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© 2011 ANSYS, Inc. April 27, 2015 1
ANSYS solutions to the challenges of developing energy efficient vehicles提高汽车能耗效率的ANSYS解决方案
Vincent Delafosse Senior Product Manager ANSYS Inc., San Jose, CA
© 2011 ANSYS, Inc. April 27, 2015 2
Fuel Economy and Emissions Regulations: CAFÉ, Euro6
Demand for Enhanced Passenger Experience
Mobility Revolution: Autonomous Vehicles
What is happening in the automotive industry? 汽车工业的现状和趋势?
I.C. Engines
Full Electric Vehicles Hybrid
Vehicles
Displays
Connectivity
Conveniences
Radars, Sensors
Connectivity
Complex Controls
© 2011 ANSYS, Inc. April 27, 2015 3
In Response To The New Challenges, Automotive Companies Are Focusing On These Initiatives面对新挑战,汽车厂家正致力于研究对策
Streamline Globally Distributed Product Development
to improve product development efficiency
Improve Fuel Economy and Emissions
to comply with governmental regulations & market
demands
Manage Complexity of Electronics & Embedded Software
across multiple engineering disciplines
Implement an Early Reliability Prediction and Quality System
to deliver high quality, safe and reliable product
Develop Hybrid and Electric Vehicles
to further improve fuel economy and emissions
Innovate Manufacturing Methods
to improve cost efficiency
Develop ADAS and Autonomous Vehicles
to improve vehicle safety, accessibility, productivity, and
fleet efficiency
IC Engines
Complex Preprocessing
(Aero, Underhood)
HEV Components and System
Radar
Multi/Multiple Physics
Auto Electronics
© 2011 ANSYS, Inc. April 27, 2015 4
Recent ANSYS Headlines In The Automotive Industry ANSYS在汽车行业的最新头条资讯
ANSYS Powers Four Out Of The Top Six F1 Racing Teams In 2012 Including Three-time Champion, Red Bull Racing PITTSBURGH, Dec. 6, 2012 /PRNewswire/ As the checkered flag is waved over Formula 1's 2012 racing season, ANSYS (NASDAQ: ANSS) is celebrating alongside the pit . . .
DENSO Selects ANSYS FEM Software to Accelerate Product Development and Drive Down Costs PITTSBURGH, /PRNewswire/ -- ANSYS (NASDAQ: ANSS) announced that DENSO, a worldwide automotive supplier, has selected ANSYS® FEM software to standardize and expedite product development globally, enabling the . . .
ANSYS Simulation Drives MANN+HUMMEL's Automotive Designs
PITTSBURGH--(BUSINESS WIRE)-- ANSYS (NASDAQ: ANSS) is helping MANN HUMMEL to access and reuse historical engineering simulation information for speeding the creation of innovative automotive designs. The . . .
Volkswagen Signs Master Agreement With ANSYS
German Car Manufacturer to Rely on Multiphysics Engineering Simulation Solutions from ANSYS SOUTHPOINTE, Pa., (BUSINESS WIRE) -- ANSYS, Inc. (NASDAQ: ANSS), a global innovator of simulation software and technologies designed to optimize product development processes . . .
ANSYS Making Electric Vehicle Batteries More Practical And Efficient Engineering Simulation Leader Working with General Motors, NREL and ESim to Improve Battery Design PITTSBURGH, June 20, 2012 /PRNewswire/ -- One year into a U.S. Department of Energy (DOE) funded project . . .
