Advanced Numerical Simulation for Hybrid Electric Vehicle Design 1

Advanced Numerical

Simulation for Hybrid

Electric Vehicle Design

Scott StantonTechnical Director

Advanced Technology Initiatives

Xiao HuLead Technical Services Engineer

ANSYS, Inc.

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

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,

Vibration,

Electric Drivetrain Power Flow

Power PlantPower

Electronics

Electric

Machine

Mechanical

Component

Power PlantPower

Electronics

Electric

Machine

Mechanical

Component

Power PlantPower

Electronics

Electric

Machine

Mechanical

Component

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

Simplorer Multiphysics System

Integration

Thermal

CFD Mechanical

FEAMagnetic

FEA-Analytical

EMC/EMI

FEAElectrochemistry/

Thermal

EM System Design

Thermal

Electromagnetic

Mechanical

Fluidic

Component

Circuit/Subsystem

System

Simplorer

Extraction

Physics Solvers

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

ANSYS Workbench – An Integrated

Solution for Battery CFD Analysis

Project page: Defines the

work flow

DesignModeler:

Geometry tool

with full

parametric

capability

Workbench

Mesher:

Quality

meshing

automation

CFD-Post :

advantage

of CFX

processing

capability

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.

Battery1 PowerTemperature1

Temperature2

Temperature3

Battery2 Power

Battery3 Power

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

- 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:

Results of a Prismatic

Lithium-Ion Cell

Geometry & Mesh

Temperature Current Density

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+ Li+

LixC6 Lix-Metal-oxidee

Simplorer ResultsNewman’s Results

eeee j

Comparison - Concentration

Simplorer’s Results Newman’s Results

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

IGBT Models

Dynamic IGBT accurately captures the switching waveforms

Static IGBT for fast system simulations

IGBT Inverter Design

Mechanical Stress Analysis

Ansoft Maxwell V13.0 coupled with ANSYS Mechanical R12.1

Line Current ProfileInput

DC Current ProfileMapping Electromagnetic Force

Mapping Power Loss Thermal-Structural

IGBT Inverter Design

Mechanical Stress Analysis

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

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

EMI/EMC

IGBT Mesh and Field Result

The structure is meshed

using automatic and

adaptive meshing

Current Distribution

-22.50

0 240.00m100.00m

2DGraphSel1 NIGBT71.IC

Extract Power Loss

474.00m

200.00m

400.00m

100.00 1.00Meg1.00k 3.00k 10.00k 100.00k

2DGraphCon1

GS_I...FFT

System Integration

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

Electric Machine Design

Power PlantPower

Electronics

Electric

Machine

Mechanical

Component

• Coupled Electromagnetic and Thermal Solution

• Detailed Transient Analysis

• Coupled with Drive Electronics

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

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

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

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

ANSYS Simplorer Multiphysics

System Integration

ANSYS Icepak

MechanicalMaxwell

RMxprtQ3D

Current profileTemperature profileFLUENT

Advanced Numerical Simulation for Hybrid Electric Vehicle Design 1

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