© 2011 ANSYS, Inc. April 27, 2015 1

ANSYS solutions to the challenges of developing energy efficient vehicles提高汽车能耗效率的ANSYS解决方案

Vincent Delafosse Senior Product Manager ANSYS Inc., San Jose, CA

© 2011 ANSYS, Inc. April 27, 2015 2

Fuel Economy and Emissions Regulations: CAFÉ, Euro6

Demand for Enhanced Passenger Experience

Mobility Revolution: Autonomous Vehicles

What is happening in the automotive industry? 汽车工业的现状和趋势？

I.C. Engines

Full Electric Vehicles Hybrid

Vehicles

Displays

Connectivity

Conveniences

Radars, Sensors

Connectivity

Complex Controls

© 2011 ANSYS, Inc. April 27, 2015 3

In Response To The New Challenges, Automotive Companies Are Focusing On These Initiatives面对新挑战，汽车厂家正致力于研究对策

Streamline Globally Distributed Product Development

to improve product development efficiency

Improve Fuel Economy and Emissions

to comply with governmental regulations & market

demands

Manage Complexity of Electronics & Embedded Software

across multiple engineering disciplines

Implement an Early Reliability Prediction and Quality System

to deliver high quality, safe and reliable product

Develop Hybrid and Electric Vehicles

to further improve fuel economy and emissions

Innovate Manufacturing Methods

to improve cost efficiency

Develop ADAS and Autonomous Vehicles

to improve vehicle safety, accessibility, productivity, and

fleet efficiency

IC Engines

Complex Preprocessing

(Aero, Underhood)

HEV Components and System

Radar

Multi/Multiple Physics

Auto Electronics

© 2011 ANSYS, Inc. April 27, 2015 4

Recent ANSYS Headlines In The Automotive Industry ANSYS在汽车行业的最新头条资讯

ANSYS Powers Four Out Of The Top Six F1 Racing Teams In 2012 Including Three-time Champion, Red Bull Racing PITTSBURGH, Dec. 6, 2012 /PRNewswire/ As the checkered flag is waved over Formula 1's 2012 racing season, ANSYS (NASDAQ: ANSS) is celebrating alongside the pit . . .

DENSO Selects ANSYS FEM Software to Accelerate Product Development and Drive Down Costs PITTSBURGH, /PRNewswire/ -- ANSYS (NASDAQ: ANSS) announced that DENSO, a worldwide automotive supplier, has selected ANSYS® FEM software to standardize and expedite product development globally, enabling the . . .

ANSYS Simulation Drives MANN+HUMMEL's Automotive Designs

PITTSBURGH--(BUSINESS WIRE)-- ANSYS (NASDAQ: ANSS) is helping MANN HUMMEL to access and reuse historical engineering simulation information for speeding the creation of innovative automotive designs. The . . .

Volkswagen Signs Master Agreement With ANSYS

German Car Manufacturer to Rely on Multiphysics Engineering Simulation Solutions from ANSYS SOUTHPOINTE, Pa., (BUSINESS WIRE) -- ANSYS, Inc. (NASDAQ: ANSS), a global innovator of simulation software and technologies designed to optimize product development processes . . .

ANSYS Making Electric Vehicle Batteries More Practical And Efficient Engineering Simulation Leader Working with General Motors, NREL and ESim to Improve Battery Design PITTSBURGH, June 20, 2012 /PRNewswire/ -- One year into a U.S. Department of Energy (DOE) funded project . . .

© 2011 ANSYS, Inc. April 27, 2015 5

Tesla Toyota Volkswagen Ford Hyundai General Motors PSA BMW Honda Renault Tata Motors SAIC Volvo Chrysler Merdeces Audi

Bosch Delphi Yazaki Magna Valeo Continental Denso Brose Visteon BorgWarner Eaton TRW Dana

Caterpillar Navistar John Deere Scania Cummins AGCO Bobcat CNH Eicher Tractors Kubota Corp. Mahindra & Mahindra Volvo Truck

Red Bull Ferrari Toyota Racing McLaren Racing Force India Hendrick Motorsports Sauber Motorsports Harley Davidson Bajaj Auto Pratt & Miller