© 2011 ANSYS, Inc. April 27, 2015 5
Tesla Toyota Volkswagen Ford Hyundai General Motors PSA BMW Honda Renault Tata Motors SAIC Volvo Chrysler Merdeces Audi
Bosch Delphi Yazaki Magna Valeo Continental Denso Brose Visteon BorgWarner Eaton TRW Dana
Caterpillar Navistar John Deere Scania Cummins AGCO Bobcat CNH Eicher Tractors Kubota Corp. Mahindra & Mahindra Volvo Truck
Red Bull Ferrari Toyota Racing McLaren Racing Force India Hendrick Motorsports Sauber Motorsports Harley Davidson Bajaj Auto Pratt & Miller
Alstom Transport Bombardier Transportation Deutsche Bahn Electromotive Diesel Railway Technical Research Institute Japan Zhuzhou Electric Locomotive
Top Automotive & Transportation Companies Rely on ANSYS Physics Simulation Tools/ANSYS仿真工具的交通行业顶级用户
© 2011 ANSYS, Inc. April 27, 2015 7
Key Vehicle Systems Are Undergoing Drastic Changes To Improve Fuel Economy And Emissions 汽车核心系统正在发生巨变,以提高燃油经济性,减少排放
Fuel Economy and Emissions
Regulations: CAFÉ, Euro6 Hybrid and Electric
Vehicles: Develop complex new
components
Aerodynamics: Styling vs Drag Lightweight Composites:
New structural aspects
• Improve Fuel Economy and Emissions
• Develop Hybrid and Electric Vehicles
Key Business Initiatives
© 2011 ANSYS, Inc. April 27, 2015 8
Fluid-Thermal Systems Design – I.C. Engines 流体-热系统设计——内燃机
Customer Keynote: Dr. Wayne Eckerle VP, Research and
Technology Cummins
© 2011 ANSYS, Inc. April 27, 2015 9
Fluid-Thermal Systems Design – I.C. Engines 流体-热系统设计——内燃机
Customer Keynote: Dr. Wayne Eckerle VP, Research and
Technology Cummins
© 2011 ANSYS, Inc. April 27, 2015 10
Fluid-Thermal Systems Design – I.C. Engines 流体-热系统设计——内燃机
10
Comprehensive Solution for: • Combustion • Cooling • Strength Analysis • Durability
© 2011 ANSYS, Inc. April 27, 2015 12
Solutions tailored for Innovative Systems – Our Focus 量身定制的创新系统解决方案
Hybrid & Electric Vehicles • Simulation Solutions for HEV: Simplorer
E/E Systems Simulation platform • Embedded Software Development:
SCADE Suite & LifeCycle for automatic code generation of Embedded Controls (AUTOSAR OS compliant)
High Safety Systems requiring ISO 26262 Certification (ADAS, Safety Critical Applications) • SCADE Suite and SCADE Lifecycle for automatic code generation of Embedded Controls (ISO 26262
Certified)
New Generation Automotive Dashboards: • SCADE Display for automatic code generation
of HMI applications for Embedded targets, Android and Apple iOS
© 2011 ANSYS, Inc. April 27, 2015 13
SCADE Suite Control
Software Design
Model Coverage Analysis
Formal Verification
Time & Stack Optimization
Debug & Simulation
Model Checks
Object Code & Compiler
Verification
SCADE Suite KCG
C & Ada
RTOS Adaptors
DO-178B DO-178C IEC 61508 EN 50128 ISO 26262
Certification Kits
Plant Model Co-simulation (incl. FMI)
PROTOTYPE & DESIGN VERIFY GENERATE
© 2011 ANSYS, Inc. April 27, 2015 14
SCADE Suite @ Subaru Electric Vehicles SCADE Suite 在 Subaru 电动汽车的应用 Subaru chose SCADE Suite for the design of its electric vehicle engine controls:
• Vehicle dynamics • Engine functions • Vehicle energy consumption
– heating & air conditioning – breaking – body controls
• Battery load management
© 2011 ANSYS, Inc. April 27, 2015 16
Sophisticated Design • Motor/Generator/Inverter/Converter/Battery/Charging, … • Electrical/Thermal/Structural/EMI/Vibration/Noise, …
