ANSYS for Hybrid Electrical Vehicles- Case Studies · © 2011 ANSYS, Inc. September 14, 2011 17 A...
Transcript of ANSYS for Hybrid Electrical Vehicles- Case Studies · © 2011 ANSYS, Inc. September 14, 2011 17 A...
© 2011 ANSYS, Inc. September 14, 2011
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ANSYS for Hybrid Electrical Vehicles- Case Studies
Xiao Hu
Lead Technical Services Engineer
ANSYS Inc
© 2011 ANSYS, Inc. September 14, 2011
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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
© 2011 ANSYS, Inc. September 14, 2011
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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
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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
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• 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
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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
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Electrical Machine (Prius) – Electromagnetic and
Thermal Coupling
Electromagnetic in Maxwell Loss and Temperature in FLUENT
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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
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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
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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
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Busbars – Electrical, Thermal, Structural Coupling
Current Density in Maxwell Temperature in FLUENT
Deformation in Mechanical
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Simulating Thermal Management of Battery Modules for the Propulsion of Hybrid Vehicles - Magna
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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
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Battery Electro-Thermo Modeling - NREL
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HEV Battery Thermal Management - NREL
Input with Variations
• Gap Thickness
• Cell Resistance
• Flow Rate
Outputs with variations
• Max temperature
• Differential temperature
• Pressure drop
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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
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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)
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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)(
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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
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3D Electrochemistry Modeling
Li concentration in electrodes during discharge
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- 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:
* 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.
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Results of a Prismatic Lithium-Ion Cell
Geometry & Mesh
Temperature Current Density
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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 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 )
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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
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Simplorer FLUENT Co-Simulation
Simplorer Battery Circuit Model
FLUENT Battery CFD Model
Heat Dissipated
Temperature
Heat dissipation
Discharge curve
Temperature
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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
© 2011 ANSYS, Inc. September 14, 2011
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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.
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Thank you !!
© 2011 ANSYS, Inc. September 14, 2011
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Simplorer System Model
for Actuator Valve
Forces Orifice opening and fluid flow
Coil Current
Armature Position