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© CADFEM 2017
Sicherheit und Innovation durch SimulationLucas Kostetzer, CADFEM GmbH
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Simulation for e-Mobility
• Motor Design• Motor Cooling• NVH (Noise Vibration Harshness)• Structural Dynamics• Power Electronics
© CADFEM 2017
• Power Electronics• Battery• Charging• EMC/EMI• System
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Simulation for e-Mobility
• 1. Motor Design• 2. Motor Cooling• 3. NVH (Noise Vibration Harshness)• Structural Dynamics• Power Electronics
© CADFEM 2017
• Power Electronics• 4. Battery• 5. Charging• EMC/EMI• 6. System
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1. Motor Design: Motor-CAD SoftwareØ Application specific tool for design and simulation of
electric motors
Ø EMag: template driven 2D FEA combined with analytical equations for fast calculation of motors electromagnetic/electrical performance
Ø Therm: heat transfer and flow network circuits
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Ø Therm: heat transfer and flow network circuits automatically set up to give quick steady-state & transient thermal predictions
Ø Lab: Provides efficiency mapping, continuous & peak torque envelopes and duty cycle transient thermal analysis within seconds/minutes
1. Motor Design: Performance Prediction for Nissan LEAF Motor
Ø Using published teardown data for Nissan LEAF motor
Ø Developed models to validate & demonstrate software tools for modellingtraction applications
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1. Motor Design: Performance Prediction for Nissan LEAF Motor
Ø Predicted efficiency map validated by test data
Ø Thermal model validated by 50kW, 60kW,
Motor-LAB
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50kW, 60kW, 70kW, 80kW thermal transient test data
good match
Measured
1. Motor Design: Drive Cycle Prediction (Nissan LEAF)
Ø Prediction of efficiency map and 10 repetitive US06 Drive Cycle thermal transient in a few minutes
Torque vs time
Total Loss
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time
Speed vs time
Copper Loss
Iron Loss
1. Motor Design: Detailed Electromagnetic Analysis
• 3D Effects• Demagnetisation• Eddy Currents, Losses• Excentricity• Tolerances
© CADFEM 2017
• Tolerances• Short Circuit, Faults• Inverter Induced Losses• Extraction of Reduced Order
Model, ECE
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2. Motor Cooling:
• Cooling• Extraction ROM, MOR, LTI• Transient Behaviour
© CADFEM 2017 10
2. Motor Cooling: Modeling Water Jacket Cooling Channels
© CADFEM 2017
Path LinesStatic Pressure
2. Motor Cooling: Modeling Water Jacket Cooling Channels
Distribution of coolant using different channel configurations
© CADFEM 2017
Temperature Profile
2. Motor Cooling: Air Cooling
© CADFEM 2017
Transient EM to calculate losses
Separate mesh for flow domain
EM loss data transferred and automatically mapped
Flows and temperatures in CFD
2. Motor Cooling: Thermal model for System Simulation
• Cooling of a electric motor with given losses
• Convective heat transport through the system due to water flow (or air, oil,…)
FEM to System
© CADFEM 2017
• Model Reduction in ANSYS Mechanical with CADFEM MOR-ACT
• Validation of the created "system" in ANSYS Simplorer
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2. Motor Cooling: ANSYS Simplorer FullDutyCycle
• Separated analysis for Load Cycle (heat losses)• duration T=800s• peak value approx. 20kW
H
0.00 100.00 200.00 300.00 400.00 500.00 600.00 700.00 800.00Time [s]
0.00
10.00
20.00
H1.
H [k
W] Curve Info
H1.HTR
heat_generation_1
CASCON_Motor_ROM
NL
LoadCycle
GAIN
Shift
© CADFEM 2017 15
• Thermal network with Reduced Order Model for the Motor
• Simulation time is about 1/1000 compared with 3D FEM • Kühlung ausreichend
• TMAX=13°C
0
THM1
0.00 100.00 200.00 300.00 400.00 500.00 600.00 700.00 800.00Time [s]
273.15
283.15
293.15
303.15
310.00
THM
1.T
[kel
]
Curve InfoTHM1.T
TR
H
H1
NL GAIN
0.00 100.00 200.00 300.00 400.00 500.00 600.00 700.00 800.00Time
273.15
283.15
293.15
303.15
310.00
THM
1.T
[kel
]
270.00
280.00
290.00
300.00
310.00
Mec
hani
calT
empe
ratu
r
Curve InfoTHM1.T
TR
MechanicalTemperaturImported
3. NVH: General Concepts of Electric Drive Acoustics inside ANSYS
Origin of Noise by Electrical Drives:
Magnetic Circuit Fluidics
Cooling
Drive Side
Gearbox etc.Reluctance, geometry
© CADFEM 2017 16
è Electric Drive Acoustics inside ANSYS
Gap forces
Magnetostriction
Inverter- synchronous pulse- asynchronous pulse
Current waveform
Magnetic saturation
Courtesy of Elektromotorenwerk Grünhain GmbH
3. NVH: Electric Drive Acoustics inside ANSYS
Workflow From Computation of Excitation Loads to ERP Postprocessing:
Electro-magnetic
Harmonic Vibration DFT
Oscillation,ERP,
External computation of excitation loads
© CADFEM 2017 17
magnetic Analysis
Vibration Analysis
DFT ERP,Waterfall PlotExcitation
Loads
ERP = Equivalent Radiated Power
3. NVH: General Concepts of Electric Drive Acoustics inside ANSYS
Harmonic Analysis Based on Mode Superposition:
• Time and memory saving
• Eigenmodes and -frequenciesas intermediate result
ANSYS Project Structure:
© CADFEM 2017
• Excitation loads will be imported into the harmonicanalysis using functions of Electric Drive Acousticsinside ANSYS.