Time to Market & Cost Reduction • OEMs all have very aggressive schedule • Cost of Hybrid/Electric is one of the biggest concerns Magnetic Components Integrated with System • Circuit & Control • Mechanics Integrated Design Environment for Multiphysics • Electric Machine – Magnetics/Thermal/Structural • Power Electronics – Electrical/Thermal/Electromagnetics Interference (EMI) Improving Design Speed: Design Automation and Optimization • Design Automation Example • Optimization and High Performance Computing
Hybrid/Electric Vehicle Design Challenges EV/HEV的设计挑战
© 2011 ANSYS, Inc. April 27, 2015 17
Robust, Efficient Traction Motor Design – Requirements And Benefits稳健高效的牵引电机设计—需求与好处
Robust, Efficient Traction Motor Design: Enables engineers to design for real-life operating conditions with a wide variety of loads and manufacturing variability, and to optimize the design by performing trade-offs amongst all design variables simultaneously
Thermal
Structural Fluid
Electromagnetic
Robust, Efficient Traction Motor Design
Data Mapping Da
ta M
appi
ng
Data Mapping
Data
Map
ping
Design Exploration • DOE Based
Response Surface
• 6σ, Optimization, Statistics
Requirements: • Couple multiple physics with
automated, accurate data transfer
• Rapid extensive exploration of design space
• Optimize machine in conjunction with power electronics
Benefits: Ensure product
performance throughout operating envelope
Achieve high efficiency Reduce cost, weight, size
System co-simulation with Power Electronics
© 2011 ANSYS, Inc. April 27, 2015 18
Analysis Methodology and Work Flow :分析方法与设计流程 Multi-physics Simulation多物理场仿真
FE Motor Analysis • Efficiency • Inductance • Cogging Torque
Motor Design Analytical • Slot Design • Winding Design • Geometry
CFD Analysis • Temp Distribution • External Cooling Requirement
Thermal FE Analysis • Temp Distribution
Structural Analysis • Stress Distribution • Deformation
Vibration Analysis • Modal • Harmonic
AutoSetup For FEA
Electromagnetic
Losses
Convective Coefficients
Electromagnetic Losses Temperature
Feedback
Electromagnetic Forces
Electromagnetic Force - FFT
Temperature
Comprehensive Motor Analysis
© 2011 ANSYS, Inc. April 27, 2015 19
Electrical Machines Magnetic Design Flow 电机电磁设计流程
RMXprt
Maxwell2D
Maxwell3D
Toolkit
UDOs &Toolkit
Initial Design FE Design Optimal Design
© 2011 ANSYS, Inc. April 27, 2015 22
• Motor specifications: Imax = 300 A (peak value) Vdc = 200 V Rdc = 8 mohm @ 20 C (per-phase stator resistance) Le = 30 uH (per-phase end-turn inductance) P = 8 Max. speed = 9000 rpm
Magna Electronics IPM Motor – Test Case Magna IPM电机—测试案例
© 2011 ANSYS, Inc. April 27, 2015 23
Magna:Experimental vs. Simulation实验与仿真对比
Experimental 2D Simulation
© 2011 ANSYS, Inc. April 27, 2015 24
Noise Vibration Analysis震动噪声分析
Magnetic Field
Structural Dynamics Acoustic Field
Forces Displacements
© 2011 ANSYS, Inc. April 27, 2015 25
Motor-CAD – Thermal Sizing热路法分析 Includes proven models for an extensive range of cooling types: TENV: Totally enclosed non-
ventilated TEFC: Totally enclosed fan
cooled Through Ventilation TE with Internal Circulating Air Open end-shield cooling Water Jackets Submersible cooling Wet Rotor & Wet Stator cooling Spray Cooling Direct conductor cooling
© 2011 ANSYS, Inc. April 27, 2015 26
Case Study - PM Machine Design 测试案例—永磁电机
• Winding also exported from RMxprt • Motor-CAD updates winding to account for
wire size available, enamel on wire and slot liner available
RMxprt - Motor CAD
© 2011 ANSYS, Inc. April 27, 2015 27
Hybrid Model : CFD Domain Definition Hybrid Model : CFD 区域定义 Motor – Thermal-Flow Network Equivalence
Motor-CAD thermal network is imported into ANSYS Icepak
ANSYS Icepak network replaces the thermal resistances between the housing and ambient with a CFD domain
