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© 2009 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary
Advanced Numerical
Simulation for Hybrid
Electric Vehicle Design
Scott StantonTechnical Director
Advanced Technology Initiatives
Xiao HuLead Technical Services Engineer
ANSYS, Inc.
© 2009 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary
MotorInverter/BusbarBattery/Cables
Controller
Key Technologies of Electronic
Drivetrain
http://commons.wikimedia.org/wiki/File:HitachiJ100A.jpg
Oakridge National Laboratory, ORNL/TM-2004/247, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System Interim Report
http://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPG
http://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpg Author {{:de:wiki:user DrJunge|DrJunge}}
.
Drive Shaft
© 2009 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary
Key Technologies of Electronic
Drivetrain
http://commons.wikimedia.org/wiki/File:HitachiJ100A.jpg
Oakridge National Laboratory, ORNL/TM-2004/247, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System Interim Report
http://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPG
http://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpg Author {{:de:wiki:user DrJunge|DrJunge}}
.
EfficiencyThermal, EMC/EMIThermal, Safety,
Electrical
Behavioral
Modeling
VHDL-AMS,
C/C++
Vibration,
Noise
© 2009 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary
Electric Drivetrain Power Flow
Power PlantPower
Electronics
Electric
Machine
Mechanical
Component
© 2009 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary
Electric Drivetrain Power Flow
Power PlantPower
Electronics
Electric
Machine
Mechanical
Component
© 2009 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary
Electric Drivetrain Power Flow
Power PlantPower
Electronics
Electric
Machine
Mechanical
Component
© 2009 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary
Controller
Drive Shaft
MotorInverterBattery
Simulation Techniques
Math Based Model
Circuits
+Mathematics
Thermal
Electromagnetics
EMC/EMI
Mechanics
Mathematics
Ansoft Road Show 2008 – Inspiring Engineering - Simulating EMC/EMI Effects for High Power Inverter Systems - Emmanuel Batista Alstom Pearl
© 2009 ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary
Simplorer Multiphysics System
Integration
Thermal
CFD Mechanical
FEAMagnetic
FEA-Analytical
EMC/EMI
FEAElectrochemistry/
Thermal
© 2009 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary
EM System Design
Thermal
Electromagnetic
Mechanical
Fluidic
Component
Circuit/Subsystem
System
Simplorer
Model
Extraction
Physics Solvers
© 2009 ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary
Power Plant
Power PlantPower
Electronics
Electric
Machine
Mechanical
Component
• Battery thermal management using CFD
• Battery system thermal management using Foster network
• Battery electric circuit model
• Battery single cell thermal model
• Battery electrochemistry
© 2009 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary
ANSYS Workbench – An Integrated
Solution for Battery CFD Analysis
Project page: Defines the
work flow
DesignModeler:
Geometry tool
with full
parametric
capability
ANSYS
Workbench
Mesher:
Quality
meshing
with
automation
CFD-Post :
takes
advantage
of CFX
post-
processing
capability
© 2009 ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary
Create a Linear Time Invariant
System Model
Output of such a system is completely characterized by its impulse (or
step) response in that the output of the system under any input is simply
the convolution of the impulse response and the input.
LTI
Battery1 PowerTemperature1
Temperature2
Temperature3
Battery2 Power
Battery3 Power
© 2009 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary
Battery Module Analysis
• Thermal model is represented by LTI Foster network
• RC values are derived from CFD results
• System level response from LTI Foster network is equivalent to the
detailed CFD analysis
• LTI Foster network executes significantly faster
Fluid Flow Region
Batteries
Results from the
Foster network are
identical to Fluent
© 2009 ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary
- Newman & Tidemann (1993);
- Gu (1983) ;
- Kim et al (2008) J
)()( TfUYJ np
Cathode Anode
Current Current
ip= Current Vectors
at Cathode plate in= Current Vectors
at Anode plate
J = Current Density
J (t, x, y, T )
Cathode Anode
Current Current
ip= Current Vectors
at Cathode plate in= Current Vectors
at Anode plate
J = Current Density
J (t, x, y, T )
Transfer current
U and Y are derived from experimentally
obtained polarization curve, dependent
on Depth of Discharge (DOD) &
Temperature
Single Battery Cell Thermal Model
The model is based on the work of:
© 2009 ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary