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Mode 1 Mode 3 Mode 6610 Hz 1456 Hz 2654 Hz
Modal Analysis Harmon. Analysis
Excitations
3. NVH: General Concepts of Electric Drive Acoustics inside ANSYS
Data Processing: Load application always at Remote Points attached to faces!
Excitation spectra in frequency domain
Excitation loads in time domain, supplied by user
DFT
© CADFEM 2017 19
Surface
Mode-SuperpositionHarmonic Analysis
(Sweep of Rot. Speed)
Computation ofERP-spectrum
Modal coordinates(.mcf-file)
3. NVH: General Concepts of Electric Drive Acoustics inside ANSYS
Concept of Interpolation of Excitations Through a Rotational Speed Range:
• Example:Supply excitations only for a few operatingpoints of the motor characteristics.
n1
n2n1 n2
Frad
© CADFEM 2017
• After DFT: One excitation spectrumper force/moment component andoperating point.è Interpolation between OPs.
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n(sweep)
n2
n3
n4
n5
n1 n2
n3 n4 n5
Motor characteristics
Torq
ue
Speed
3. NVH: Vibration Function Overview
ERP-Visualization:
• ERP Spectrum(selected single speed point)
© CADFEM 2017
• ERP Waterfall (speed range)
• Watt or dB
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4. Battery: Challenges in battery pack design
• Minimize temperature differencesbetween cells and inside cells
• Guarantee an optimal temperature range
© CADFEM 2017 22
• Balance cell usage• Resistance/Capacitance f(T)
• Operating conditions under control to avoid explosion / run-away
Thermal runaway of the battery for auxiliary power of a Japan Airlines 787Source: U.S. national Transportation Safety
4. Battery: Chalenges
• Multi-Scale Physics in Li+ Batterymaterial electrode pair cell, pack
Pos
itive
el
ectro
de
Neg
ativ
e el
ectro
de
Sep
arat
or
© CADFEM 2017
• Approaches in this presentation• Cell, pack : Field based• Pack and Vehicle integration: System based
10-6~10-4 10-2~10010-9~10-8
Pos
itive
el
ectro
de
Neg
ativ
e el
ectro
de
Sep
arat
or
23
Length scale[m]
4. Battery: Equivalent Circuit Model (ECM)
© CADFEM 2017
• Circuit components• A)
• B)User Defined
• Coupling @ Cell level
24
VolIj = ( ) ÷
øö
çèæ ---= -+ dT
dUTVVol
Iq OCVECh jj&
( )( )( )( ) 210
210
expexp
aSOCaaCaSOCaaR
ai
ai
+=+=
÷ø
öçè
æ=
÷ø
öçè
æ=
å
å
=
=
5
0
5
0
n
nni
n
nni
SoCaC
SoCaR
ECM: typical approach from OEM‘s!Circuit tables are derived fromstandard measurementsOR
Contour of φ-
4. Battery: Example: single battery cell
© CADFEM 2017
Contour of φ-
Temperature
Cylindrical cell with discrete tabsPrismatic cell 25
4. Battery: 1P20S with air cooling channel
Velocity field
© CADFEM 2017
Total heat generation rate
Temperature profile26
4. Battery: Module Level – CFD Thermal - Optimization
Initial Optimized
© CADFEM 2017
Velocity Distribution
27
Velocity Distribution
4. Battery: System based battery simulation
• How about current load conditions and the design of thermal management control?>System simulation
© CADFEM 2017 28
• How to use detailed FIELD models/results to improve System modeling ?>ROM ( Reduce Order Model ) + System Simulation
Drive cycle BMW I3 Pack, Source: BMWBlog
4. Battery: LTI – ROM - Principle
• Thermal model is a linear system (Linear Time Invariant)
Input1_Tin
Input2_Cyl1
Input3_Cyl2
Output1_Tout
Output2_Cyl1
Output3_Cyl2
HeatTemperature
© CADFEM 2017 29
• LTI can be characterized and indentified with step response (or impulse)• Convolution is used to build any response of this system
• ROM: find a simple LTI to emulate the original CFD response
timetime
4. Battery: LTI – ROM - Workflow
1) Get step responses of the system
3) Use ROM in system simulation
2) Extract ROM
© CADFEM 2017 30Fluent or Mechanical SimplorerSimplorer
Heat
time
Temperature
time
Heat Profile
4. Battery: Application example
© CADFEM 2017
LTI ROM gives the same results as CFD. LTI ROM runs in less than 2 seconds while the CFD runs 2 hours on one single CPU.
X. Hu, S. Lin, S. Stanton, W. Lian, “A Foster Network Thermal Model for HEV/EV Battery Modeling,” IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 47, NO. 4, JULY/AUGUST 2011X. Hu, S. Lin, S. Stanton, W. Lian, “A State Space Thermal Model for HEV/EV Battery Modeling", SAE 2011-01-1364 31
4. Battery: Application example 2
Cell model Battery pack
Heat
Temperature
Pack thermal Model
© CADFEM 2017
Cell Electrochemistry Model
Temp.
Heat loss
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5. Inductive Charging: Wireless Charging for Electro or Hybrid VehiclesWhy?
• Comfortable (no searching for the charging cable, fitting connectors)
• Protection against vandalism at public areas• Automatic wireless charging (several shorter charge cycles
lead to longer battery life)• Fast energy transfer with high efficiency• Dynamic charging while driving
© CADFEM 2017 33
• Dynamic charging while driving
Challenges• Positioning of the vehicle• Stray fields and EMC• Matching network and parasitic effects• Transmission and system efficiency• Detecting foreign objects• Standards and compatibility
Ref.: www.mercedes-benz.de
Ref.: www.qualcomm.com
Ref.: www.toyota-global.com
5. Inductive Charging: BasicsTransformer principle• With closed magnetic circuit:
• Magnetic circuit bundles flow and leads to a lower leakage flux
• Analytical calculation possible• With Air gap:
• Analytically difficult to calculate -> FEM Ref.: Prof. Dr.-Ing. Nejila Parspour, „Induktives Laden – ein Themenschwerpunkt der Elektromobilität“
© CADFEM 2017 34
• Analytically difficult to calculate -> FEM Themenschwerpunkt der Elektromobilität“
1mm 1cm 10cm 1m 10m 100m
100%
50%
0%
Transfer Distance
Effi
cien
cy
Resonance type
Induction type (~15W)Induction type (~50kW)
Microwave type
5. Inductive Charging: Analysis Plan
Electromagnetic field simulation• Identifying of saturated areas• Extracting of equivalent circuit parameters• Position dependent sensitivity analysis • Determination of stray fields and losses
© CADFEM 2017
00
E1
W
+
WM1
W
+
WM2
C1
11.74nF
C2
30.45nF
Rload
3ohm
R1dc
21mOhm
R2dc
7.2mOhm
Current1:src Current2:srcCurrent1:snk Current2:snk
Mx_SS1
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Electrical circuit and system simulation• Circuit optimization (resonant capacitors)• Calculation of the system efficiency
5. Inductive Charging: Demonstrator Model
Components• Two flat cylindrical coils• Ferrite shell (Ground Module)• Ferrite disc (Car Module)• Aluminum shielding plates
Transmitter Coil
Reciver CoilFerrite Disc
Aluminum Shielding Plate
Car Module:
Ground Module:
© CADFEM 2017 36
Position
Gap
Sliding
Ferrite Shell
Aluminum Shielding Plate
Spulen Spezifikationen:• Litzendraht: Æ 0.25mm x 384 strands• Kupfer: 5.8x107 [S/m]• Anzahl Wicklungen: 10
Ferrit:• Relative Permeability: μi = 2400 • Relative Loss Factor: 1x10-9
Speisung:• Spannung: 200 V / 10 kW• Design Resonanz Frequenz: 150 kHz
5. Inductive Charging: Model Simulation with ANSYS
Eddy Current Analyses (Maxwell – Eddy Current Solver)
Magnetostatic Analyses (Maxwell – Magnetostatic Solver)
Preliminary Investigation:
Electromagnetic Field Simulation:
• Maximum B-Fields
• Eddy Currents• Core Losses• Inductance matrix
© CADFEM 2017 37
(Maxwell – Eddy Current Solver)
Circuit and System Simulation (Simplorer)
System Simulation:
Temperature, mechanical stress, electromagnetic radiation
• Inductance matrix
• Resonance frequency • Efficiency
Further investigations
5. Inductive Charging: Eddy Current Analyses – Inductance Matrix
• The self- and mutual inductances are position dependent
• A parametric sweep was used to determine a matrix for the coupling coefficent, self- and mutual inductance
© CADFEM 2017 38
5. Inductive Charging: Circuit Simulation – Equivalent Circuit • An equivalent circuit can be created from the
electric circuit components and the parameter extracted from the electromagnetic field simulation
• Additional losses can be taken into account by additional resistors in the circuit (analytically calculated or measured)
