Using the GT-SUITE-toolchain for an electrical machine model supporting a XIL-cooling-circuittestbench

Transcription

1 Using the GT-SUITE-toolchain for an electrical machine model supporting a XIL-cooling-circuittestbench Marcus Gsell, Marian Lutz, Michael Auerbach University of Applied Sciences Esslingen, Germany

2 Outline Introduction Project scope Using the GT-toolchain engine design CAD model GEM 3D GT ISE Simulation results Further steps 2

3 Introduction Basic idea: XIL-cooling-circuit-testbench Entire tubing, hoses, actors and sensors are physically built up Components such as electrical machine, inverter and battery are replaced by heating elements Electrical components are simulated and heat losses are imposed by heating elements to cooling-fluid 3

4 Introduction XIL-cooling-circuit-testbench three layer design Control P pump,i POS vent,i Testbench Cooling circuit dv i /dt p i T komp Wind-Tunnel Simulation dq i /dt v Fzg T umg 4

5 Project scope 1. Generating a thermal simulation model for an existing permanent magnet synchronous machine a. Measuring a running electrical machine b. creating a 3D-CAD-model c. transferring it to GEM 3D d. transferring it to GT-ISE 2. Evaluation/validation of the model 3. Optimization of flow geometries and cooling concepts Source: N. Karras, Optimierung der Wärmeabfuhr eines Fahrzeug-Elektromotors 5

6 Using the GT-toolchain Engine design Source: Bosch Nominal Power [W] Nominal Voltage [V] 48 Max. Rotation Speed [1/min] Max. torque [Nm] 60 Rotor diameter [mm] 85,3 Active lenght [mm] 80 Terminal pair 4 Coils 3 phases; open coils 6

7 Overview modeling process Engine design CAD-model SpaceClaim-model GT-ISE-model GEM-3D-model 7

8 Using the GT-toolchain Engine design Front view - stator Top view - rotor Front view - rotor 8

9 Using the GT-toolchain front view - stator CAD-3D-model Cut - stator+rotor Front view - rotor 9

10 Using the GT-toolchain SpaceClaim GEM-3D 10

11 Using the GT-toolchain GT-model overview Electro-magnetical model Thermal model Flow model 11

12 Using the GT-toolchain GT-model Electro-magnetic model 12

13 Using the GT-toolchain GT-model Thermal model thermal masses conduction con 13

14 Using the GT-toolchain GT-model Flow model 14

15 Using the GT-toolchain thermal model electro-magnetical model flow model 15

16 Simulation results 10Nm-Low-Torque-Performance Steady-state Coil temperature Fluid temperature Speed [rpm] Speed [rpm] T crit 420K T crit 398,15K 16

17 Simulation results 40Nm-High-Torque-Performance Steady-state Coil temperature Fluid temperature T 10Nm Torque 320K 17

18 Next steps Evaluation/validation of the model Optimization of flow geometries and cooling concepts Connecting model to XIL-cooling-circuit-testbench 18

19 Next steps Simulating entire drivetrain & vehicle Modelling Battery and Inverter Building up vehicle and drivetrain model with simple controllers Running transient drivecycles to get dynamic component operating points Interaction of all electrical components with XIL test bench E-Engine Battery Inverter Enables investigating derating of entire powertrain 19

20 Thank you for your attention! Marcus Gsell Marian Lutz Prof. Dr.-Ing. Michael Auerbach Phone: