Virtual Prototyping by Multiphysics
Simulations at CSEM
Dr Ivar KJELBERG
Systems Engineer & Senior Project Manager, CSEM sa, Neuchâtel (CH)
VPE Symposium,
Rapperswil, 2012, Apr 19
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 1
Overview
• Some words about CSEM sa
• Importance of Virtual Prototyping & Simulations
• Different types of Modelling
• What is needed for Modelling: People, Software, Data & Interfacing
• Model Testing, Validation, and Verification
• Model Reduction and Model Interfacing to next Modelling level
• Some examples of Multiphysics Simulations at CSEM
• Conclusions
CSEM
the Swiss platform
for transfer in
micro-technology
Our mission:
Development and transfer of micro-
technologies to the industrial sector
– in Switzerland, as a priority –
in order to reinforce its competitive
advantage
• Cooperation agreements with
established companies
• Creation of start-ups
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 3
Federal contributions
29%
Cantons 11%
CTI 12%
EU projects 12%
Other public projects
5%
Industrial income
31%
• Incorporated, not-for-profit Research and Technology Organization
(RTO), supported by the Swiss Government
• A public-private partnership
• 31 % public
• 69 % private
• Key figures (2010)
• Revenues ~ CHF 70 mio
• Employees ~ 400
16% Swiss Confederation (EPFL)
15% Neuchatel (city and canton)
69% Private organizations
share
hold
ers
CSEM at a glance
Centre Suisse d’Electronique et de Microtechnique SA
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 4
CSEM’s technology programs
Centre Suisse d’Electronique et de Microtechnique SA
• MEMS
• Ultra-low-power integrated
systems
• Systems
• Surface engineering
technologies
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 5
Closer to industry …
Centre Suisse d’Electronique et de Microtechnique SA
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 6
CSEM’s national network
Our strategic research partners
Universities
Universities
of applied sciences
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 7
CSEM’s European network
At European Level – HTA Heterogeneous Technology Alliance
Dresden, Berlin, München
Empl. 1’600
Turnover : 220 M€
Clean room : 8450 m2
Division Recherche Technologique
Grenoble
Empl. 1’400
Turnover : 191 M€
Clean room : 8’000 m2
Neuchâtel
Empl. 400
Turnover: 50 M€
Clean room : 1200 m2
Espoo, Oulu
Empl 2’700
Turnover : 217 M€
Clean room : 2450 m2
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 8
Research
Development and integration of technologies
Transfer to industry
Production and commercialization
CSEM’s positioning
European
Allies EMPA, PSI
EPFL, ETHZ
Universities
Industrial partners
Spin-off, Start-ups
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 9
Virtual Prototyping by Multiphysics Simulations at CSEM
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 10
Virtual Prototyping & Simulations are essential at CSEM
• As technology and systems developers, virtual prototyping and detailed
simulations is a mandatory task to all our activities: before we start to
prototype, as well as to optimise further before we start to manufacture
• With the very diverse activities at CSEM, modelling and simulations cover:
• Micro-electronics & -optics production technologies,
• Galvano, chemistry etching, plasma, material depositing, … processes
• ASIC electronic design, and extensive software testing, also before fab
production launch
• MEMS and Silicon (mechanics) machining technologies,
• MEMS behaviour and integration simulations (structural, vibrations,
thermal, ACDC, RF, micro-fluidics …)
• Full Systems simulations at (multi-) physical and component level
• …
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 11
Types of Modelling
• I distinguish classes of modelling:
• Physics detailed models
FEM: i.e. ANSYS®, NASTRAN®, MARC®,
COVENTOR®, COMSOL Multiphysics®,…
Analytical: Maple®, Mathematica®,
Numerical: Matlab®, Scilab®,…)
• Systems (block) models
Simulink®, SciLab®, … or
Modelica® based: MapleSim®,
SimulationX®, Dymola® …
See also www.modelica.org
Narrowing down on modelling definitions
From: “Introduction to Modelling and Simulations of Technical and Physical Systems
with Modelica”, by P. Fritzson, IEEE-Wiley, 2011, ISBN: 978-1-118-09245-9
® Registered Trademarks
by respective commercial
software suppliers
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 12
And many other specific types of Modelling
• CAD & CAM modelling
• Data acquisition modelling
• Electronics circuit modelling
• FPGA modelling
• Proprietary tools for automation and PLCs modelling
• Optics ray tracing modelling
• Company specific custom codes
• etc.
• Important question: How to get all these models to link to each other
flawless, and in a simple manner ?
A standard interfacing mean is missing, today !
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 13
What is needed for efficient (Multi-)Physics Simulations?
