ANSYS for Hybrid Electrical Vehicles- Case Studies · © 2011 ANSYS, Inc. September 14, 2011 17 A Battery Module Coupled Analysis 0 0 0 0 0 0 0 CONST RT_S RT_L H00 CT_S CT_L Ccapacity

© 2011 ANSYS, Inc. September 14, 2011

1

ANSYS for Hybrid Electrical Vehicles- Case Studies

Xiao Hu

Lead Technical Services Engineer

ANSYS Inc


2

HEV/EV systems consist of a variety of components.

Different physics interact with each other in one component

Different components interact with each other in a system

Introdcution

Battery Inverter Electric Machine Mechanic Load

Controls


3

Rotor Loss in 3PH Induction Motor – Siemens

Simulated vs Measured Results

60 slot with cage

36 slot with cage

Maxwell Results with cage

36 slot without cage

Motor with its cage removed


4

Induced currents and eddy losses due to rotation

Reduction in Magnet Loss for PMSM Motor – Siemens

• Permanent magnets located on spinning rotor • Reduce eddy losses by cutting the magnets • Need to find optimum number of axial cuts


5

• For magnets, add cuts using insulation boundaries

•Same mesh re-used between cases •Reduces Eddy Currents and Loss

Reduction in Magnet Loss for PMSM Motor – Siemens

0

0.2

0.4

0.6

0.8

1

0 1 4 8 16

Normalized Power Loss

Number of Cuts


6

OCV test data vs. Maxwell transient analysis

Skewed rotor

-20.0

-15.0

-10.0

-5.0

0.0

5.0

10.0

15.0

20.0

0.00 0.01 0.01 0.02 0.02 0.03 0.03

Time (s)

Vo

lta

ge

(l-

n)

Measured emf Calculated emf (maxwell)

0

1000

2000

3000

4000

5000

6000

7000

0 50 100 150 200 250 300 350

los

se

s

current

generator mode

calculated

measured

adjusted

Integrated Starter Alternators – Ford


7

Electrical Machine (Prius) – Electromagnetic and

Thermal Coupling

Electromagnetic in Maxwell Loss and Temperature in FLUENT


8

IGBT

Module

Package Parameter

Extraction

Electro-

magnetic

Study

Design and

Coupling Electrical

Model

• 3d IGBT pack model and EM study

• Parasitic model extraction

• IGBT circuit model

Far Field

Study

• Far Field Study for Electric Field EM

High Power Inverter Systems


9

High Power Inverter Systems

The structure is

meshed using

automatic and

adaptive meshing

Current Distribution

IGBTs on, Diodes off

Power Module from Q3D

for board parasitics


10

Thermal Model Extraction for IGBTs

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


11

Busbars – Electrical, Thermal, Structural Coupling

Current Density in Maxwell Temperature in FLUENT

Deformation in Mechanical


12

Simulating Thermal Management of Battery Modules for the Propulsion of Hybrid Vehicles - Magna


13

Full Hybrid Electrical Vehicle Battery Pack System Design, CFD Simulation and Testing - Ford & Delphi

velocity contour of airflow through the brick, inlet and outlet plenum

airflow path into the battery pack airflow path and air outlet

the front view of the pack with the two bricks assembled and inlet busbar


14

Battery Electro-Thermo Modeling - NREL


15

HEV Battery Thermal Management - NREL

Input with Variations

• Gap Thickness

• Cell Resistance

• Flow Rate

Outputs with variations

• Max temperature

• Differential temperature

• Pressure drop


16

Model Order Reduction for a Battery Module - GM

State space model gives the same results as CFD. State space model runs in less than 5 seconds while the CFD runs 2 hours on one single CPU.

1. X. Hu, S. Lin, S. Stanton, W. Lian, “A Novel Thermal Model for HEV/EV Battery Modeling Based on CFD Calculation” IEEE Energy Conversion Congress and Expo, Atlanta, Sep 12-16, 2010 2. X. Hu, S. Lin, S. Stanton, W. Lian, “A State Space Thermal Model for HEV/EV Battery Modeling", SAE 2011-01-1364


17

A Battery Module Coupled Analysis

0

0

0

0

0

00

CONST

H00RT_LRT_S

CT_LCT_SIBattCcapacity

Rseries

VOC

E1

R1

C1 I7C2 C3

R2 R3

CONST

H01

E2

R5

C4 I8C5 C6

R6 R7

CONST

H02

E3

R9

C7 I9C8 C9

R10 R11

CONST

H03

E4

R13

C10 I10C11 C12

R14 R15

CONST

H04

E5

R17

C13 I11C14 C15

R18 R19

CONST

H05

RLoad

SIMPARAM1

Qcell1

Qcell2

Qcell3

Qcell4

Qcell5

Qcell6

Tambien

Temp_block_1

Temp_block_2

Temp_block_3

Temp_block_4

Temp_block_5

Temp_block_6

0.00 2000.00 4000.00 6000.00 8000.00Time [s]