Inside the housing, the machine is modelled using Motor-CAD thermal network, whereas the convective heat transfer outside the housing is modelled using an Icepak CFD domain
The thermal network and the CFD domain are coupled together through multi-faceted cylinder housing interfaces
Thermal-Net
Flow-Net
For the current application only thermal network is used
© 2011 ANSYS, Inc. April 27, 2015 28
Detailed and Hybrid Models: Comparison 具体和混合模型:比较
Detailed Model : 2M elements Network Model : 67k elements
3D Natural Convection Simulation on Hybrid Model • Turbulent flow model • Radiative heat transfer model • Fully parallelized solver • Converged CFD solution in ~ 2 minutes
© 2011 ANSYS, Inc. April 27, 2015 29
System Simulation – Wireless Power Transfer 系统仿真——无线充电系统
AC200V Rectify Inverter Wireless Power Transformer Battery
Controller
© 2011 ANSYS, Inc. April 27, 2015 31
Safe, Long–Lasting Battery Design –安全、长效的电池分析 Requirements And Benefits需求与好处
Safe, Long Lasting Battery Development: The solution ensures that battery design options are thoroughly investigated from electrode level, to cells, to modules, to pack and to controls, and the battery is optimized as a part of the entire powertrain system
Thermal
Structural
Electromagnetic
Safe, Long- Lasting Battery Development
Data Mapping
Design Exploration • DOE Based
Response Surface
• 6σ, Optimization, Statistics
Requirements: • Multiscale simulation • Ability to simulate long-
transient drive cycles • Comprehensive multiphysics • Extensive design exploration Benefits: Explore entire design
space and range of operating conditions thoroughly
Increase battery life and capacity
Extensively identify and eliminate failure modes
Gain confidence in life and safety of battery
Data
Map
ping
Data Mapping
Data
Map
ping
Fluid
© 2011 ANSYS, Inc. April 27, 2015 32
A Total Li-Ion Battery Simulation Solution完整的锂电池仿真解决方案
Electric Circuit, System Model
High Fidelity Physics, Chemistry Models
Reduced Order Modeling (ROM)
© 2011 ANSYS, Inc. April 27, 2015 33
Full Battery Simulation全电池解决方案
Voc = -1.031*exp(-35*(abs(IBatt.V/Vinit))) + 3.685 + 0.2156*(abs(IBatt.V/Vinit)) - 0.1178*(abs(IBatt.V/Vinit))^2 + 0.3201*(abs(IBatt.V/Vinit))^3 + 0.3/30.0*(U1.Temp_block_1-273)
© 2011 ANSYS, Inc. April 27, 2015 35
What is a System?什么是系统?
Energy Storage
Power Generation
Software
Actuators
Sensors Temperature
Pressure
Humidity
The Environment Disturbances Uncertainty Variability Extremes Failures
© 2011 ANSYS, Inc. April 27, 2015 36
Comprehensive Component-Level Design部件级设计
Electronics Structures Fluids Embedded Software
Immersive Multiphysics
© 2011 ANSYS, Inc. April 27, 2015 37
Systems
The Next Level: Systems系统级
• Assemblies of components – powered, sensed, & controlled as an integrated system
• Must be designed & optimized as a system
© 2011 ANSYS, Inc. April 27, 2015 38
ANSYS Systems Modeling & Simulation系统建模与仿真
Heat Exchangerhigh_t
low_t
outlet_hinlet_h
outlet_c
inlet_c
U2_heat_ex
inletoutlet
U1_low_pump
inletoutlet
U3_h_pump
temp
temp
0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [s]
300.00
350.00
400.00
450.00
500.00
550.00
600.00
Y2
[kel
]
Ansoft LLC Simplorer1XY Plot 1Curve InfoU2_heat_ex.tc100
TRU2_heat_ex.th100
TR
0
100
200
300
400
500
600
700
800
0 0.5 1 1.5 2
時間 (us)
電圧
(V)
0
100
200
300
400
500
600
700
800
電流
(A)
VCE-実測
VCE-SIM
IC-実測IC-SIM
-22.50
60.00
0
25.00
50.00
0 240.00m100.00m
2DGraphSel1 NIGBT71.IC
0
474.00m
200.00m
400.00m
100.00 1.00Meg1.00k 3.00k 10.00k 100.00k
2DGraphCon1
GS_I...