Alstom Transport Bombardier Transportation Deutsche Bahn Electromotive Diesel Railway Technical Research Institute Japan Zhuzhou Electric Locomotive

Top Automotive & Transportation Companies Rely on ANSYS Physics Simulation Tools/ANSYS仿真工具的交通行业顶级用户

© 2011 ANSYS, Inc. April 27, 2015 6

Key Initiative:关键对策 Improve Fuel Economy 改善燃油经济性

© 2011 ANSYS, Inc. April 27, 2015 7

Key Vehicle Systems Are Undergoing Drastic Changes To Improve Fuel Economy And Emissions 汽车核心系统正在发生巨变，以提高燃油经济性，减少排放

Fuel Economy and Emissions

Regulations: CAFÉ, Euro6 Hybrid and Electric

Vehicles: Develop complex new

components

Aerodynamics: Styling vs Drag Lightweight Composites:

New structural aspects

• Improve Fuel Economy and Emissions

• Develop Hybrid and Electric Vehicles

Key Business Initiatives

© 2011 ANSYS, Inc. April 27, 2015 8

Fluid-Thermal Systems Design – I.C. Engines 流体-热系统设计——内燃机

Customer Keynote: Dr. Wayne Eckerle VP, Research and

Technology Cummins

© 2011 ANSYS, Inc. April 27, 2015 9

Fluid-Thermal Systems Design – I.C. Engines 流体-热系统设计——内燃机

Customer Keynote: Dr. Wayne Eckerle VP, Research and

Technology Cummins

© 2011 ANSYS, Inc. April 27, 2015 10

Fluid-Thermal Systems Design – I.C. Engines 流体-热系统设计——内燃机

10

Comprehensive Solution for: • Combustion • Cooling • Strength Analysis • Durability

© 2011 ANSYS, Inc. April 27, 2015 11

Key Initiative:关键对策 Embedded software嵌入式软件

© 2011 ANSYS, Inc. April 27, 2015 12

Solutions tailored for Innovative Systems – Our Focus 量身定制的创新系统解决方案

Hybrid & Electric Vehicles • Simulation Solutions for HEV: Simplorer

E/E Systems Simulation platform • Embedded Software Development:

SCADE Suite & LifeCycle for automatic code generation of Embedded Controls (AUTOSAR OS compliant)

High Safety Systems requiring ISO 26262 Certification (ADAS, Safety Critical Applications) • SCADE Suite and SCADE Lifecycle for automatic code generation of Embedded Controls (ISO 26262

Certified)

New Generation Automotive Dashboards: • SCADE Display for automatic code generation

of HMI applications for Embedded targets, Android and Apple iOS

© 2011 ANSYS, Inc. April 27, 2015 13

SCADE Suite Control

Software Design

Model Coverage Analysis

Formal Verification

Time & Stack Optimization

Debug & Simulation

Model Checks

Object Code & Compiler

Verification

SCADE Suite KCG

C & Ada

RTOS Adaptors

DO-178B DO-178C IEC 61508 EN 50128 ISO 26262

Certification Kits

Plant Model Co-simulation (incl. FMI)

PROTOTYPE & DESIGN VERIFY GENERATE

© 2011 ANSYS, Inc. April 27, 2015 14

SCADE Suite @ Subaru Electric Vehicles SCADE Suite 在 Subaru 电动汽车的应用 Subaru chose SCADE Suite for the design of its electric vehicle engine controls:

• Vehicle dynamics • Engine functions • Vehicle energy consumption

– heating & air conditioning – breaking – body controls

• Battery load management

© 2011 ANSYS, Inc. April 27, 2015 15

Key Initiative:关键对策 HEV/EV混合/纯电动车

© 2011 ANSYS, Inc. April 27, 2015 16

Sophisticated Design • Motor/Generator/Inverter/Converter/Battery/Charging, … • Electrical/Thermal/Structural/EMI/Vibration/Noise, …

Time to Market & Cost Reduction • OEMs all have very aggressive schedule • Cost of Hybrid/Electric is one of the biggest concerns Magnetic Components Integrated with System • Circuit & Control • Mechanics Integrated Design Environment for Multiphysics • Electric Machine – Magnetics/Thermal/Structural • Power Electronics – Electrical/Thermal/Electromagnetics Interference (EMI) Improving Design Speed: Design Automation and Optimization • Design Automation Example • Optimization and High Performance Computing

