Thermal and Mechanical

System Simulation

ANSYS CONFERENCE & 27. CADFEM USERS MEETING

18 20 November 2009, Congress Center Leipzig
Evgenii Rudnyi, CADFEM GmbH
erudnyi@cadfem.de
Outline

System level simulation

Simplorer

Coupling Workbench and

Simplorer
Model Order Reduction

Thermal simulation
Electrothermal

Mechanical simulation
Control

Other papers at ACUM

1
Mechatronics: mechanical + electrical + computer sciences

2
Simplorer: http://www.ansoft.com/

Circuits

Block Diagrams

State Machines

Equation Blocks

VHDL-AMS

3
Example of VHDL-AMS

4
Compact Modeling: Transistor Compact Model

Figure from J. Lienemann, E. B. Rudnyi and J. G. Korvink. MST MEMS model

order reduction: Requirements and Benchmarks. Linear Algebra and its
Applications, v. 415, N 2-3, p. 469-498, 2006.
From Finite Elements to System Simulation

Electrothermal Simulation with power MOSFET:

From ANSYS Workbench to Simplorer

6
Model Order Reduction

Relatively new technology

Solid mathematical background:

Approximation of large scale
dynamic systems

Dynamic simulation:
Harmonic or transient simulation

Industry application level:

Linear dynamic systems

7
Model Reduction as Projection

Projection onto low- Ex Kx Bu

dimensional subspace

E
x Vz

z V T EVz V T KVz V T Bu
x = V
How to find Er
subspace?
Mode
superposition is
not the best way
to do it.

8
Implicit Moment Matching

Pad approximation Ex Kx Bu
Matching first moments for the
H ( s) sE K B
transfer function 1

H mi ( s s0 )i
0

H red mi ,red ( s s0 )i
0

mi mi,red , i 0, ,r

Implicit Moment Matching: s0 0

via Krylov Subspace V span{(K 1 E,K 1b)}

9
MOR for ANSYS: http://ModelReduction.com

Simulink,
ANSYS Model Simplorer, VerilogA,

Small dimensional
FULL files matrices

Mx Ex Kx Bu Linear Dynamic
MOR Algorithm
y Cx System, ODEs

Current version 2.5

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MOR for ANSYS Timing: MOR as Fast Solver

Reduced model of dimension 30

Dimension, nnz MOR Time

DoFs /ANSYS
static
4 267 20 861 1.4
11 445 93 781 1.8
20 360 265 113 1.7
79 171 2 215 638 1.5
152 943 5 887 290 2.2
180 597 7 004 750 1.9
375 801 15 039 875 1.7

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System Thermal Simulation in Simplorer

Current : Heat Flow

Voltage : Temperature

Resistor : Thermal
resistance

Capacitor : Thermal
capacitor

Voltage source :
Temperature source

Current source :
Heat Flow source
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Compact Thermal Models

Looks understandable but how to do it in practice?

Figure from the book Fast Simulation of Electro-Thermal MEMS: Efficient Dynamic
13 Compact Models. Springer, 2006.
 Electrical vs. Thermal

Electrical flow Heat flow

cond / ins 108 cond / ins 102

Conductor

Insulator

Thermal phenomena are much more distributed, it is hard to lump

them.

Figure from the book Fast Simulation of Electro-Thermal MEMS: Efficient Dynamic
Compact Models. Springer, 2006.
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 Freescale Multi-channel Power Devices
control
heavy gauge chip
MOR for ANSYS at wires power
chip
Therminic 2009

Leadframe PCB

More information: Thursday 09:20 - 09:40 Thermoelectric System

simulation: Compact Model Simulation with ANSYS Workbench, Freescale
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Chip and its Model in Workbench

Two power MOSFET transistors

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Interface to call MOR for ANSYS in Workbench

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Import Reduced Model in Simplorer

Simplorer supports state space model

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Test Thermal Circuit in Simplorer

Conservative thermal subsystem in Simplorer

Voltage Temperature
Current Heat flow

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Thermal Impedance and Comparison with ANSYS
ANSYS: about 300 000 DoFs, Reduced model: 30 DoFs
The difference is less than 1%
Timing: 60 timesteps is about 30 min in ANSYS

