evhev value chain and battery design - comprehensive solution presentation
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8/18/2019 EVHEV Value Chain and Battery Design - Comprehensive Solution Presentation
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© 2011 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary
© 2011 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary
EV/HEV Value Chain
and Battery DesignSandeep SovaniZed TangMark Christini
January 26, 2011 ANSYS Sales Conference
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© 2011 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary
Outline
• EV/HEV Market – Trends – Value Chain
• EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics
• Success Stories
• 2011 Marketing Campaign
• Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators
• R13 Advances• 2011 ANSYS Targets
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© 2011 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary
The automotive powertrain has changed for good
A once-in-a-lifetime landslide change
Market Trends
I.C. EnginePowertrain
Augmentedwith
ElectricPowertrain
Hybrid Powertrain
I.C. EnginePowertrain
OLD NEW
ElectricPowertrain
FUTURE
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Market Trends
Why?• Environmental concerns in the west• Oil dependence concerns in the east
Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA
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Market Trends
MicroHybrid
HEV PHEV ER EV EV FCEV
Types of Hybrid Electric Vehicles
xEV = General term to reference all types of EVsRef: Bly, M. – General Motors, “Developing a Battery Value Chain,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA
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Market Trends
Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA
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Market Trends
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Market Trends
PowerSource
PowerElectronics
ElectricMachine
MechanicalComponents
Control
Electric Powertrain Power Flow
Battery/BMS Inverter/Busbar Traction Motor Drive Shaft
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 Reporthttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpg Author {{:de:wiki:user DrJunge|DrJunge}}.
http://commons.wikimedia.org/wiki/File:HitachiJ100A.jpghttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpghttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpghttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:HitachiJ100A.jpg
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Market Trends
Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA
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Market Trends
Ref: Bly, M. – General Motors, “Developing a Battery Value Chain,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA
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Outline
• EV/HEV Market – Trends – Value Chain
• EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics
• Success Stories
• 2011 Marketing Campaigns
• Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators
• R13 Advances• 2011 ANSYS Targets
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EV/HEV Value Chain
Samp le Bus iness In i t ia t ives
Y2020 Estimates
Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA
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Battery Value Chain
Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA
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EV/HEV Value Chain
Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA
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Battery Value Chain
Ref: Iyengar, J. – Chrysler, “EV Battery Business Analysisand Vision for Commercialization” EV Battery TechnologyConference, Sept 21-22, 2010, Troy, MI, USA
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Battery Value Chain
Ref: Iyengar, J. – Chrysler, “EV Battery Business Analysis and Vision for Commercialization” EV Battery Technology Conference, Sept 21 -22,2010, Troy, MI, USA
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Battery Value Chain
Involvement of Different Types of Organizations in the Battery Value Chain
Ref: Iyengar, J. – Chrysler, “EV Battery Business Analysis and Vision for Commercialization” EV Battery Technology Conference, Sept 21 -22,2010, Troy, MI, USA
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Outline
• EV/HEV Market – Trends – Value Chain
• EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics
• Success Stories
• 2011 Marketing Campaigns
• Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators
• R13 Advances• 2011 ANSYS Targets
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Numerical Simulation will be a key differentiatorin the electrification competition
Numerical Simulation is particularly advantageous inelectrification development
Firms that strategically deploy numerical simulation willgain significant competitive advantage
EV/HEV Simulation
Message to Executive Decision Makers –
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Why is Numerical Simulationparticularly advantageous inelectrification development?
EV/HEV Simulation
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Challenges indeveloping disruptiveinnovations
No precedenceMany unknownsNew paradigms
Uncertainty
Time pressure
Last powertrain took~100 years to develop
New powertrainexpected in ~10 years
EV/HEV Simulation
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Many ChoicesMany Decisions
Cylindrical, Prismatic?Air Cooling, Liquid Cooling?Cell Chemistry?…
…
Established Demands
SafetyReliability
Cost Life
Same as or surpassingcurrent vehicle standards
Multitude of ideas need to be generated, digested,validated, developed, tested, perfected, delivered, in
a short time
EV/HEV Simulation
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Multitude of ideas need to be generated, digested,validated, developed, tested, perfected, delivered, in ashort time
Numerical Simulation is particularly wellsuited for this need provides
• In-depth engineering insights• Speedy design evaluation via virtual testing• Enabler of fast, extensive design
EV/HEV Simulation
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Next Generation Simulation for Next Generation Vehicles
Old Paradigms
Component Simulation
Single Physics
Few Instances
New Paradigms
Integrated Simulation(Component and System)
Multiphysics Simulation(Flow, thermal, structural,
electrical, electrochem.)
