System Modeling and Simulation

System Modeling and Simulation Trends and Enablers for Electrified Vehicle Systems Kazuhiro Kawamura ANSYS Japan 1 2014 ANSYS, Inc. October 7, 2014

Agenda 1. Today s Electrified Vehicle Systems Motivations & Requirements for System Simulation 2. System Modeling and Simulation in Practice Multi Domain Vehicle Simulation with ANSYS Simplorer 3. Directions in System Simulation Trends ANSYS / Modelon Partnership 2 2014 ANSYS, Inc. October 7, 2014

Today s Electrified Vehicle Systems To reduce environmental impact Motors & Electric Drives Idling stop Regenerative control Power saving technology Heat recovery To Improve comfort 3 2014 ANSYS, Inc. October 7, 2014 Introduction of New Technologies ITS : Intelligent Transport Systems ( http://www.its jp.org/english/ ) Driver Assist functions (brake etc.) Noise control technology To enhance safety Information technology utilization Inter vehicle distance sensing Interlocking functions with car navigation system System simulation is necessary and getting applied more broadly.

Utilizing CAE for Electric Motors Precise Verification of Performance Maxwell Fluent Iron loss distribution Steady state temperature distribution 20 110 Efficiency and torque maps (Over 180 operation conditions must be considered.) A large amount of computation is conducted in parallel by distributed processing. CAE is getting applied to precisely evaluate losses and coupling with thermal effects. 4 2014 ANSYS, Inc. October 7, 2014 Updating maps Thermal demagnetization of the permanent magnet (Magnetic flux density distribution)

Utilizing CAE for Distance Sensing HFSS Millimeter wave Radar Simulation 20mm(5.1λ) 75mm(19.1λ) Too many meshes Too large space to be analyzed CAE simulation is getting applied to objects with above difficulties furthermore. 75mm(19.1λ) Millimeter wave radar transceiver Simulated with 250GB memory Reflection analysis on millimeter wave radar, with Boundary Integral Equation Method 5 2014 ANSYS, Inc. October 7, 2014

CAE Utilization for Noise Control Vibration and noise analysis with Motor Maxwell Mechanical Electromagnetic force analysis Modal analysis Acoustic field analysis CAE simulation is applicable for harmonic distortion analysis on coils and capacitors. Coupling simulation is realized in conjunction with different CAE tools. 6 2014 ANSYS, Inc. October 7, 2014

Needs to simulate the Whole System for Optimization With the use of CAE technologies, concurrent design has already been ready for each component. Portfolio Planning Concept Development Design Production & Testing Maintenance & Support Retirement & Disposal Requirements Engineering Systems Modeling Systems Engineering System Integration & Test Validation & Verification Service and Asset Management Integrated Product Change Management SOFTWARE ELECTRONIC MECHANICAL For further accuracy improvement of conceptual design, concurrent framework including system requirements and component design. Model based concurrent development realizes reduced time to market. 7 2014 ANSYS, Inc. October 7, 2014

The Complexity of Systems Challenges Motivating System Simulation Systems are: Dynamic: they move, transmit, convey, transform, emit, measure,... Multi Domain: product behaviors span multiple engineering domains & physical phenomena that interact with one another Uncertain: they under/over perform, they interact with the environment, they drift, they fail... Multi Disciplinary: conception through production spans engineering and organizational disciplines and processes 8 2014 ANSYS, Inc. October 7, 2014

Ansoft LLC Simplorer1 600.00 Curve Info U2_heat_ex.tc100 TR U2_heat_ex.th100 TR 550.00 300.00 0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00 Time [s] 500.00 450.00 400.00 350.00 Integrating Multiple Domains: temp temp inlet_h high_t low_t inlet_c Simplorer is a powerful environment for modeling, simulating, and analyzing virtual system prototypes... outlet...enabling product development teams to verify and optimize performance of their outlet inlet software controlled, multi domain system DAMP_ROT6 U3_h_pump designs outlet_h before physical prototypes are DAMP_ROT4 DAMP_ROT5 SPRING_ROT1 SPRING_ROT2 SPRING_ROT3 Heat Exchanger outlet_c U2_heat_ex inlet U1_low_pump available. XY Plot 1 Y2 [kel] F_ROT3 T MASS_ROT1 Steam Turbine DAMP_ROT1 MASS_ROT2 Gear Compressor DAMP_ROT2 MASS_ROT3 Motor F_ROT1 DAMP_ROT3 T MASS_ROT4 Expander F_ROT2 Air Gap Torque of Motor DAMP_ROT7 T 電圧 (V) 800 700 600 500 400 300 200 100 0 IC-SIM VCE- 実測 VCE-SIM IC- 実測 0 0.5 1 1.5 2 時間 (us) 800 700 600 500 400 300 200 100 0 電流 (A) 9 2014 ANSYS, Inc. October 7, 2014