Hybrid/Electric Vehicle Design Challenges EV/HEV的设计挑战

© 2011 ANSYS, Inc. April 27, 2015 17

Robust, Efficient Traction Motor Design – Requirements And Benefits稳健高效的牵引电机设计—需求与好处

Robust, Efficient Traction Motor Design: Enables engineers to design for real-life operating conditions with a wide variety of loads and manufacturing variability, and to optimize the design by performing trade-offs amongst all design variables simultaneously

Thermal

Structural Fluid

Electromagnetic

Robust, Efficient Traction Motor Design

Data Mapping Da

ta M

appi

ng

Data Mapping

Data

Map

ping

Design Exploration • DOE Based

Response Surface

• 6σ, Optimization, Statistics

Requirements: • Couple multiple physics with

automated, accurate data transfer

• Rapid extensive exploration of design space

• Optimize machine in conjunction with power electronics

Benefits: Ensure product

performance throughout operating envelope

Achieve high efficiency Reduce cost, weight, size

System co-simulation with Power Electronics

© 2011 ANSYS, Inc. April 27, 2015 18

Analysis Methodology and Work Flow :分析方法与设计流程 Multi-physics Simulation多物理场仿真

FE Motor Analysis • Efficiency • Inductance • Cogging Torque

Motor Design Analytical • Slot Design • Winding Design • Geometry

CFD Analysis • Temp Distribution • External Cooling Requirement

Thermal FE Analysis • Temp Distribution

Structural Analysis • Stress Distribution • Deformation

Vibration Analysis • Modal • Harmonic

AutoSetup For FEA

Electromagnetic

Losses

Convective Coefficients

Electromagnetic Losses Temperature

Feedback

Electromagnetic Forces

Electromagnetic Force - FFT

Temperature

Comprehensive Motor Analysis

© 2011 ANSYS, Inc. April 27, 2015 19

Electrical Machines Magnetic Design Flow 电机电磁设计流程

RMXprt

Maxwell2D

Maxwell3D

Toolkit

UDOs &Toolkit

Initial Design FE Design Optimal Design

© 2011 ANSYS, Inc. April 27, 2015 20

IEEE Webinar

© 2011 ANSYS, Inc. April 27, 2015 21

IEEE Webinar

© 2011 ANSYS, Inc. April 27, 2015 22

• Motor specifications: Imax = 300 A (peak value) Vdc = 200 V Rdc = 8 mohm @ 20 C (per-phase stator resistance) Le = 30 uH (per-phase end-turn inductance) P = 8 Max. speed = 9000 rpm

Magna Electronics IPM Motor – Test Case Magna IPM电机—测试案例

© 2011 ANSYS, Inc. April 27, 2015 23

Magna：Experimental vs. Simulation实验与仿真对比

Experimental 2D Simulation

© 2011 ANSYS, Inc. April 27, 2015 24

Noise Vibration Analysis震动噪声分析

Magnetic Field

Structural Dynamics Acoustic Field

Forces Displacements

© 2011 ANSYS, Inc. April 27, 2015 25

Motor-CAD – Thermal Sizing热路法分析 Includes proven models for an extensive range of cooling types: TENV: Totally enclosed non-

ventilated TEFC: Totally enclosed fan

cooled Through Ventilation TE with Internal Circulating Air Open end-shield cooling Water Jackets Submersible cooling Wet Rotor & Wet Stator cooling Spray Cooling Direct conductor cooling

© 2011 ANSYS, Inc. April 27, 2015 26

Case Study - PM Machine Design 测试案例—永磁电机

• Winding also exported from RMxprt • Motor-CAD updates winding to account for

wire size available, enamel on wire and slot liner available

RMxprt - Motor CAD

© 2011 ANSYS, Inc. April 27, 2015 27

Hybrid Model : CFD Domain Definition Hybrid Model : CFD 区域定义 Motor – Thermal-Flow Network Equivalence

Motor-CAD thermal network is imported into ANSYS Icepak

ANSYS Icepak network replaces the thermal resistances between the housing and ambient with a CFD domain