Extensive AutomatedDesign Exploration
EV/HEV Simulation ANSYS Positioning Message
Competitors’ Propositions ANSYS Differentiators
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© 2011 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary
Outline
• EV/HEV Market – Trends – Value Chain
• EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics
• Success Stories
• 2011 Marketing Campaigns
• Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators
• R13 Advances• 2011 ANSYS Targets
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Integrated Simulation
PowerSource
PowerElectronics
ElectricMachine
MechanicalComponents
Control
What is Integrated Simulation?
Battery/BMS Inverter/Busbar Traction Motor Drive Shaft
http://commons.wikimedia.org/wiki/File:HitachiJ100A.jpgOakridge National Laboratory, ORNL/TM-2004/247, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System Interim Reporthttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpg Author {{:de:wiki:user DrJunge|DrJunge}}.
http://commons.wikimedia.org/wiki/File:HitachiJ100A.jpghttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpghttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpghttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:HitachiJ100A.jpg
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Integrated Simulation
Integrated Simulation:Combining high-fidelity component simulation withsubsystem and system level simulation
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Integrated Simulation
Why is Integrated Simulation critical for HEV?
• HEVs are all about fuel efficiency• High level of optimization is needed• Cannot be achieved by designing components and
systems in isolation
• HEV components are by nature highly
dependent on each other • E.g. Battery Management System (controller) needs to dynamically
change loads on battery cells to maintain temperature uniformity• E.g. Traction Motor cannot run without being governed by advanced
power electronics – the two have to be designed together
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Integrated Simulation
ANSYS Differentiator: No competitor can performintegrated simulation with the same multiphysicsbreadth and depth as ANSYS
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Outline
• EV/HEV Market – Trends – Value Chain
• EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics
• Success Stories
• 2011 Marketing Campaigns
• Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators
• R13 Advances• 2011 ANSYS Targets
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Battery: Key Problems
CellManufacturing
MaterialBehavior in Cell
Assembly
Ageing, Life
Thermal Management(Temperature Uniformity)
Safety, Crash, Abuse
NVH, Durability
Battery ManagementSystem and Algorithms
BatteryPerformance inVehicle Level TestCycles
Load Matching forChargingDischarging
Overall Concerns:• Cost• Life• Safety• Power Density
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Battery : ANSYS Solutions
• Pack Level Simulation
• Cell Level Simulation
• System Level Simulation
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Battery : ANSYS Solutions – Pack Level
ANSYS Workbench – An Integrated Solution for Battery CFD Analysis
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Build-in What-if Study in WB
Battery : ANSYS Solutions – Pack Level
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HEV Battery Thermal Management: Six Sigma Analysis
Battery : ANSYS Solutions – Pack Level
Ref: Valhinos et al, “Improving Battery Thermal Management Using Design for Six SigmaProcess”, 20 th Electric Vehicle Symposium, Long Beach, CA (November 15-18, 2003)
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Reduced Order Modeling
Battery : ANSYS Solutions – Pack Level
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Reduced Order Model Extraction Process Using Simplorer
Battery : ANSYS Solutions – Pack Level
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LTI (Foster Network) vs ANSYS FLUENT
Battery : ANSYS Solutions – Pack Level
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Battery Bus Bar Heating Multiphysics Simulation• For steady (or low frequency) currents under
temperature dependent conductivity
Battery : ANSYS Solutions – Pack Level
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Coupled Simulation in ANSYS FLUENT
Battery : ANSYS Solutions – Pack Level
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• Other solutions at Pack Level – Capabilities exist in standard ANSYS products
but currently there are no demonstration cases
• NVH – Fluid noise for air-cooled packs• Crash, impact• Durability
– 2011 HEV marketing campaign will createthese demonstration cases
Battery : ANSYS Solutions – Pack Level
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Battery : ANSYS Solutions
• Pack Level Simulation
• Cell Level Simulation
• System Level Simulation
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Cell Manufacturing: Coating Analysis
Courtesy: ANSYS Japan Technical Team
Battery : ANSYS Solutions – Cell Level
