ANSYS for Hybrid Electrical Vehicles- Case Studies Xiao Hu Lead Technical Services Engineer ANSYS Inc

Transcription

1 ANSYS for Hybrid Electrical Vehicles- Case Studies Xiao Hu Lead Technical Services Engineer ANSYS Inc 1 ANSYS, Inc. September 14,

2 Introdcution Battery Inverter Electric Machine Mechanic Load Controls 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 2 ANSYS, Inc. September 14,

3 Rotor Loss in 3PH Induction Motor Siemens Simulated vs Measured Results 36 slot with cage 36 slot without cage 60 slot with cage Motor with its cage removed Maxwell Results with cage 3 ANSYS, Inc. September 14,

4 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 Induced currents and eddy losses due to rotation 4 ANSYS, Inc. September 14,

5 Reduction in Magnet Loss for PMSM Motor Siemens For magnets, add cuts using insulation boundaries Same mesh re-used between cases Reduces Eddy Currents and Loss 1 Normalized Power Loss Number of Cuts ANSYS, Inc. September 14,

6 losses Voltage (l-n) Integrated Starter Alternators Ford 20.0 OCV test data vs. Maxwell transient analysis Skewed rotor Measured emf Calculated emf (maxwell) generator mode Time (s) calculated measured adjusted ANSYS, Inc. September 14, current

7 Electrical Machine (Prius) Electromagnetic and Thermal Coupling 7 ANSYS, Inc. September 14, Electromagnetic in Maxwell Loss and Temperature in FLUENT

8 High Power Inverter Systems IGBT Module Package Parameter Extraction Design and Coupling Electrical Model Far Field Study 3d IGBT pack model and EM study Parasitic model extraction Electromagnetic Study IGBT circuit model Far Field Study for Electric Field EM 8 ANSYS, Inc. September 14,

9 High Power Inverter Systems Current Distribution IGBTs on, Diodes off The structure is meshed using automatic and adaptive meshing Power Module from Q3D for board parasitics 9 ANSYS, Inc. September 14,

10 Thermal Model Extraction for IGBTs Data processing Simplorer Icepak Transfer T(time) into Zth(time) Specify the geometry of the multi-heatsource system Apply each heat source individually measure temperature at nodes of interest (parametric analysis) Filter Extract parameters through curve fitting Generate model Normalize 10 ANSYS, Inc. September 14,

11 Busbars Electrical, Thermal, Structural Coupling Deformation in Mechanical 11 ANSYS, Inc. September 14, Current Density in Maxwell Temperature in FLUENT

12 Simulating Thermal Management of Battery Modules for the Propulsion of Hybrid Vehicles - Magna 12 ANSYS, Inc. September 14,

13 Full Hybrid Electrical Vehicle Battery Pack System Design, CFD Simulation and Testing - Ford & Delphi the front view of the pack with the two bricks assembled and inlet busbar velocity contour of airflow through the brick, inlet and outlet plenum 13 airflow path into the battery pack ANSYS, Inc. September 14, airflow path and air outlet

14 Battery Electro-Thermo Modeling - NREL 14 ANSYS, Inc. September 14,

15 HEV Battery Thermal Management - NREL Input with Variations Gap Thickness Cell Resistance Flow Rate Outputs with variations Max temperature Differential temperature Pressure drop 15 ANSYS, Inc. September 14,

16 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, X. Hu, S. Lin, S. Stanton, W. Lian, A State Space Thermal Model for HEV/EV Battery Modeling", SAE ANSYS, Inc. September 14,

17 Y1 [kel] A Battery Module Coupled Analysis Voc=f(SOC, U1.Temp_block_1) Rseries RT_S RT_L H00 SIMPARAM1 Ccapacity IBatt VOC CT_S CT_L CONST C1 0 I7 E1 R1 R2 C2 R3 C3 H01 CONST Qcell1 Qcell2 Qcell3 Temp_block_1 Temp_block_2 Temp_block_3 Qcell4 Temp_block_4 C4 0 I8 E2 R5 R6 C5 R7 C6 RLoad H02 CONST Qcell5 Qcell6 Tambien Temp_block_5 Temp_block_6 0 R9 R10 R11 H C7 I9 E3 C8 C9 CONST R13 R14 R15 H C10 I10 E4 C11 C12 CONST TR Curve Info U1.Temp_block_1 C13 0 I11 E5 R17 R18 C14 R19 C15 H05 CONST Time [s] TR TR U1.Temp_block_3 U1.Temp_block_ ANSYS, Inc. September 14,