300.00

310.00

320.00

330.00

340.00

350.00

Y1

[ke

l]

Curve Info

U1.Temp_block_1TR

U1.Temp_block_3TR

U1.Temp_block_5TR

Voc=f(SOC, U1.Temp_block_1)


18

Newman Pseudo 2d 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-oxide

e

Jump

Results from Simplorer Results from Newman

Li

eeee j

F

tcD

t

c

1)(


19

Newman Model – Quantitative Comparison

Simplorer’s Results

x=0

x=Lp+Ls+Ln

x=Lp+Ls

x=Lp

1/10 C 1/2 C 1 C 2 C 4 C 6 C 8 C 10 C

•Reference: Long Cai, Ralph E. White, Journal of Electrochem. Soc., 156 (3), A154-A161 (2009)

White’s Results


20

3D Electrochemistry Modeling

Li concentration in electrodes during discharge


21

- 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 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:

* Reference: U. S. Kim, C. B. Shin , C. S. Kim, “Effect of electrode configuration on the thermal behavior of a lithium-polymer battery”, Journal of Power Sources 180 (2008) 909–916.


22

Results of a Prismatic Lithium-Ion Cell

Geometry & Mesh

Temperature Current Density


23

From Electrochemistry to Single Cell Thermal Model

Li+

e

Li+

Li+ Li+

LixC6 Lix-Metal-oxide

e

Jump

Li

eeee j

F

tcD

t

c

1)(

1/10 C 1/2 C 1 C 2 C 4 C 6 C 8 C 10 C

Cathode Anode

Current Current

ip= Current Vectors


at Anode plate

J = Current Density

J (t, x, y, T )

Cathode Anode

Current Current

ip= Current Vectors


at Anode plate

J = Current Density

J (t, x, y, T )


24

Simplorer FLUENT Co-Simulation

Simplorer Battery Circuit Model

Cell 4

Cell 5

Cell 6

Cell 1

Cell 2

Cell 3

FLUENT Battery CFD Model

Heat Dissipated

Temperature


25

Simplorer FLUENT Co-Simulation

Simplorer Battery Circuit Model

FLUENT Battery CFD Model

Heat Dissipated

Temperature

Heat dissipation

Discharge curve

Temperature


26

Thermal Domain

Electrical Domain MechanicalDomain

0

R1 R2 R3

MASS_ROT1

DR1

SINE2

SINE1

A

A

A

IN_A

IN_B

IN_C

OUT_A

OUT_B

OUT_C

I_motSimplorer4

A

B

C

N

ROT1

ROT2

Induction_Motor_20kW

Q

Ambient

P1

P2

P3

P4

P5

P6

P7

P8 P

9

P1

0

P1

1

P1

2

P_

RE

F

z_um z_vm z_wm

z_wpz_vpz_up

+

V

VM311 R6 R5 R4

E1

RZM

DR1

RZM

0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]

-500.00

-250.00

0.00

250.00

500.00

Y1 [

V]

Curve Info rms

R1.VTR 230.9405

R4.VTR 313.3812

0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [ms]

1475.00

1485.00

1495.00

1500.00

MA

SS

_R

OT

1.O

ME

GA

[rp

m]

0.00

50.00

100.00

150.00

180.00

MA

SS

_R

OT

1.P

HI

[deg]

Curve Info

MASS_ROT1.OMEGATR

MASS_ROT1.PHITR

System Simulation Example

Model Extraction from FEM / CFD

IGBT Device Characterization

VHDL-AMS Macro-Model

VHDL-AMS Macro-Model

Electrical Domain

Thermal Domain

Mechanical Domain


27

Conclusion

• ANSYS simulation tools have been widely used by our customers to design various HEV components. Some perform single physics analysis while others consider multiphysics.

• The interaction of different components can also be considered using ANSYS system tool Simplorer.


28

Thank you !!


29

Simplorer System Model

for Actuator Valve

Forces Orifice opening and fluid flow

Coil Current

Armature Position

Documents

ANSYS for Hybrid Electrical Vehicles- Case Studies · © 2011 ANSYS, Inc. September 14, 2011 17 A Battery Module Coupled Analysis 0 0 0 0 0 0 0 CONST RT_S RT_L H00 CT_S CT_L Ccapacity