Physical Modeling Breadth & Depth Behaviors Signal Flow Conserved Analog/Mixed-Signal Discrete Event Languages SML VHDL-AMS C / C++ SPICE Modelica Interfaces Functional Mock-up Interface (FMI) Embedded SW FMUs ANSYS Co-Simulation EM CFD RBD 3 rd Party Simulink Models Libraries Model Characterization & Generation Multi-Domain Power Systems Analog Manufacturers Digital App-Specific Reduced Order Models Electromagnetic Mechanical Thermal Fluidic Power Electronic Devices & Modules 10 2014 ANSYS, Inc. October 7, 2014

Native Simplorer Model Libraries Multi Domain Components Semiconductors (advanced power electronics devices and characterization tools) Digital & Logic (state machines, blocks, etc.) Electrical Circuits Magnetics MMF JA Mechanics J M(t) STF GND F(t) Thermal m STF GND Hydraulics H L 11 2014 ANSYS, Inc. October 7, 2014

Native Simplorer Model Libraries Multi Domain Components Semiconductors (advanced power electronics devices and characterization tools) Digital & Logic (state machines, blocks, etc.) NIGBT_Average_T1 NIGBT_BasicDyn1 NIGBT_AdvDyn1 00.0 00.0 00.0 00.0 33.3 33.3 66.7 66.7 0 50.0-231.0 0 200.0 400.0 618.0 0 50.0-172.0 0 200.0 400.0 600.0 750.0 12 2014 ANSYS, Inc. October 7, 2014

Native Simplorer Model Libraries Multi Domain Components Semiconductors (advanced power electronics devices and characterization tools) Digital & Logic (state machines, blocks, etc.) Block Diagrams Digital Logic 13 2014 ANSYS, Inc. October 7, 2014

Reduced Order Models (ROMs) Direct Link from 2 D/3 D Physics to System Simulation Thermal Magnetic Electrical Mechanical 14 2014 ANSYS, Inc. October 7, 2014

Examples: ROMs for E/E Simulation Linking 2/3 D with the System Level Parasitic Extraction Electric Machine Design Wireless Power Transfer Excitations for EMC/EMI 15 2014 ANSYS, Inc. October 7, 2014

Platform for Testing the Virtual System Models Verify performance Tune responses Explore alternatives Identify optimums Assess fault effects Predict reliability... More performant More efficient More reliable Less expensive... Time Domain E1 R1 L1 0.00909 0.00909 0.000227 9.09 9.09 RC 25mH Steady State 10 0.00909 C1 0 1e-006farad Rload 0.00909 VM1 1000ohm + V TR_Probe1 TR Probe 0 Quickly Evaluate Basic Performance Frequency Domain Explore & Optimize System Performance 16 2014 ANSYS, Inc. October 7, 2014

In Practice: System Modeling and Simulation for Vehicles Control Algorithm Hydrodynamic/Rigid-body dynamics model Battery and Motor model I gass Fuel Consumption I self sdpd cap e 100 24hrs T T0 sd _ t V cell gass _ th' r _ curr exp 1 gass _ sl d 1d(, t ) v1 d() t i1 d( t) R1 p ( t) 1q(, t ) dt d 1q(, t ) v1 q() t i1 q( t) R1 p () t 1d(, t ) dt Heat recovery 17 2014 ANSYS, Inc. October 7, 2014 Power Management 4 2 RT H SO4 ln E d Response speed H O 2 2F H 2O SO 2 2 0 4 2 2 H 0 4 0 2