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Cell Manufacturing: Flow Inside Die
Courtesy: ANSYS Japan Technical Team
Battery : ANSYS Solutions – Cell Level
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Cell Electrical Model:• Simple enough for systemlevel analysis
– Detailed electrochemistry models
are too time consuming for systemlevel analysis
• Accurate enough for virtual prototyping – Non-linear circuit voltage as a function of SOC – Transient I-V performance – Runtime prediction – Discharge rate dependent capacity – Temperature effect – Accurate transient temperature prediction
Battery : ANSYS Solutions – Cell Level
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Single Cell Thermal Model
- Newman &Tidemann (1993);
- Gu (1983) ;- Kim et al (2008)*
Model based on:
Battery : ANSYS Solutions – Cell Level
B ANSYS S l i
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Electrochemistry: Newman’s 1D Model in Simplorer
Battery : ANSYS Solutions – Cell Level
B ANSYS S l i
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3D Electrochemistry Modeling
Battery : ANSYS Solutions – Cell Level
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Battery : ANSYS Solutions –
• Pack Level Simulation
• Cell Level Simulation
• System Level Simulation
B tt ANSYS S l ti
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Battery: ANSYS Solutions – System Level
• 60 Cells connected in matrix pack• Packs are connected in matrix to
final configuration
5cells
Pack Circuit Model
B tt ANSYS S l ti
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Battery in Control System with Motor Controller
Battery: ANSYS Solutions – System Level
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Battery: Competition Analysis
• CD-AdapcoPack Level –CD-Adapco ANSYS
Basic CFD needed forBattery Simulation
Comparable to ANSYS Comparable
Design Exploration Rudimentaryparameterization
SpaceClaim andDesignXplorer giveadvantage
LTI Method No comparable solution Easy Simplorer based
solution
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Battery: Competition Analysis
• CD-AdapcoCell Level –CD-Adapco ANSYS
Cell Electrical Model Partnership with BatteryDesign LLC. Providesadvantage in standardcell characteristics andcell material properties
Simplorer based model.Needs cell properties asinput.
Cell Thermal Model Demonstrated examples Comparable capability
1D Electrochemistry No demonstratedsolution
Simplorer based solution
3D Electrochemistry Some demonstratedexamples
Some demonstratedexamples
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Battery: Competition Analysis
• CD-AdapcoMultiphysics and System Level –
CD-Adapco ANSYS
Multiphysics (E.g. busbar deformation)
No comparable solution ANSYS core advantage
Durability, Impact, Abuse No direct solution ANSYS mechanical
NVH Some acoustics models,no structural solution
Broadband acousticsmodels in CFD,Structural NVH
System Integration No direct solution Simplorer based solution
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Battery: Competition Analysis
ResourcesMore information on automotive google site:
https://sites.google.com/a/ansys.com/automotive/https://sites.google.com/a/ansys.com/automotive/marketing-
material/campaign-1/battery/general-references
https://sites.google.com/a/ansys.com/automotive/https://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/
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Battery: 2011 Targets
• OEMs – All major car, truck OEMs have ambitious
electrification plans: All are targets• Battery Suppliers
– Over 150 battery companiesin the world• Full list on Automotive Google Site
– E.g. Saft, LG Chem
• Major concentration in China, Korea
• Other Suppliers (Integrators, Battery Management System)• E.g. Continental, Magna
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Outline
• EV/HEV Market – Trends – Value Chain
• EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics
• Success Stories
• 2011 Marketing Campaigns
• Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators
• R13 Advances• 2011 ANSYS Targets
Traction Motor – Key Problems
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Traction Motor – Key Problemsand Simulation Needs
• Traction Motors: Optimization needs – – Efficiency (key importance for HEVs) – Size and cost – NVH; reliability and durability
• Technical Challenges – Optimizing magnetics design (speed, torque, losses)
• Numerous variables have influence; virtually impossible to study effectsthrough physical testing
– Thermal management (accurate loss mapping)• Performance drops with temperature increase
– Noise and Vibration• Motor is the biggest noise source in electric vehicles
– System integration (optimize motor and controls)• Modern motor controls are highly complex; motor and controls have critical
need to be designed together as one system
Traction Motor – Key Problems
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Traction Motor Key Problemsand Simulation Needs
• More Innovative and Complex Designs
19 machine types to choose from
Different machine geometry templates
Traction Motor – Key Problems
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Traction Motor Key Problemsand Simulation Needs
• Integration with Controls and Power Electronics
-172.00
172.00
-100.00
0
100.00
74.95m 85.00m80.00m
Phase Current RA.I[A] RB.I[A] RC .I [A]
Electric Machine does not work by itself;two optimized components do not add upto be an optimized system; integratedmotor / electronics / control simulation is
needed
Traction Motor – Key Problems
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Traction Motor Key Problemsand Simulation Needs
• Multiphysics Coupling
Deformation of the stator Deformation of coilsThe electromagnetic force densityfrom Maxwell is used as load inStructural
Thermal-Stress with Electromagnetic Force load
Traction Motor – Key Problems
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Traction Motor Key Problemsand Simulation Needs
• Shorten Time to Market
…
…
Host
Nodes
Parametric variations: 2,200
Solve time, one processor: 7.6 days
Solve time, distributed, 48 COREs: 4.5 hours
Speed improvement: 43.2X
Let computers work 24/7, freeing engineers’time for other important tasks
Traction Motor – Competition
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Traction Motor CompetitionAnalysis and Differentiators
ANSYS offers Functionality Competition
Maxwell Electromagnetic FiniteElement Solvers
JMag, FLUX, MagNet,…
Simplorer Circuit/SystemSimulator Saber, PSpice,Matlab /SIMULINK, …
ANSYSMechanical/CFD
Stress, Thermal Abaqus, STAR- CD, …
Q3D Parasitics Extraction
DX, MPO, DSO Design Automation &Optimization
RMxprt
Closed-form analyticalsolution, quickly reducedesign space
SPEED, MotorSolve …
ANSYS Simulation Driven Product DevelopmentElectric Machine Design Methodology
Traction Motor – Competition
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Traction Motor CompetitionAnalysis and Differentiators
ANSYS offers Functionality Competition
Maxwell Electromagnetic FiniteElement Solvers
JMag, FLUX, MagNet,…
Simplorer Circuit/SystemSimulator Saber, PSpice,Matlab /SIMULINK, …
Mechanical/CFD Stress, Thermal Abacus, STAR- CD, …
Q3D Parasitics Extraction
DX, MPO, DSO Design Automation &Optimization
RMxprt
Closed-form analyticalsolution, quickly reducedesign space
SPEED, MotorSolve …
ANSYS Simulation Driven Product DevelopmentElectric Machine Design Methodology
ANSYS
Electric
Machine
Design
Methodology
FullyIntegratedElectricMechine
SystemDesign
NONE!
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Traction Motor – 2011 ANSYS
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Traction Motor 2011 ANSYSTargets
• General Trends• It takes years for major auto OEMs to realizethat they have to control their own destiny interms of designing traction motors bythemselves. For example, GM. Ford isstarting to realize that.• It also takes years for motor suppliers to
realize that they need to re-design a motor forauto traction application.
Traction Motor – 2011 ANSYS
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Traction Motor 2011 ANSYSTargets
• Maintain Success and Expand• Use success story in one OEM and apply to more
• GM -> Ford -> Chrysler
• Use success story in one physics and apply tomore• Magnetics design -> Structural/Thermal -> Electronics
• Use success story in traction motor and apply toother applications
• Battery, electronics, system integration, EMI/EMC
Traction Motor – 2011 ANSYS
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Targets
• Expand Success to Major Suppliers andCommercial Vehicles/Off-highway Vehicles
• Suppliers Want to do More too
• Commercial Vehicle companies have huge interestin HEV/EV too• Eaton Trucks, Prestolite, ArvinMeritor, etc.
• Off-highway industry also starts looking intoHEV/EV
• CAT, John Deere, Cummins, etc.
Traction Motor – 2011 ANSYS
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Targets
• Expand Success to other Motor Areas• Power Steering, Electric Pumps, WindShields, etc.
• These applications have the same physics(motor, controller, power source/electronics,mechanical components)• HEV/EVs need new designs for theseapplications because requirements are verydifferent from traditional vehicles
O li
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Outline
• EV/HEV Market – Trends – Value Chain
• EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics
• Success Stories
• 2011 Marketing Campaigns
• Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators• ANSYS 13.0 Advances• 2011 ANSYS Targets
HEV Power Electronics – Key
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yProblems and Simulation Needs
Charging SystemsHigh Power Distribution SystemsEnergy
ManagementSystems
Typical HEV System
(internal use only)
HEV Power Electronics – Key
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System
Control
Thermal
Digital
…
yProblems and Simulation Needs
HEV Power Electronics
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Simplorer
Simulink
MathcadCo Simulation
ModelSIM
ANSYS Solutions
ANSYS is the only providerof a complete powerelectronics design solutionfor Hybrid Electric Vehicles!