SlR
s=
C 1=
DC Resistance:
Ss
l
Resonant Capacitance:
© CADFEM 2017 39
00
E1
W
+WM1
W
+ WM2C1
11.74nF
C2
30.45nF
Rload
3ohm
R1dc
21mOhm
R1ac
85.656mOhm
R2ac
46.715mOhm
R2dc
7.2mOhm
L1
95.861uH
L2
36.969uH
M12
0.09232
Resonant Circuit Conductiv LossesLoad
LC 2
0w=
Behaviour Model
5. Inductive Charging: System Simulation
SlR
s=
C 1=
DC Resistance:
Ss
l
Resonant Capacitance:
• An equivalent circuit can be created from the electric circuit components and the parameter extracted from the electromagnetic field simulation
• Additional losses can be taken into account by additional resistors in the circuit (analytically calculated or measured)
• Replacing the concentrated quantities with a behavioral model or SPICE model
© CADFEM 2017 40
LC 2
0w=
00
E1
W
+WM1
W
+ WM2C1
11.74nF
C2
30.45nF
Rload
3ohm
R1dc
21mOhm
R1ac
85.656mOhm
R2ac
46.715mOhm
R2dc
7.2mOhm
L1
95.861uH
L2
36.969uH
M12
0.09232
Resonant Circuit Conductiv LossesLoad
Behaviour Model
behavioral model or SPICE model
6. System: Which parts belong to our system?Safety Requirements
Actuators
Battery
© CADFEM 2017 41
Sensors
Electronic Control Units
Operating ConditionsEmbedded Software
Operational Profiles
6. System: ….and how do they interact with each other?
© CADFEM 2017 42
6. System: System simulation – some thoughts to start with
• Which design-stage?
• In which physical domain? Across domains?
• How big is the system:
© CADFEM 2017
• How big is the system: • System with several components across several physical domains• System of Systems
• What are the time-scales?
→Level of abstraction
43
6. System: Which Representation?
Reduced Order Model Creation
System Model Interoperability
Embedded Software Integration
Co-simulationwith 3D Physics
Language-Based Modeling
Multi-Domain Model Libraries
© CADFEM 2017 44
Thousands of Built-inComponent Models
Industry Standardsfor System Modeling
Interfaces with all ANSYS 3D Physics 3rd Party SystemModeling Tools
ANSYS SCADEand More
6. System: ECE Model extraction
• FEM to System • model order reduction: ECE-model
(equiv. circuit extraction)• variation of currents Id, Iq and
rotational angle θm
b
© CADFEM 2017 45
rotational angle θm• lookup-table: flux linkage Ψd, Ψq, Ψ0 + torque
• takes into account: saturation due to material nonlinearities
• does not take into account: eddy current effects
a
c
6. System Simulation Motor control
© CADFEM 2017 46
6. System: Next Step: Add driving cycle and thermal model?
• Different time scales!• Existing motor model too
detailed• Use VHDL-AMS model
instead
© CADFEM 2017
instead
47
…maybe like this
© CADFEM 2017 48
Advanced Magnetics ModelingElectric Drive Acoustics
Motor / Inductive Charging
Lab
Efficient Motor Design ToolkitMotor-Design Battery
Control logic, softwareSystem Validation
LabElectro-thermal modeling
ROM for system simulation
Design Analysis Operation
© CADFEM 2017
EmagThermal
3D Physical Validation
Concept Design
System Validation
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Many Thanks to
• Martin Hanke• James Goss, Dave Staton, MDL• Matthias Voss• Rene Fuger• Hanna Baumgartl
© CADFEM 2017
• Hanna Baumgartl• Evgeny Rudnyi• Ulrich Bock• Kanchan Mahajan• Jürgen Wibbeler• Christian Römelsberger
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CADFEM – Simulation is more than Software
PRODUCTS Software und IT Solutions
SERVICESAdvice, Support, Engineering
© CADFEM 2017 51
KNOW-HOWTransfer of knowledge
CADFEM in D, A, CH• 1985 founded• 2,300 customers• 11 locations• 220 employees (worldwide > 350)• ANSYS Elite Channel Partner
Career-integrated Master Applied Computational Mechanics
Master‘s Students
150+
Certificate andModule Students
30+
© CADFEM 2017 www.esocaet.com/en/studies
„The master course allows me to apply simulationmethods to their full potential. Furthermore I don‘tonly apply simulation now, I really understand it.“Stefan Hermann, M.Eng.Liebherr Aerospace Lindenberg GmbH
150+ 30+
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