Inside the housing, the machine is modelled using Motor-CAD thermal network, whereas the convective heat transfer outside the housing is modelled using an Icepak CFD domain

The thermal network and the CFD domain are coupled together through multi-faceted cylinder housing interfaces

Thermal-Net

Flow-Net

For the current application only thermal network is used

© 2011 ANSYS, Inc. April 27, 2015 28

Detailed and Hybrid Models: Comparison 具体和混合模型：比较

Detailed Model : 2M elements Network Model : 67k elements

3D Natural Convection Simulation on Hybrid Model • Turbulent flow model • Radiative heat transfer model • Fully parallelized solver • Converged CFD solution in ~ 2 minutes

© 2011 ANSYS, Inc. April 27, 2015 29

System Simulation – Wireless Power Transfer 系统仿真——无线充电系统

AC200V Rectify Inverter Wireless Power Transformer Battery

Controller

© 2011 ANSYS, Inc. April 27, 2015 30

Radiated Emissions电磁辐射

© 2011 ANSYS, Inc. April 27, 2015 31

Safe, Long–Lasting Battery Design –安全、长效的电池分析 Requirements And Benefits需求与好处

Safe, Long Lasting Battery Development: The solution ensures that battery design options are thoroughly investigated from electrode level, to cells, to modules, to pack and to controls, and the battery is optimized as a part of the entire powertrain system

Thermal

Structural

Electromagnetic

Safe, Long- Lasting Battery Development

Data Mapping

Design Exploration • DOE Based

Response Surface

• 6σ, Optimization, Statistics

Requirements: • Multiscale simulation • Ability to simulate long-

transient drive cycles • Comprehensive multiphysics • Extensive design exploration Benefits: Explore entire design

space and range of operating conditions thoroughly

Increase battery life and capacity

Extensively identify and eliminate failure modes

Gain confidence in life and safety of battery

Data

Map

ping

Data Mapping

Data

Map

ping

Fluid

© 2011 ANSYS, Inc. April 27, 2015 32

A Total Li-Ion Battery Simulation Solution完整的锂电池仿真解决方案

Electric Circuit, System Model

High Fidelity Physics, Chemistry Models

Reduced Order Modeling (ROM)

© 2011 ANSYS, Inc. April 27, 2015 33

Full Battery Simulation全电池解决方案

Voc = -1.031*exp(-35*(abs(IBatt.V/Vinit))) + 3.685 + 0.2156*(abs(IBatt.V/Vinit)) - 0.1178*(abs(IBatt.V/Vinit))^2 + 0.3201*(abs(IBatt.V/Vinit))^3 + 0.3/30.0*(U1.Temp_block_1-273)

© 2011 ANSYS, Inc. April 27, 2015 34

Key Initiative: 关键对策 System simulation系统仿真

© 2011 ANSYS, Inc. April 27, 2015 35

What is a System?什么是系统？

Energy Storage

Power Generation

Software

Actuators

Sensors Temperature

Pressure

Humidity

The Environment Disturbances Uncertainty Variability Extremes Failures

© 2011 ANSYS, Inc. April 27, 2015 36

Comprehensive Component-Level Design部件级设计

Electronics Structures Fluids Embedded Software

Immersive Multiphysics

© 2011 ANSYS, Inc. April 27, 2015 37

Systems

The Next Level: Systems系统级

• Assemblies of components – powered, sensed, & controlled as an integrated system

• Must be designed & optimized as a system

© 2011 ANSYS, Inc. April 27, 2015 38

ANSYS Systems Modeling & Simulation系统建模与仿真

Heat Exchangerhigh_t

low_t

outlet_hinlet_h

outlet_c

inlet_c

U2_heat_ex

inletoutlet

U1_low_pump

inletoutlet

U3_h_pump

temp

temp

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

300.00

350.00

400.00

450.00

500.00

550.00

600.00

Y2

[kel

]

Ansoft LLC Simplorer1XY Plot 1Curve InfoU2_heat_ex.tc100

TRU2_heat_ex.th100

TR

0

100

200

300

400

500

600

700

800

0 0.5 1 1.5 2

時間　（us）

電圧

　（V）

0

100

200

300

400

500

600

700

800

電流

　（A）

VCE-実測

VCE-SIM

IC-実測IC-SIM

-22.50

60.00

0

25.00

50.00

0 240.00m100.00m

2DGraphSel1 NIGBT71.IC

0

474.00m

200.00m

400.00m

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

2DGraphCon1

GS_I...