Simplorer Differentiation Unmatched versatility for System Simulation Standard modeling languages, mixed digital and analog solver technology, and standard co simulation interfaces for simulation of electrical, electronics and embedded software systems. Adheres to physical laws Behind every modeling component is a corresponding conservation law which ensures real world physics are being respected. 3D precision when you need it Co simulation with 3D solvers and reduced order modeling (ROM) captures complex multi physics interactions when precise system verification is required. Leader in electromechanical and power electronics Rich modeling libraries and design automation designed especially for high performance power electronics and electromechanical simulation. 18 2014 ANSYS, Inc. October 7, 2014

System Level Hybrid Electric Vehicle Model Full Description in VHDL AMS 19 2014 ANSYS, Inc. October 7, 2014

25.00 HEV Simulation: Fuel consumption (10 15 mode) XY Plot 4 v_soll: desired speed from driving cycle data. v_ist: simulated actual vehicle speed. v_ctrl: is the difference between v_soll and v_ist. Simplorer1 20.00 15.00 Y1 10.00 5.00 0.00-3.75 0.00 250.00 500.00 750.00 1000.00 1250.00 1500.00 1700.39 Time [s] TR driver1.v_ist Curve Inf o XY Stacked Plot 3 Simplorer1 30.00 20.00 10.00 0.00 TR SubSheet1.batcell_t_test1.soc_cell 0.71 0.71 0.70 20 2014 ANSYS, Inc. October 7, 2014 0.00 250.00 500.00 750.00 1000.00 1250.00 1500.00 1700.39 Time [s] 0.69

HEV Simulation: Battery Cell Thermal Behavior 296.64 XY Plot 12 Simplorer1 296.00 Y1 295.00 294.00 293.00 0.00 500.00 1000.00 1500.00 2000.00 2500.00 3000.00 3500.00 4000.00 Time [s] XY Plot 12 Simplorer1 296.00 Y1 295.95 295.90 0.02 XY Plot 13 295.85 1006.18 1010.00 1015.00 1020.00 1025.00 1030.00 Time [s] Simplorer1-0.10-0.23 Y1-0.35-0.48-0.60 0.00 500.00 1000.00 1500.00 2000.00 2500.00 3000.00 3500.00 4000.00 Time [s] 21 2014 ANSYS, Inc. October 7, 2014

Review: Simplorer Capability Multi Domain System Modeling & Verification Detailed Power Electronics Flexible Model Exchange Links with 3 D FMU Simulationbased Test TR Curve Info driver_hev1.v_ref XY Plot 1 Simplorer1 30.00 20.00 10.00 Embedded SW TR driver_hev1.v_veh 0.00 30.00 20.00 10.00 22 2014 ANSYS, Inc. October 7, 2014 0.00 250.00 500.00 750.00 1000.00 1250.00 1500.00 1750.00 Time [s] 0.00

Directions in System Simulation ANSYS / Modelon Partnership Focus on: Awareness & expertise Reuse & portability Exchange & distribution FMI Functional Mock-up Interface 23 2014 ANSYS, Inc. October 7, 2014

Modelica Significance Modelica is a standard language used to model behavior of complex, multi domain systems Modelica is an expanding collection of libraries used to model applications in automotive, aerospace, industrial equipment, energy, and more Modelica is a vibrant, global community of users and contributors in industry, research and academia 24 2014 ANSYS, Inc. October 7, 2014

Modelica advances our Vision Today, Simplorer provides: 1. Strongest focus and capabilities for electrical and electromechanical system analysis 2. Tight connections with best in class embedded SW design (SCADE) and detailed simulation (ANSYS 2/3 D) 3. Interoperability with the broadest set of languages, interfaces, and libraries With the addition of Modelica: 1. Allows us to extend competency to new domains (e.g. Fluid, Mechanical), and bring a tighter link with VHDL AMS 2. Gives us opportunity to bring the E/E perspective to the Modelica community 25 2014 ANSYS, Inc. October 7, 2014

Enabling System Virtual Prototyping ANSYS has signed an agreement with Modelon to license their Modelica compiler and to integrate it into Simplorer Key Modelon Technologies: Modelica compiler the Optimica Compiler Toolkit Model Libraries Spanning many domains and industrial applications www.modelon.com 26 2014 ANSYS, Inc. October 7, 2014

