EV/HEV Value Chain and Battery Designregister.ansys.com.cn/ansyschina/minisite/201411_em... ·...

© 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 Design

Sandeep Sovani

Zed Tang

Mark Christini

January 26, 2011 ANSYS Sales Conference

© 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


The automotive powertrain has changed for good

A once-in-a-lifetime landslide change

Market Trends

I.C. Engine

PowertrainAugmented

with

Electric

Powertrain

Hybrid Powertrain

I.C. Engine

Powertrain

OLDNEW

Electric

Powertrain

FUTURE


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


Market Trends

Micro

Hybrid

HEV PHEV ER-EV BEV 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


Market Trends



Market Trends

Power

Source

Power

Electronics

Electric

Machine

Mechanical

Components

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 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}}

.





http://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpg


Market Trends



Market Trends

Ref: Bly, M. – General Motors, “Developing a Battery Value Chain,” EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA


Outline

• EV/HEV Market

– Trends

– Value Chain



– Battery

– Traction Motor


• Success Stories

• 2011 Marketing Campaigns


• ANSYS Solutions


• R13 Advances



EV/HEV Value Chain

Sample Business Initiatives

Y2020 Estimates



Battery Value Chain



EV/HEV Value Chain



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


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


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


Outline

• EV/HEV Market

– Trends

– Value Chain



– Battery

– Traction Motor


• Success Stories



• ANSYS Solutions


• R13 Advances



Numerical Simulation will be a key differentiator

in the electrification competition

Numerical Simulation is particularly advantageous in

electrification development

Firms that strategically deploy numerical simulation will

gain significant competitive advantage

EV/HEV Simulation

Message to Executive Decision Makers –


Why is Numerical Simulation

particularly advantageous in

electrification development?

EV/HEV Simulation


Challenges in

developing disruptive

innovations

No precedence

Many unknowns

New paradigms

Uncertainty

Time pressure

Last powertrain took

~100 years to develop

New powertrain

expected in ~10 years

EV/HEV Simulation


Many Choices

Many Decisions

Cylindrical, Prismatic?

Air Cooling, Liquid Cooling?

Cell Chemistry?

…

…

Established Demands

Safety

Reliability

Cost

Life

Same as or surpassing

current vehicle standards

Multitude of ideas need to be generated, digested,

validated, developed, tested, perfected, delivered, in

a short time

EV/HEV Simulation


Multitude of ideas need to be generated, digested,

validated, developed, tested, perfected, delivered, in a

short time

Numerical Simulation is particularly well

suited for this need; provides –• In-depth engineering insights

• Speedy design evaluation via virtual testing

• Enabler of fast, extensive design

EV/HEV Simulation


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 Automated

Design Exploration

EV/HEV Simulation

ANSYS Positioning Message

Competitors’ Propositions ANSYS Differentiators


Outline

• EV/HEV Market

– Trends

– Value Chain



– Battery

– Traction Motor


• Success Stories



• ANSYS Solutions


• R13 Advances




Power

Source

Power

Electronics

Electric

Machine

Mechanical

Components

Control

What is Integrated Simulation?

Battery/BMS Inverter/Busbar Traction Motor Drive Shaft


Oakridge National Laboratory, ORNL/TM-2004/247, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System Interim Report


http://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpg Author {{:de:wiki:user DrJunge|DrJunge}}

.





http://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpg



Integrated Simulation:

Combining high-fidelity component simulation with

subsystem and system level 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



ANSYS Differentiator: No competitor can perform

integrated simulation with the same multiphysics

breadth and depth as ANSYS


Outline

• EV/HEV Market

– Trends

– Value Chain



– Battery

– Traction Motor


• Success Stories



• ANSYS Solutions


• R13 Advances



Battery: Key Problems

Cell

Manufacturing

Material

Behavior in Cell

Assembly

Ageing, Life

Thermal Management

(Temperature Uniformity)

Safety, Crash, Abuse

NVH, Durability

Battery Management

System and Algorithms

Battery

Performance in

Vehicle Level Test

Cycles

Load Matching for

Charging

Discharging

Overall Concerns:

• Cost

• Life

• Safety

• Power Density


Battery : ANSYS Solutions

• Pack Level Simulation

• Cell Level Simulation

• System Level Simulation


Battery : ANSYS Solutions –

Pack Level

ANSYS Workbench – An Integrated Solution for Battery CFD

Analysis


Build-in What-if Study in WB


Pack Level


HEV Battery Thermal Management: Six Sigma Analysis


Pack Level

Ref: Valhinos et al, “Improving Battery Thermal Management Using Design for Six Sigma

Process”, 20th Electric Vehicle Symposium, Long Beach, CA (November 15-18, 2003)


Reduced Order Modeling


Pack Level


Reduced Order Model Extraction Process Using Simplorer


Pack Level


LTI (Foster Network) vs ANSYS FLUENT


Pack Level


Additional

Information on LTI

Separate training

material exists for

LTI method.


