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Agenda
2 ©2020 ANSYS, Inc.
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Challenges in Electric Vehicle (Power) Development
• Mileage/Range• Charge Times• Operational Life Span
Performance
• Crash Worthiness – Passenger Safety
• Operational Conditions• Thermal Management (Batteries,
etc.)
Safety
• Production• Warranty/Recall (Reliability)• Maintenance
Cost
ANSYS Platform for EV Powertrain Development
5 ©2020 ANSYS, Inc.
3D CFD Based Modeling Approach in FLUENT
Multi-Scale Physics in Li+ Battery modeled using (MSMD) framework
10-6~10-4 10-2~10010-9~10-8
material electrode pair cell, pack
Multi-Scale Multi-Dimensional (MSMD) Approach Electrode layer structure is a sub-grid-scale model, not resolved by mesh
G-H Kim et al, “Multi-Domain Modeling of Lithium-Ion Batteries Encompassing Multi-Physics in Varied length Scales” J. of Electrochemical. Soc. 158 (8) A955-A969 (2011).
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NTGK Model
− Newman & Tidemann: 1D− Gu: 1D− Kim et al: 2D− ANSYS: 3D− Semi-Empirical Model− Relies on Battery’s Discharge
curves at different C rates and under different temperature conditions
Electrochemistry Models
✔ U.S. Kim et al, “Modeling the Dependence of the Discharge behavior of a Lithium-Ion Battery on the Environmental Temperature” J. Electrochem. Soc., 158(5), A611-A618 (2001)
✔ M. Chen and G. A. Rincon-Mora, “Accurate Electrical Battery Model Capable of Predicting Runtime and I-V Performance” IEEE Trans. On Energy Conversion, Vol. 21. No.2 (2006)
✔ M. Doyle, T.F. Fuller and J. Newman. “Modeling of Galvanostatic Charge and Discharge of the Lithium/Polymer/Insertion Cell”. J. of Electrochemical Soc.. Vol 140, No. 6. 1526-1533 (1993)
ECM Model
− Chen & Rincon-Mora− Equivalent Circuit Model− HPPC Testing Data
− Doyle, Fuller & Newman− Physics Based Model− Solves for Charge and Mass
Transport Equations at a Particle/Electrolyte Level
− Physical Parameters Required
Newman P2D
Battery Modeling Examples
Battery Module Simulation
Multiphysics Simulation - Thermal Abuse
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Battery Thermal Abuse SimulationStructural Impact
Analysis(LS-DYNA)
Damage Zone Characterization(ANSYS Fluent)
Electrochemical-Thermal Analysis
(ANSYS Fluent)
Deformation Decrease in Contact Resistance Thermal Runaway
ANSYS Simulation Platform…
Language-based/Behavioral Models - VHDL-AMS, Modelica, C++, etc.
Equivalent Circuit - Thermal Network - Foster Network
ROMs -LTI, SVD, etc.
Co-Simulation
Electrical & Thermal Perspectives
Language-based/Behavioral Models- VHDL-AMS, Modelica, C++, etc.
Equivalent Circuit
ROMs -LTI, SVD, etc.
Co-Simulation
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Thermal Model Electrical/Electrochemistry Model
Language-based/Behavioral Models - VHDL-AMS, Modelica, C++, etc.
Equivalent Circuit - Thermal Network - Foster Network
ROMs -LTI, SVD, etc.
Co-Simulation
Electrical & Thermal Perspectives
Language-based/Behavioral Models- VHDL-AMS, Modelica, C++, etc.
Equivalent Circuit
ROMs -LTI, SVD, etc.
Co-Simulation
••
Thermal Model Electrical/Electrochemistry Model
ANSYS Battery Design Toolkit (ACT Extension)Submod
el Unit Group Module Pack
ANSYS Battery Design Toolkit (ACT Extension)Submod
el Unit Group Module Pack
ANSYS Battery Design Toolkit (ACT Extension)Submod
el Unit Group Module Pack
ANSYS Battery Design Toolkit (ACT Extension)Submod
el Unit Group Module Pack
Validation: Test Data vs. ABDT Twin Builder Model
Yen, C., Han, T., Kaushik, S., and Khalighi, B., "Application of CAEBAT System Approach for a Liquid-Cooled Automotive Battery Pack," SAE Technical Paper 2016-01-1205, 2016, doi:10.4271/2016-01-1205.
Pack Voltage of 24-Cell Module during Five Consecutive US06 Driving
Schedules.
System-Level Simulation with ABDT in ANSYS Twin Builder
ABDT based Battery Module Model can be plugged into EV System Model to estimate range of Battery Module
What is Reduced-Order Modeling (ROM)?
A Reduced-Order Model (ROM) is a simplification of a high-fidelity dynamical model that preserves essential behavior and dominant effects, for the purpose of reducing solution time or storage capacity required for the more complex model.TECHNIQUES FOR RANGE OF
PHYSICS Fluid Flow, Thermal, Mechanical, EM SOLVES IN SECONDS (vs.
HOURS)
Fluent CFD Simulation:3 hours on 12 cores
ROM Simulation:Real-time
ROM Techniques Linear Case (Static & Dynamic)
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Applications• Electronics/Battery Cooling• Mechanical vibrations• Conducted EMI• EM actuators & machines• …
Input #2(step input)
Create the CFD/FEA model
Input #1(step input) …
System response to input #1
System response to input #2
System response to input #n
ROM
Input #n(step input)
Actual inputs(for 1, 2, … n)
ROM solution to actual
inputs
CFD/FEA solving
CFD/FEA solving
ROM solving
ROM preparation
ROM simulation
Stag
e 1
Stag
e 2
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ROM Generation Process
Input #2(step input)
Create the CFD/FEA model
Input #1(step input) …
System response to input #1
System response to input #2
System response to input #n
ROM
Input #n(step input)
Actual inputs(for 1, 2, … n)
ROM solution to actual
inputs
CFD/FEA solving
CFD/FEA solving
ROM solving
ROM preparation
ROM simulation
Stag
e 1
Stag
e 2
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ROM Generation Process
ROM Step Response A CT’s & Extraction Toolkits
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X. Hu, S. Asgari, I. Yavuz, S. Stanton, C-C Hsu, Z. Shi, B. Wang, H-K Chu, “A Transient Reduced Order Model for Battery Thermal Management Based on Singular Value Decomposition,“ ECCE 2014.
Heat Profile
Battery Model - ECM Coupled with Thermal ROMs
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Calculated Temperatures passed from the ROMs to the
Electrical ECM.
Electrical ECM calculates heat generation rates, which are passed to the ROMs
30 ©2020 ANSYS, Inc. / Confidential
Battery Modeling – Systems-Level Perspective
Battery Modeling Toolset Summary
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