Results of a Prismatic
Lithium-Ion Cell
Geometry & Mesh
Temperature Current Density
© 2009 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary
Newman’s 1D Electrochemistry
Model in Simplorer
Lithium Ion Batteries
• Electrochemical Kinetics
• Solid-State Li Transport
• Electrolytic Li Transport
• Charge Conservation/Transport
• (Thermal) Energy Conservation
Li+
e
Li+
Li+ Li+
LixC6 Lix-Metal-oxidee
Jump
Simplorer ResultsNewman’s Results
Li
eeee j
F
tcD
t
c
1)(
© 2009 ANSYS, Inc. All rights reserved. 17 ANSYS, Inc. Proprietary
Comparison - Concentration
Simplorer’s Results Newman’s Results
© 2009 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary
Power Electronics: IGBT
Power PlantPower
Electronics
Electric
Machine
Mechanical
Component
• High Power System Design Concept
– Electro-Thermal Model: Average and Dynamic
– Package Thermal Model Extracted from CFD
• Mechanical Stress Analysis
– Thermal Stress
– Electromagnetic Forces
• EMC/EMI Analysis
– Parameter Extraction: R, L, C, G
– Radiated Emissions – Full Wave Effects
© 2009 ANSYS, Inc. All rights reserved. 19 ANSYS, Inc. Proprietary
IGBT Models
Dynamic IGBT accurately captures the switching waveforms
Static IGBT for fast system simulations
© 2009 ANSYS, Inc. All rights reserved. 20 ANSYS, Inc. Proprietary
IGBT Inverter Design
Mechanical Stress Analysis
Ansoft Maxwell V13.0 coupled with ANSYS Mechanical R12.1
Input
Line Current ProfileInput
DC Current ProfileMapping Electromagnetic Force
Mapping Power Loss Thermal-Structural
© 2009 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary
IGBT Inverter Design
Mechanical Stress Analysis
© 2009 ANSYS, Inc. All rights reserved. 22 ANSYS, Inc. Proprietary
IGBT Package
Thermal Model: Technical Background
• Temperature rise at any point in the system is the sum of the
independently derived temperature increase attributable to each heat
source in the system
• Assumptions:
– Temperature assumed to be a linear function of heat sources
– This requires that the fluid flow is constant (for each study) and density
and all properties are constants
– Geometry remains fixed
ANSYS Icepack
© 2009 ANSYS, Inc. All rights reserved. 23 ANSYS, Inc. Proprietary
IGBT Package Thermal Model
Implementation
Apply each heat source
individually
measure temperature at
nodes of interest
(parametric analysis)
Specify the geometry
of the multi-heat-
source system
Icepak Transfer T(time)
into Zth(time)
Filter
Normalize
Extract parameters
through curve fittingGenerate model
Data processingSimplorer
© 2009 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary
EMI/EMC
IGBT Mesh and Field Result
The structure is meshed
using automatic and
adaptive meshing
Current Distribution
© 2009 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary
-22.50
60.00
0
25.00
50.00
0 240.00m100.00m
2DGraphSel1 NIGBT71.IC
Extract Power Loss
0
474.00m
200.00m
400.00m
100.00 1.00Meg1.00k 3.00k 10.00k 100.00k
2DGraphCon1
GS_I...FFT
System Integration
© 2009 ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary
0
474.00m
200.00m
400.00m
100.00 1.00Meg1.00k 3.00k 10.00k 100.00k
2DGraphCon1
GS_I...
Freq. res.
Normalized S para.MagE@10m by
specified inputs
Multiplied magE plots
by Simplorer
Emission Test
Full Wave Effect
Ansoft HFSS
© 2009 ANSYS, Inc. All rights reserved. 27 ANSYS, Inc. Proprietary
Electric Machine Design
Power PlantPower
Electronics
Electric
Machine
Mechanical
Component
• Coupled Electromagnetic and Thermal Solution
• Detailed Transient Analysis
• Coupled with Drive Electronics
© 2009 ANSYS, Inc. All rights reserved. 28 ANSYS, Inc. Proprietary
Coupled Thermal Analysis
EM Field Calculation Including:
Core Loss: Kh, Kc, Ke, Kdc
Solid Loss: J2/
Copper Loss: I2*R
Seamless Automatic Mapping from
Maxwell to ANSYS
© 2009 ANSYS, Inc. All rights reserved. 29 ANSYS, Inc. Proprietary
Loss Mapping and Thermal
Analysis
• Spatial eddy loss distribution for the magnets
• Spatial core loss distribution for the rotor, stator yoke and stator teeth
• Stranded winding copper loss
• All losses, which are highly non-uniform, are from Maxwell
Time Average Loss Thermal Results
© 2009 ANSYS, Inc. All rights reserved. 30 ANSYS, Inc. Proprietary
Co-simulation Between Field
Solver and System Simulator
Core Loss: Kh, Kc, Ke, Kdc
Solid Loss: J2/ Copper Loss: I2*R
Lamination Stacking Factor
Adaptive Time Stepping
© 2009 ANSYS, Inc. All rights reserved. 31 ANSYS, Inc. Proprietary
Simplorer – Model Order
Reduction
Simplorer - ANSYS Mechanical Link
From ~45,000 equations to 18 states and 6 terminals
(Rotational and translational for each DOF)
ANSYS Mechanical Simplorer
© 2009 ANSYS, Inc. All rights reserved. 32 ANSYS, Inc. Proprietary
ANSYS Simplorer Multiphysics
System Integration
ANSYS Icepak
ANSYS
MechanicalMaxwell
RMxprtQ3D
Current profileTemperature profileFLUENT