HEV Power Electronics
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ANSYS Solutions
• ANSYS Complete Power Electronics Design Solution – Can assist engineers in designing and analyzing power systems, drives,
and components for HEV market – Provides true multi-physics coupled solutions for electrical, magnetic,
mechanical, fluid, and thermal simulations – Integrates electromagnetic, circuit, and system engineering using a
common desktop environment – Three Basic Simulation types on same schematic:
– Circuits – Block Diagrams – State Machines
– Co-simulation with Maxwell and Simulink – Couples directly to:
– EM tools (Maxwell, PExprt, Q3D, RMxprt, HFSS) – Thermal tools (ANSYS CFD, ANSYS Icepak)
– Optimization and Statistical analysis – VHDL-AMS capability
HEV Power Electronics
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ThermalElectromagnetic MechanicalFluidicComponent
CircuitSubsystem
System
ANSYS
Mechanical,CFD, Icepak
Q3D,Xprt Tools
Simplorer
Maxwell, HFSSFEA solvers
ANSYS System Solutions
HEV Power Electronics
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Simplorer
System Design
PP:=6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
JPMSYNCIA
IB
IC
Torque JPMSYNCIA
IB
IC
TorqueD2D
MaxwellElectromagnetic Components
PExprtMagnetics
RMxprtMotor Design
Q3DParasitics
ANSYSMechanicalThermal/Stress
ANSYS CFDThermal
Model order Reduction
Co-simulation
Field Solution
Model Generation
Icepak
ANSYS Coupled Solutions
HEV Power Electronics
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Competitive Differentiators
ANSYS offers Functionality DifferentiatorsSimplorer Circuit/System Simulator Multi-domain, multi-physics
Maxwell Electromagnetic Finite ElementSolvers for components
Automatic adaptive meshing,3D transient w/ circuits, motion
PExprt Closed-form analytical solution
for Transformers and Inductors
Couples to Simplorer and
Maxwell for complete FEARMxprt Closed-form analytical solution
for Motors and GeneratorsCouples to Simplorer andMaxwell for complete FEA
Q3D R,L,C,G parasitic extraction forwiring harnesses andinterconnects
Frequency dependent modelcoupled to Simplorer
ANSYSMechanical
Basic Stress and ThermalAnalysis
Couples directly to Maxwell viaWorkbench
ANSYS CFD Thermal analysis using fluid flow Couples directly to Maxwell
ANSYS Icepak Electronics Cooling Couples directly to Simplorer
HEV Power Electronics
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Simplorer v8.1 and v9 Advances
• Integrated with the ANSYS
Workbench interface. Can becreated and launched from WB
• Improved co-simulation capabilitieswith Maxwell 3D
• Enhanced IGBT ParameterizationWizard with more accurate fittingalgorithm – important for EMC/EMIanalysis
• Direct link with ANSYS Icepak• Q3D State-Space Model from S-
Parameters• State-space model to simulate
multi-domain state-space models• Dynamic plot updates and numeric
displays while simulating
HEV Power Electronics
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2011 ANSYS Target #1
• Expand Success to other Major Suppliersof HEV components and systems such asXYZ Corp.