Systems

A platform for modeling, simulating, and analyzing virtual system prototypes...

...enabling product teams to verify and optimize software-controlled, multi-domain power systems

© 2011 ANSYS, Inc. April 27, 2015 39

Simplorer 用于系统仿真

Heat Exchangerhigh_t

low_t

outlet_hinlet_h

outlet_c

inlet_c

U2_heat_ex

inletoutlet

U1_low_pump

inletoutlet

U3_h_pump

temp

temp

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

300.00

350.00

400.00

450.00

500.00

550.00

600.00

Y2

[kel

]

Ansoft LLC Simplorer1XY Plot 1Curve InfoU2_heat_ex.tc100

TRU2_heat_ex.th100

TR

0

100

200

300

400

500

600

700

800

0 0.5 1 1.5 2

時間　（us）

電圧

　（V）

0

100

200

300

400

500

600

700

800

電流

　（A）

VCE-実測

VCE-SIM

IC-実測IC-SIM

Proven in Power Electronics

Links with Detailed Physics

Multi-Fidelity, Multi-Domain

Modeling

-22.50

60.00

0

25.00

50.00

0 240.00m100.00m

2DGraphSel1 NIGBT71.IC

0

474.00m

200.00m

400.00m

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

2DGraphCon1

GS_I...

Simulation-Based Test Embedded

Control / SW

© 2011 ANSYS, Inc. April 27, 2015 40

Modeling the System系统建模 Powerful Capabilities for Assembly and Reuse

Reduced Order Model Creation

Functional Mockup Interface (FMI)

3rd Party System Modeling tools

(AMESim, Simulink, Dymola, GT Suite etc.)

Embedded Software Integration

ANSYS SCADE

Simulink C Code

Co-simulation with 3D Physics

ANSYS 3D Physics

Mech EM Thermal Fluid

Multi-Domain Model Libraries

Language-Based Modeling

VHDL-AMS C/C++ SPICE SML

Modelica

Analog

Digital

Multi-Domain

App-Specific

Power Systems

Manufacturers

© 2011 ANSYS, Inc. April 27, 2015 41

0

0 0 0

PMSM_DQ n1

n2

n3

m1

Stepsize

SIMPARAM1

L1

L2

L3

N1

N2

N3

I1 I3

I_Motor

- ~ P

N

V

U

W

V1 V2 V3 V4 V5 V6

U1 E1

EMF=1000V

A B C

N

U_UMR

PWM Modulator

DC-Link Voltage

Integrating Current Sampling

Mechanical Angle Input

u1 u2

Udc

u3

V1 V2 V3 V4 V5 V6

I_1

I_3

I1f

I3f

phi_m

phi_el

w_el

FPGA PWM_3PH1

+ V

VM1

+ Φ SM_ROTB1

A B C

N

U_MOT

L1

L2

L3

N1

N2

N3

S_Motor

CTRL=S1

n_ref

TDELAY=5ms AMPL=n_ref-n0 TRISE=300ms OFF=n0

MASS_ROTB1

A

AM4

C1

C2

R1

R2

R3 L1

T F_ROTB1 Load_Torque

TDELAY=t_load AMPL=trq_load

TRISE=20ms OFF=0

w_ref

phi_el

i1f

i3f

w_el

dT

u1 u2 u3

Power Source/电源

Control控制 (FPGA & Software)

Power Electronics : Inverter电力电子

Permanent Magnet Synchronous Motor电机

Rotational position sensor传感器

Mechanical Load负载

Hybrid Vehicle Drivetrain/混合车辆动力总成系统

© 2011 ANSYS, Inc. April 27, 2015 42

Conclusion/总结

ANSYS offers a wide range of simulation tools to design Automotive systems:

ANSYS提供了不同领域和层次的仿真软件，用于汽车系统设计

- On the Component Level/部件级

- On the Embedded software level/嵌入式软件级

- On the system level/系统级