Systems
A platform for modeling, simulating, and analyzing virtual system prototypes...
...enabling product teams to verify and optimize software-controlled, multi-domain power systems
© 2011 ANSYS, Inc. April 27, 2015 39
Simplorer 用于系统仿真
Heat Exchangerhigh_t
low_t
outlet_hinlet_h
outlet_c
inlet_c
U2_heat_ex
inletoutlet
U1_low_pump
inletoutlet
U3_h_pump
temp
temp
0.00 2.50 5.00 7.50 10.00 12.50 15.00 17.50 20.00Time [s]
300.00
350.00
400.00
450.00
500.00
550.00
600.00
Y2
[kel
]
Ansoft LLC Simplorer1XY Plot 1Curve InfoU2_heat_ex.tc100
TRU2_heat_ex.th100
TR
0
100
200
300
400
500
600
700
800
0 0.5 1 1.5 2
時間 (us)
電圧
(V)
0
100
200
300
400
500
600
700
800
電流
(A)
VCE-実測
VCE-SIM
IC-実測IC-SIM
Proven in Power Electronics
Links with Detailed Physics
Multi-Fidelity, Multi-Domain
Modeling
-22.50
60.00
0
25.00
50.00
0 240.00m100.00m
2DGraphSel1 NIGBT71.IC
0
474.00m
200.00m
400.00m
100.00 1.00Meg1.00k 3.00k 10.00k 100.00k
2DGraphCon1
GS_I...
Simulation-Based Test Embedded
Control / SW
© 2011 ANSYS, Inc. April 27, 2015 40
Modeling the System系统建模 Powerful Capabilities for Assembly and Reuse
Reduced Order Model Creation
Functional Mockup Interface (FMI)
3rd Party System Modeling tools
(AMESim, Simulink, Dymola, GT Suite etc.)
Embedded Software Integration
ANSYS SCADE
Simulink C Code
Co-simulation with 3D Physics
ANSYS 3D Physics
Mech EM Thermal Fluid
Multi-Domain Model Libraries
Language-Based Modeling
VHDL-AMS C/C++ SPICE SML
Modelica
Analog
Digital
Multi-Domain
App-Specific
Power Systems
Manufacturers
© 2011 ANSYS, Inc. April 27, 2015 41
0
0 0 0
PMSM_DQ n1
n2
n3
m1
Stepsize
SIMPARAM1
L1
L2
L3
N1
N2
N3
I1 I3
I_Motor
- ~ P
N
V
U
W
V1 V2 V3 V4 V5 V6
U1 E1
EMF=1000V
A B C
N
U_UMR
PWM Modulator
DC-Link Voltage
Integrating Current Sampling
Mechanical Angle Input
u1 u2
Udc
u3
V1 V2 V3 V4 V5 V6
I_1
I_3
I1f
I3f
phi_m
phi_el
w_el
FPGA PWM_3PH1
+ V
VM1
+ Φ SM_ROTB1
A B C
N
U_MOT
L1
L2
L3
N1
N2
N3
S_Motor
CTRL=S1
n_ref
TDELAY=5ms AMPL=n_ref-n0 TRISE=300ms OFF=n0
MASS_ROTB1
A
AM4
C1
C2
R1
R2
R3 L1
T F_ROTB1 Load_Torque
TDELAY=t_load AMPL=trq_load
TRISE=20ms OFF=0
w_ref
phi_el
i1f
i3f
w_el
dT
u1 u2 u3
Power Source/电源
Control控制 (FPGA & Software)
Power Electronics : Inverter电力电子
Permanent Magnet Synchronous Motor电机
Rotational position sensor传感器
Mechanical Load负载
Hybrid Vehicle Drivetrain/混合车辆动力总成系统