System Modeling Directions Focus on: Awareness & expertise Reuse & portability Exchange & distribution FMI Functional Mock-up Interface 27 2014 ANSYS, Inc. October 7, 2014

The Functional Mock up Interface The FMI is a tool independent standard for exchanging and simulating complex multi domain system models Initiated by Daimler AG in 2008 and developed by the European ITEA 2 MODELISAR consortium A primary goal is to support the exchange of simulation models between suppliers and manufacturers Key contributions: FMI Specification, compliance checking tools 28 2014 ANSYS, Inc. October 7, 2014

FMI Support in Simplorer Full support for FMI Model Exchange Import Standard connection with SCADE Provides interoperability with several Modelica vendors Driving FMI interoperability with VHDL AMS components AMESim Vendor Support FMI 1.0 Model Exchange Export 29 2014 ANSYS, Inc. October 7, 2014

Ansoft LLC XY Plot 1 Simplorer1 600.00 Curve Info U2_heat_ex.tc100 TR U2_heat_ex.th100 TR 550.00 300.00 0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00 Tim e [s] 500.00 450.00 400.00 350.00 Modelica Support in Simplorer via FMI Available Today in Version 2014 and later ANSYS Simplorer Functional Mock up FMU Unit (Compiled C code) 800 800 700 VCE- 実測 700 600 600 VCE-SIM 500 500 400 400 300 300 200 IC-SIM IC- 実測 200 100 100 0 0 0 0.5 1 1.5 2 Modelica Model Creation: 3時間 rd (us) Party Tool 電圧 (V) 電流 (A) outlet inlet DAMP_ROT6 U3_h_pump DAMP_ROT4 temp temp inlet_h high_t low_t Heat Exchanger outlet_h outlet_c DAMP_ROT1 DAMP_ROT2 DAMP_ROT5 SPRING_ROT1 SPRING_ROT2 SPRING_ROT3 FMI 1.0 for Model Exchange Export DAMP_ROT3 DAMP_ROT7 inlet_c outlet U2_heat_ex inlet Y2 [kel] F_ROT3 T MASS_ROT1 Steam Turbine MASS_ROT2 Gear Compressor MASS_ROT3 Motor F_ROT1 T MASS_ROT4 Expander F_ROT2 T U1_low_pump Air Gap Torque of Motor 30 2014 ANSYS, Inc. October 7, 2014

Ansoft LLC XY Plot 1 Simplorer1 600.00 Curve Info U2_heat_ex.tc100 TR U2_heat_ex.th100 TR 550.00 300.00 0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00 Tim e [s] 500.00 450.00 400.00 350.00 Native Modelica Modeling in Simplorer Release R17 and Beyond ANSYS Simplorer Modelica 電圧 (V) 800 800 700 VCE- 実測 700 600 600 VCE-SIM 500 500 400 400 300 300 200 IC-SIM IC- 実測 200 100 100 0 0 0 0.5 1 1.5 2 時間 (us) 電流 (A) outlet inlet DAMP_ROT6 U3_h_pump DAMP_ROT4 temp inlet_h outlet_h DAMP_ROT5 temp high_t low_t Heat Exchanger outlet_c SPRING_ROT1 DAMP_ROT1 SPRING_ROT2 DAMP_ROT2 SPRING_ROT3 DAMP_ROT3 DAMP_ROT7 inlet_c U2_heat_ex outlet inlet U1_low_pump Y2 [kel] F_ROT3 T MASS_ROT1 Steam Turbine MASS_ROT2 Gear Compressor MASS_ROT3 Motor MASS_ROT4 Expander F_ROT1 T F_ROT2 T Air Gap Torque Built in of Motor Modelica Modeling Capabilities 31 2014 ANSYS, Inc. October 7, 2014

Summary: To the multi language platform Behavioral/Descriptive Modeling Available Standard Models MODELICA VHDL AMS FMI dll Co-Sim Modelica SCADE MATLAB/ Simulink 3D Physics Modeling Electromagnetics Mechanical Thermal CFD Simplorer s evolution is realizing the multi language modeling and simulation environment for wide spreading various fields and applications. 32 2014 ANSYS, Inc. October 7, 2014 Reducer order modeling (ROM) ANSYS Workbench

33 2014 ANSYS, Inc. October 7, 2014 Thank You