := 1
KE := 544m
J := 4m
LA := 9.8m
MOS1
DFW
FML_INIT1
MAX:=-1e36
WAIT STATE1
NEW_MAX
TRC := E1.I>MAX
TRANS1
D1 D2
D3 D4 GA
IN
GAIN1
5 V
AxialSpeedWheele
RefSpeed
RefCurrent
Controller
Wheele Mechanical Load
-9.95
10.00
0 160.00m100.00m
Amplified Voltage Output VM6.V [V]
0
346.00
0 160.00m100.00m
Sensed Angle Encoder.Angle
0
1.05k
500.00
0 160.00m100.00m
Controled Wheele Speed Wheele.Speed_RPM
deg/s -> RPM
GAIN
CONST
GAIN
GAIN LIMIT
I
Speed
KP := 16.66667
NError
RefSpeed
CONST := 16.6666
Current
KP := 1
GAIN
KP := 1
SUM LIMIT1
UL := 20
LL := 0
IError TPH1
THRES1 := -2.5
VAL2 := 1VAL1 := -1THRES2 := 2.5INTG
KI := 2
Angle
speed
System Model for Speed Control
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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.
Drive Coil Core
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Arrows Indicate Magnetization Direction
• Typical Flux Gate Sensor Applications include:
• Proximity Sensing
• Magnetic Field Measurement (Navigation, Geomagnetics)
• Speed & Position Sensing
• Sensor has Linear Response Characteristic
Fluxgate Sensor
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Arrows Indicate Magnetization Direction
Typical B-H Curve
-2
-1.5
-1
-0.5
0
0.5
1
1.5
2
-8.0E+05 -6.0E+05 -4.0E+05 -2.0E+05 0.0E+00 2.0E+05 4.0E+05 6.0E+05 8.0E+05
H (A/m)
B (T
)
Sensor is Driven Between Linear and Saturated Regions of the B-H Curve
Saturated Region - Low Inductance
Saturated Region - Low Inductance
Fluxgate Sensor Basics
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Saturated Region
Linear RegionCurve Shifts Due To Influence of External Field
Parametric Analysis
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oi_p
oi_m Bz
Fluxgate_Sensor_1
E2
E1
R1
Sensor Current Response to a 2.5V, 100kHz Sinusoid20.00m
-20.00m
0
-10.00m
10.00m
80.00u 100.00u85.00u 90.00u 95.00u
External Field Source
EMF := 0
System Analysis
Cur
rent
(A)
Time (s)
Positive and Negative Areas are Equal
Waveform Distortion caused by traversing the B-H Curve
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Sinusoidal Response
Force = 3.72N
External Field Shifts Curve Positively or NegativelyPositive and Negative Areas are No Longer Equal
Cur
rent
(A)
Time (s)
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Cur
rent
(A)
Time (s)
Square Wave Response
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Differential Configuration System Simulation
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Differential Sensor ResponseExternal Field For Sensor 2 Changes from 0G to –2G at 2msOutput Voltage Shifts Downward to Reflect the Change
Differential Flux Gate Sensor System Output Voltage2.50
2.402.41
2.42
2.43
2.44
2.45
2.46
2.47
2.48
2.49
1.00e-003 4.00e-0032.00e-003 3.00e-003
Differential Results
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Eddy Current Flaw Sensor
Current density for unflawed and flawed cases very differentFlaw changes stored energy, and thereby affects mutual inductances of coils
Differential voltage calculated by:
)( 2121 pudpuddriveroc LLNNIV −− −= ω
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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
22 mm
1.3 mm thick
µ = 1.001
σ = 970,000
Skin depth:
0.6mmδ1.6mmδ
600kHz
100kHz
==
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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
SourceCoil
Pick up Coils
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:1. Solve the design with the
crack as vacuum2. Duplicate the design3. 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
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Summary
• 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