Pack Level


Battery Bus Bar Heating Multiphysics Simulation

• For steady (or low frequency) currents under

temperature dependent conductivity


Pack Level


Coupled Simulation in ANSYS FLUENT


Pack Level


• 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 create

these demonstration cases


Pack Level


Battery : ANSYS Solutions





Cell Manufacturing: Coating Analysis

Courtesy: ANSYS Japan Technical Team


Cell Level


Cell Manufacturing: Flow Inside Die

Courtesy: ANSYS Japan Technical Team


Cell Level


Cell Electrical Model:

• Simple enough for system

level analysis– Detailed electrochemistry models

are too time consuming for system

level 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


Cell Level


Single Cell Thermal Model

- Newman &

Tidemann (1993);

- Gu (1983) ;

- Kim et al (2008)*

Model based on:


Cell Level


Electrochemistry: Newman’s 1D Model in Simplorer


Cell Level


3D Electrochemistry Modeling


Cell Level


Battery: ANSYS Solutions –

System Level

• 60 Cells connected in matrix pack

• Packs are connected in matrix to

final configuration

5

cells

Pack Circuit Model


Battery in Control System with Motor Controller

Battery: ANSYS Solutions –

System Level


Battery: Competition Analysis

• CD-Adapco

Pack Level –

CD-Adapco ANSYS

Basic CFD needed for

Battery Simulation

Comparable to ANSYS Comparable

Design Exploration Rudimentary

parameterization

SpaceClaim and

DesignXplorer give

advantage

LTI Method No comparable solution Easy Simplorer based

solution

Please do no display this slide outside of the ANSYS and ANSYS Channel Partner Organizations



• CD-AdapcoCell Level –

CD-Adapco ANSYS

Cell Electrical Model Partnership with Battery

Design LLC. Provides

advantage in standard

cell characteristics and

cell material properties

Simplorer based model.

Needs cell properties as

input.

Cell Thermal Model Demonstrated examples Comparable capability

1D Electrochemistry No demonstrated

solution

Simplorer based solution

3D Electrochemistry Some demonstrated

examples

Some demonstrated

examples




• CD-Adapco

Multiphysics and System Level –

CD-Adapco ANSYS

Multiphysics (E.g. bus

bar deformation)