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Thermal Runaway

Transistor is considered as temperature dependent RDSon

The VHDL-AMS model

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Thermal Runaway Model

Conservative coupling between electrical and thermal part

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Transient Turn-on of an Automotive Light-Bulb

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Transient Turn-on of an Automotive Light-Bulb
Ansoft LLC Lamp Currents at turn-on FET_Light_Bulb_P21W_2 Curve Info
35.00 SL1='1' SL2='0' SL
SL1='1' SL2='1' SL
30.00 SL1='1' SL2='1' SL

25.00

20.00
E2.I [A]

15.00
3 lamps

10.00 2 lamps

5.00
1 lamp

0.00
Ansoft LLC 0.00 Junction
10.00 Temperature
20.00 at turn-on
30.00 FET_Light_Bulb_P21W_2
40.00 50.00 Curve Info
550.00 Time [ms] THM1.T
SL1='1' SL2='0' SL3='0'
THM1.T
500.00 3 lamps SL1='1' SL2='1' SL3='0'
THM1.T
SL1='1' SL2='1' SL3='1'
450.00
THM1.T [kel]

400.00
2 lamps

350.00
1 lamp

300.00

250.00
0.00 10.00 20.00 30.00 40.00 50.00
Time [ms]
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Example of Mechanical System

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System Level Simulation

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Hard Disk Drive Actuator/Suspension System

Michael R Hatch, Vibration Simulation Using MATLAB and ANSYS

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Model Reduction

3352 elements
7344 nodes
21227 equation

400 frequencies takes about 12

min

MOR takes only 3 s

Comparison for head

ANSYS
MOR 30
MOR 80

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Comparison

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Comparison

30
Velocity Control: Device as a Black Box

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Velocity Control: Multiphysics Modeling

32
Model Reduction for the FEM Model

13 347 elements
11 765 nodes

55 481 equations to
solve

200 frequencies
takes about 20 min

Model reduction
takes 8 second

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Comparison

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Efficient Simulation of Acoustic FSI

Wednesday 17:00 - 17:20, CADFEM + Simetris

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 System Level Battery Thermal Behavior Study

Thursday, 12:20 - 12:40, CADFEM

TCell1

RT_S RT_L HeatConfig10

Rseries Rptc
Temp

IBatt RLoad
CONST H
capacity 1
Tref
VOC CT_S CT_L REF
FML1
2
EQU

Heating
Q
CONST H
0 0

Electrical cell model TCell2

(cell1) HeatConfig01

Battery thermal model

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Elektrothermische Simulation eines IGBT Wechselrichters

Thursday 11:40 12:20, CADFEM + ANSOFT

Ambient

P _RE F
Thermal Domain

P 10
P 11
P 12
P1
P2
P3
P4

P5
P6
P7
P8

P9
Electrical Domain Mechanical
E1
z_up z_vp z_wp

I_mot
Domain
Induction_Motor_20kW
Simplorer4
MASS_ROT1
IN_A OUT_A A N
A
IN_B OUT_B B ROT1
A
IN_C OUT_C C ROT2
A
VM311 R6 R5 R4 R1 R2 R3
z_um z_vm z_wm
+ 0

SINE1 RZM

SINE2 RZM
DR1

DR1

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Extraction of Thermal Properties of Thin Films

Thursday, 12:20 - 12:40, T. Bechtold, NXP

Parametric Model Reduction

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Also on Thursday

16:20 - 16:40, Export von modal reduzierten Krpern aus ANSYS

und deren Echtzeitberechnung, P. Sekler, A. Dadalau

17:00 - 17:20 Application of MOR for ANSYS to Hydro Turbine

Runner Dynamics, F. Lippold (Voith Hydro Holding GmbH & Co. KG,
Heidenheim)

17:00 - 17:20 Zustandsraumbeschreibung von piezo-mechanischen

Systemen auf Grundlage einer Finite-Elemente-Diskretisierung, B.
Kranz (Fraunhofer-Institut IWU, Dresden)

17:20 - 17:40 Parametric Reduction of Multiphysics Models, J.

Mohring (Fraunhofer-Institut ITWM, Kaiserslautern)

17:40 - 18:00 Novel Model Reduction Techniques for Control of

Machine Tools, P. Benner (Technische Universitt Chemnitz)
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Conclusion

ANSYS device level model

Simplorer system level simulation

MOR for ANSYS model reduction for ANSYS models

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