− XYZ Corporation in Detroit is a Tier 1,2 supplier (traditionallyseating) for major automotive OEMs− Previously owned ANSYS Mechanical and ANSYS Icepak− Made a strategic decision several years ago to move into theautomotive power electronics market− Currently developing a high voltage power supply for a HEVbattery charging system− Over the past 2 years, XYZ has acquired:
Maxwell, PExprt, Simplorer, Q3D, and HFSS− Team of (8) engineers using this software today− Currently evaluating SIwave …
Potential Areas for Simulation
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Potential Areas for Simulation
HEV Power Electronics
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IGBT Module Pack 3Daccurate model
ParametersExtraction
Electromagnetic(EM) study
Design and CouplingsModel
IGBT Model
• Tridimensional IGBT pack model and EM study
• Parasitic model extraction
• IGBT circuit model
Far Field Study
• Far Field Study for Electric Field EM
2011 ANSYS Target #2
• Expand Success to Major Automotive OEM’s for radiated
EMC/EMI analysis of power supplies
Analysis Methodology Using
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• Tridimensional IGBT pack model and EM study
• Parasitic model extraction
• IGBT circuit model
• Far Field Study for Electric Field EM
Finite Element Method
Finite ElementMethodFEA / BoundaryElement Method System Simulation
Different Techniques
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Simplorer to HFSS Radiated Field
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E-field @ 100 MHz, Power = 10kW
p
HEV Power Electronics
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2011 ANSYS Target #2
• Expand Success to Major Automotive OEM’s for
conducted EMC/EMI analysis of power supplies
Characterize and reduce EMI emissions from SwitchedMode Power Supply (SMPS) by:
- Model SMPS- Determine critical components in system- Determine noise attenuating techniques
Detailed Procedure:
− Model: Actives and Passives (discrete componentsand interconnects)− Use simulations to find critical paths− Focus attention on these paths to mitigate noise
Modeling Process
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g
ProprietaryMaterial has
been removed
System Simulation
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y
Proprietary
Material hasbeen removed
Reduction of Conducted EMI
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Proprietary
Material hasbeen removed
Outline
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Outline
• EV/HEV Market – Trends – Value Chain
• EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics
• Success Stories
• 2011 Marketing Campaigns
• Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators• R13 Advances• 2011 ANSYS Targets
Success Story 1 Company #1Car Manufacturer
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• What did they buy? – DSO, Optimetrics, Maxwell – ANSYS CFD, ANSYS Mechanical, DM, DX
• What are they using it for? – Electric Motors, Battery, Power electronics
Success Story 1 Car Manufacturer
Success Story 1 Company #1Car Manufacturer
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• What did they prefer ANSYS? – Motors: very fast analysis of 1000s of designs
using DSO –
Battery: WB workflow integrating multiplephysics• Future growth potential
– Structural mechanics & explicit – Simplorer – EKM?
Success Story 1 Car Manufacturer
Success Story 2 Company #2Battery Manufacturer
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• Who are they? – A prominent
U.S. battery company
• What did they buy? – CFD (Fluent)
• What are they usingit for?
– Battery Simulation
Success Sto y Battery Manufacturer
Success Story 2 Company #2Battery Manufacturer
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• What did they prefer ANSYS? – They replaced CD-Adapco that was in use for 2
years –
Preferred ANSYS due to• Workbench• Opinion about ANSYS leadership in battery simulation• Expert onsite visits, presentations, reference materials
• Prior FLUENT use by key engineering manager
y Battery Manufacturer
Success Story 3 Company #3Car Manufacturer
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• What did they buy? – Maxwell 2D/3D + RMxprt + Optimetrics +
ANSYS FLUENT + DesignXplorer
• What are they using it for? – Departments: (a) R&D (b) Production) – Applications
• Verify performance map of supplier produced motor • Simplorer co-simulation for circuit and system level• Battery cooling
y Car Manufacturer
Success Story 3 Company #3Car Manufacturer
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• What did they prefer ANSYS? – Competitors beaten – CEDRAT, CD-Adapco – Preffered ANSYS due to
• Single vendor for battery, motor, electronics• Simulation workflow (from CATIA V5 thru DX/DOE)• Coupling Maxwell & FLUENT• ROM of Maxwell & FLUENT into Simplorer
• ANSYS more stable company compared to CEDRAT• Excellent support
• Future growth potential – DSO, Q3D
y Car Manufacturer
Success Story 4 Company #3Multinational Parts Supplier
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• What did they buy? – Q3D + ANSYS FLUENT + ANSYS Mechanical
• What are they using it for?
– Micro-hybrid systems (start-stop alternator,electronics) – Mechatronics simulation• Thermal – FLUENT• Structural Acoustics – ANSYS Mechanical
• Electromagnetics – Maxwell• Co-Simulation – Simplorer
y Multinational Parts Supplier
Success Story 4 Company #3Multinational Parts Supplier
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• What did they prefer ANSYS? – Competitors beaten – CEDRAT, CST,
Dassault, CD-Adapco – Corporate focus on simulation at Valeo – Why did they prefer ANSYS –
• ANSYS Vision for Hybrid Electric Vehicles• Workbench workflow
• Multiphysics• Integrated simulation
y Multinational Parts Supplier
Success Story 5 Company #5Car Manufacturer
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y
HEV related sale
Maxwell - Motor DesignCFD - Battery Design
See details in Day 4presentation by Greg Fallonand Tom Smithyman
Car Manufacturer
Outline
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• EV/HEV Market – Trends – Value Chain
• EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics
• Success Stories
• 2011 Marketing Campaigns
• Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators• R13 Advances• 2011 ANSYS Targets
Marketing Campaigns
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Proprietary
Material hasbeen removed
Thank you!
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