No comparable solution ANSYS core advantage

Durability, Impact, Abuse No direct solution ANSYS mechanical

NVH Some acoustics models,

no structural solution

Broadband acoustics

models in CFD,

Structural NVH

System Integration No direct solution Simplorer based solution




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-references








Battery: 2011 Targets

• OEMs

– All major car, truck OEMs have ambitious

electrification plans: All are targets

• Battery Suppliers

– Over 150 battery companies

in 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


Outline

• EV/HEV Market

– Trends

– Value Chain



– Battery

– Traction Motor


• Success Stories



• ANSYS Solutions


• R13 Advances



Traction Motor – Key Problems

and 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 effects

through 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




• More Innovative and Complex Designs

19 machine types to choose from

Different machine geometry templates




• 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 up

to be an optimized system; integrated

motor / electronics / control simulation is

needed




• Multiphysics Coupling

Deformation of the stator Deformation of coils

The electromagnetic force density

from Maxwell is used as load in

Structural

Thermal-Stress with Electromagnetic Force load




• 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

Analysis and Differentiators

ANSYS offers Functionality Competition

Maxwell Electromagnetic Finite

Element Solvers

JMag, FLUX, MagNet,

…

Simplorer Circuit/System

Simulator

Saber, PSpice,

Matlab/SIMULINK, …

ANSYS

Mechanical/CFD

Stress, Thermal Abaqus, STAR-CD, …

Q3D Parasitics Extraction

DX, MPO, DSO Design Automation &

Optimization

RMxprt

Closed-form analytical

solution, quickly reduce

design space

SPEED, MotorSolve …

ANSYS Simulation Driven Product Development

Electric Machine Design Methodology


Traction Motor – Competition

Analysis and Differentiators

ANSYS offers Functionality Competition

Maxwell Electromagnetic Finite

Element Solvers

JMag, FLUX, MagNet,

…

Simplorer Circuit/System

Simulator

Saber, PSpice,

Matlab/SIMULINK, …

Mechanical/CFD Stress, Thermal Abacus, STAR-CD, …

Q3D Parasitics Extraction

DX, MPO, DSO Design Automation &

Optimization

RMxprt

Closed-form analytical

solution, quickly reduce

design space

SPEED, MotorSolve …

ANSYS Simulation Driven Product Development

Electric Machine Design Methodology

ANSYS

Electric

Machine

Design

Methodology

Fully

Integrated

Electric

Mechine

System

Design

NONE!


Traction Motor – ANSYS 13.0

Advances

• Ansoft Tools inside ANSYS Workbench

• Easier and more efficient coupling

• Using DM for geometry

• Using DX for optimization/statistical study

• Maxwell TAU Meshing

• More robust and efficient

• Can use MP license

• More Robust DSO

• Easier to set up

• Speed, scalability getting even better


Traction Motor – 2011 ANSYS

Targets

• General Trends

• It takes years for major auto OEMs to realize

that they have to control their own destiny in

terms of designing traction motors by

themselves. For example, GM. Ford is

starting to realize that.

• It also takes years for motor suppliers to

realize that they need to re-design a motor for

auto traction application.



Targets

• 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 to

more

• Magnetics design -> Structural/Thermal -> Electronics

• Use success story in traction motor and apply to

other applications

• Battery, electronics, system integration, EMI/EMC



Targets

• Expand Success to Major Suppliers and

Commercial Vehicles/Off-highway Vehicles

• Suppliers Want to do More too

• Commercial Vehicle companies have huge interest

in HEV/EV too

• Eaton Trucks, Prestolite, ArvinMeritor, etc.

• Off-highway industry also starts looking into

HEV/EV

• CAT, John Deere, Cummins, etc.



Targets

• Expand Success to other Motor Areas

• Power Steering, Electric Pumps, Wind

Shields, etc.

• These applications have the same physics

(motor, controller, power source/electronics,

mechanical components)

• HEV/EVs need new designs for these

applications because requirements are very

different from traditional vehicles


Outline

• EV/HEV Market

– Trends

– Value Chain



– Battery

– Traction Motor


• Success Stories



• ANSYS Solutions


• ANSYS 13.0 Advances



HEV Power Electronics – Key

Problems and Simulation Needs

Charging SystemsHigh Power Distribution SystemsEnergy

ManagementSystems

Typical HEV System

(internal use only)


System

Control

Thermal

Digital

…

HEV Power Electronics – Key

Problems and Simulation Needs


Simplorer

Simulink

MathcadCo Simulation

ModelSIM

HEV Power Electronics

ANSYS Solutions

ANSYS is the only provider

of a complete power

electronics design solution

for Hybrid Electric Vehicles!



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

–


ThermalElectromagnetic MechanicalFluidicComponent

CircuitSubsystem

System

ANSYS

Mechanical,

CFD, Icepak

Q3D,

Xprt Tools

Simplorer

Maxwell, HFSS

FEA solvers


ANSYS System Solutions


SimplorerSystem Design

PP := 6

ICA:

A

A

A

GAIN

A

A

A

GAIN

A

JPMSYNCIA

IB

IC

Torque JPMSYNCIA

IB

IC

Torque

D2D

MaxwellElectromagnetic Components

PExprtMagnetics

RMxprtMotor Design

Q3DParasitics

ANSYS

MechanicalThermal/Stress

ANSYS CFDThermal

Model order Reduction

Co-simulation

Field Solution

Model Generation

Icepak


ANSYS Coupled Solutions



Competitive Differentiators

ANSYS offers Functionality Differentiators

Simplorer Circuit/System Simulator Multi-domain, multi-physics

Maxwell Electromagnetic Finite Element

Solvers 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 FEA

RMxprt Closed-form analytical solution

for Motors and Generators

Couples to Simplorer and

Maxwell for complete FEA

Q3D R,L,C,G parasitic extraction for

wiring harnesses and

interconnects

Frequency dependent model

coupled to Simplorer

ANSYS

Mechanical

Basic Stress and Thermal

Analysis

Couples directly to Maxwell via

Workbench

ANSYS CFD Thermal analysis using fluid flow Couples directly to Maxwell

ANSYS Icepak Electronics Cooling Couples directly to Simplorer



Simplorer v8.1 and v9 Advances

• Integrated with the ANSYS

Workbench interface. Can be

created and launched from WB

• Improved co-simulation capabilities

with Maxwell 3D

• Enhanced IGBT Parameterization

Wizard with more accurate fitting

algorithm – important for EMC/EMI

analysis

• 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



2011 ANSYS Target #1

• Expand Success to other Major Suppliers

of HEV components and systems such as

XYZ Corp.

− XYZ Corporation in Detroit is a Tier 1,2 supplier (traditionally

seating) for major automotive OEMs

−Previously owned ANSYS Mechanical and ANSYS Icepak

−Made a strategic decision several years ago to move into the

automotive power electronics market

−Currently developing a high voltage power supply for a HEV

battery 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


IGBT Module Pack 3D

accurate model

Parameters

Extraction

Electromagnetic

(EM) study

Design and Couplings

ModelIGBT Model

• Tridimensional IGBT pack model and EM study

• Parasitic model extraction

• IGBT circuit model

Far Field Study

• Far Field Study for Electric Field EM



• Expand Success to Major Automotive OEM’s for radiated

EMC/EMI analysis of power supplies


• Tridimensional IGBT pack model and EM study

• Parasitic model extraction

• IGBT circuit model

• Far Field Study for Electric Field EM

Finite Element Method

Finite Element

Method

FEA / Boundary

Element Method System Simulation

Analysis Methodology Using

Different Techniques


SheetScan

IGBT Characterization


E-field @ 100 MHz, Power = 10kW

Simplorer to HFSS Radiated Field




• Expand Success to Major Automotive OEM’s for

conducted EMC/EMI analysis of power supplies

Characterize and reduce EMI emissions from Switched

Mode Power Supply (SMPS) by:

- Model SMPS

- Determine critical components in system

- Determine noise attenuating techniques

Detailed Procedure:

− Model: Actives and Passives (discrete components

and interconnects)

− Use simulations to find critical paths

− Focus attention on these paths to mitigate noise


Modeling Process

Proprietary

Material has

been removed


System Simulation

Proprietary

Material has

been removed


Reduction of Conducted EMI

Proprietary

Material has

been removed


Outline

• EV/HEV Market

– Trends

– Value Chain



– Battery

– Traction Motor


• Success Stories



• ANSYS Solutions


• R13 Advances



• 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 1Company #1

Car Manufacturer


• What did they prefer ANSYS?

– Motors: very fast analysis of 1000s of designs

using DSO

– Battery: WB workflow integrating multiple

physics

• Future growth potential

– Structural mechanics & explicit

– Simplorer

– EKM?


Car Manufacturer


• Who are they?

– A prominent

U.S. battery company


– CFD (Fluent)

• What are they using

it for?

– Battery Simulation


Battery Manufacturer



– 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


Battery Manufacturer



– Maxwell 2D/3D + RMxprt + Optimetrics +

ANSYS FLUENT + DesignXplorer


– Departments: (a) R&D (b) Production)

– Applications

• Verify performance map of supplier produced motor

• Simplorer co-simulation for circuit and system level

• Battery cooling


Car Manufacturer



– 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


Car Manufacturer



– Q3D + ANSYS FLUENT + ANSYS Mechanical


– Micro-hybrid systems (start-stop alternator,

electronics) – Mechatronics simulation

• Thermal – FLUENT

• Structural Acoustics – ANSYS Mechanical

• Electromagnetics – Maxwell

• Co-Simulation – Simplorer


Multinational Parts Supplier



– 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


Multinational Parts Supplier


Success Story 5

HEV related sale

Maxwell - Motor Design

CFD - Battery Design

See details in Day 4

presentation by Greg Fallon

and Tom Smithyman

Company #5

Car Manufacturer


Outline

• EV/HEV Market

– Trends

– Value Chain



– Battery

– Traction Motor


• Success Stories



• ANSYS Solutions


• R13 Advances



Marketing Campaigns

Proprietary

Material has

been removed


Thank you!

EV/HEV Value Chain and Battery Designregister.ansys.com.cn/ansyschina/minisite/201411_em... ·...

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