18 Newman Pseudo 2d Electrochemistry Model in Simplorer Li + Li + Jump Lithium Ion Batteries Li + Li x C 6 e ( ece ) t 1 e e t F Li D c j Li + e Lix -Metal-oxide Electrochemical Kinetics Solid-State Li Transport Electrolytic Li Transport Charge Conservation/Transport (Thermal) Energy Conservation 18 Results from Simplorer ANSYS, Inc. September 14, Results from Newman

19 Newman Model Quantitative Comparison x=l p +L s +L n x=l p +L s x=l p x=0 1/10 C 1/2 C 1 C 2 C 4 C 6 C 8 C 10 C 19 ANSYS, Inc. September 14, Simplorer s Results White s Results Reference: Long Cai, Ralph E. White, Journal of Electrochem. Soc., 156 (3), A154-A161 (2009)

20 3D Electrochemistry Modeling Li concentration in electrodes during discharge 20 ANSYS, Inc. September 14,

21 Single Battery Cell Thermal Model The model is based on the work of: - Newman & Tidemann (1993); - Gu (1983) ; - Kim et al (2008)* J Current i p = Current Vectors at Cathode plate Current J = Current Density J (t, x, y, T ) i n = Current Vectors at Anode plate J Y( U) f ( T) p n Transfer current U and Y are derived from experimentally obtained polarization curve, dependent on Depth of Discharge (DOD) & Temperature Cathode Anode * Reference: U. S. Kim, C. B. Shin, C. S. Kim, Effect of electrode configuration on the thermal 21 behavior of a lithium-polymer battery, Journal of Power Sources 180 (2008) ANSYS, Inc. September 14,

22 Results of a Prismatic Lithium-Ion Cell Geometry & Mesh 22 Temperature ANSYS, Inc. September 14, Current Density

23 From Electrochemistry to Single Cell Thermal Model Li + e Li x C 6 Li + Li+ Jump ( ece ) t 1 e e t F Li D c j Li + e Lix -Metal-oxide 1/10 C 1/2 C 1 C 2 C 4 C 6 C 8 C 10 C Current Current i p = Current Vectors at Cathode plate i n = Current Vectors at Anode plate J = Current Density J (t, x, y, T ) 23 ANSYS, Inc. September 14, Cathode Anode

24 Simplorer FLUENT Co-Simulation Heat Dissipated Cell 4 Cell 5 Cell 6 Cell 3 Cell 2 Cell 1 Temperature Simplorer Battery Circuit Model FLUENT Battery CFD Model 24 ANSYS, Inc. September 14,

25 Simplorer FLUENT Co-Simulation Heat Dissipated Heat dissipation Temperature Discharge curve Simplorer Battery Circuit Model Temperature FLUENT Battery CFD Model 25 ANSYS, Inc. September 14,

26 P1 P2 P3 P4 P5 P6 P7 P8 P 12 P 11 P 10 P9 MASS_ROT1.OMEGA [rpm] Y1 [V] P _RE F System Simulation Example Model Extraction from FEM / CFD Ambient Q Thermal Domain E1 z_up z_vp z_wp Electrical Domain Electrical Domain I_mot Simplorer4 Induction_Motor_20kW Mechanical Domain Domain z_um z_vm z_wm VM311 R6 R5 R4 + IN_A IN_B IN_C A A A OUT_A OUT_B OUT_C R1 R2 R3 A B C N ROT1 ROT2 0 MASS_ROT V VHDL-AMS Macro-Model SINE1 SINE2 DR1 RZM RZM VHDL-AMS Macro-Model DR IGBT Device Characterization ANSYS, Inc. September 14,

27 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. 27 ANSYS, Inc. September 14,

28 Thank you!! 28 ANSYS, Inc. September 14,

29 Simplorer System Model for Actuator Valve Coil Current Armature Position Forces Orifice opening and fluid flow 29 ANSYS, Inc. September 14,