• The software user’s personal skills to understand the simulations performed
• The adapted software tool(s)
• The geometry and CAD data and extensive data exchange availabilities
• The detailed material data base and material knowledge: material detailed
dependency on temperature, pressure, magnetic field strength, damping …
• But also the same user’s ability and willing to actively participate to:
• To verify and validate the models via simple analytical or numerical
analysis
• Test by prototyping the models, or parts of the models
A “model” (a simplified representation of reality), is to be used, ̶ NOT to be believed !
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 14
How to best cover Multi-Physics Systems Simulations ?
• Check software tools ability to perform true multiphysics Simulations under
the same software environment, with simple and efficient interfacing means.
• Do NOT choose a
• For Multi-Physics, do select an “open” software
“BlacBox” SW Data in Results (?) out
“Open” SW Data in
Results out Equation example taken from COMSOL Multiphysics®
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 15
Some “public” examples of Multiphysics Simulations
at CSEM
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 16
Silicon’s conquest of the watchmaking industry
Examples of technology transfer Silicon (anisotropic crystal) spirals
1996 2002 TODAY
Development & Integration
Transfer & Industrialization
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 17
Spherical reaction wheel – rotor, with 728 magnets and 20 stator
coils, and rotor in magnetic levitation
• With 728 magnets on spherical rotor (Ø180 mm) and 20 fixed stator coils,
• Rotor in magnetic levitation
• Excellent agreement between measurements FEM and analytical simulations
Examples of COMSOL Multiphysics Simulations from CSEM Neuchâtel (L. Rossini)
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 18
Transient capacitor discharge into a MEMS heater
• Embedded Spice model for
driving circuit, conduction, radiation
and convective cooling
100 µs time span
MEMS size: 300x200x100 µm3
Examples of COMSOL Multiphysics Simulations from CSEM Neuchâtel
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 19
Water boiler heating, heat source at bottom
• Heater (10kW) at bottom of 600 litre water tank, natural convection
• Nice convective turbulence pattern displayed in animation mode
• After 24 minutes T = 9.5 °C after 2 hours => T = 17 °C
Examples of COMSOL Multiphysics Simulations from CSEM Neuchâtel
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 20
Water boiler heating, heat source at top
• Heater (10kW) at top of 600 litre water tank, natural convection
• Little heat exchange lower down due to low heat diffusivity of water
• After 24 minutes T = 29.5 °C after 37 minutes => T = 44 °C
Examples of COMSOL Multiphysics Simulations from CSEM Neuchâtel
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 21
Simulation of alternating flow air heat-exchanger
• Air heat exchanger with alternating flow, air temperature drop and storage
and recovery efficiency optimisation for 4 alternating cycles
• Air flow, + solid material and gas heat exchange
Examples of COMSOL Multiphysics Simulations from CSEM Neuchâtel
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 22
Flexible guidance systems with very high resolution
mechanisms
SOFIA (Stratospheric Observatory for Infrared Astronomy)
Activation of a secondary mirror on an airborne telescope
• SiC Mirror Ø 350 mm
• Displacement ± 3 mm, resolution > 1:32’000 (bandwidth > 100 Hz)
Scientific instrumentation
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 23
SOFIA Airborne IR Telescope M2 drive mechanism
• Stress analysis of deformed M2 mirror guiding flexures
• CAD model view Reduced FEM solid model
Examples of COMSOL Multiphysics Simulations from CSEM Neuchâtel
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 24
Thermo-Fluid-mechanical modelling
Examples of COMSOL Multiphysics Simulations from CSEM Alpnach (G. Spinola Durante)
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 25
Accurate calculations of resistive path
Examples of COMSOL Multiphysics Simulations from CSEM Alpnach (G. Spinola Durante)
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 26
Diffusion-driven packaging model
Examples of COMSOL Multiphysics Simulations from CSEM Alpnach (G. Spinola Durante)
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 27
Thermal circuit model
Examples of COMSOL Multiphysics Simulations from CSEM Alpnach (G. Spinola Durante)
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 28
Microfluidic model
Examples of COMSOL Multiphysics Simulations from CSEM Alpnach (G. Spinola Durante)
© 2012 CSEM | Virtual Prototyping & Multiphysics Simulation | Ivar KJELBERG | Page 29
CONSLUSIONS
• Advanced Multi-Physics Simulations are readily available today with the new software
developed over the last decade
• Multi-Physics Modelling requires high level skills from the user, and a regular use of the
tool, but allows then to rapidly build very complex models (days ̶ versus months a
decade ago)
• Correct and extensive knowledge of the material property data is essential
• Easy CAD and data exchange allows rapid update of the model with minimal effort for
verification and validation
• The most important for successful modelling is to verify and validate the models, as
well as to perform critical prototypes and tests, this remains the users responsibility
• The prices of such software are affordable also to SME’s
• Consultancy services can also be readily found on the market (but check the skills of
the provider for YOUR model needs)
• Multi-Physics FEM tool is the physicist and systems engineers best “sandbox”
Thank you for your attention!