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EVHEV Value Chain and Battery Design - Comprehensive Solution Presentation

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  • 8/18/2019 EVHEV Value Chain and Battery Design - Comprehensive Solution Presentation

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    © 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 DesignSandeep SovaniZed TangMark Christini

    January 26, 2011 ANSYS Sales Conference

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    © 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

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    © 2011 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary

    The automotive powertrain has changed for good

    A once-in-a-lifetime landslide change

    Market Trends

    I.C. EnginePowertrain

    Augmentedwith

    ElectricPowertrain

    Hybrid Powertrain

    I.C. EnginePowertrain

    OLD NEW

    ElectricPowertrain

    FUTURE

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    © 2011 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

    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

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    © 2011 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary

    Market Trends

    MicroHybrid

    HEV PHEV ER EV EV 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

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    © 2011 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary

    Market Trends

    Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA

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    Market Trends

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    Market Trends

    PowerSource

    PowerElectronics

    ElectricMachine

    MechanicalComponents

    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 Reporthttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpg Author {{:de:wiki:user DrJunge|DrJunge}}.

    http://commons.wikimedia.org/wiki/File:HitachiJ100A.jpghttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpghttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpghttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:HitachiJ100A.jpg

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    Market Trends

    Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA

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    Market Trends

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

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    Outline

    • EV/HEV Market – Trends – Value Chain

    • EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics

    • Success Stories

    • 2011 Marketing Campaigns

    • Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators

    • R13 Advances• 2011 ANSYS Targets

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    EV/HEV Value Chain

    Samp le Bus iness In i t ia t ives

    Y2020 Estimates

    Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA

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    Battery Value Chain

    Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA

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    EV/HEV Value Chain

    Ref: Hazimeh, O. – PRTM Consultants, “50% Battery Cost Reduction,” EV Battery Technology Conference, Sept 21 -22, 2010, Troy, MI, USA

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    Battery Value Chain

    Ref: Iyengar, J. – Chrysler, “EV Battery Business Analysisand Vision for Commercialization” EV Battery TechnologyConference, Sept 21-22, 2010, Troy, MI, USA

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    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

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    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

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    Outline

    • EV/HEV Market – Trends – Value Chain

    • EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics

    • Success Stories

    • 2011 Marketing Campaigns

    • Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators

    • R13 Advances• 2011 ANSYS Targets

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    Numerical Simulation will be a key differentiatorin the electrification competition

    Numerical Simulation is particularly advantageous inelectrification development

    Firms that strategically deploy numerical simulation willgain significant competitive advantage

    EV/HEV Simulation

    Message to Executive Decision Makers –

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    Why is Numerical Simulationparticularly advantageous inelectrification development?

    EV/HEV Simulation

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    Challenges indeveloping disruptiveinnovations

    No precedenceMany unknownsNew paradigms

    Uncertainty

    Time pressure

    Last powertrain took~100 years to develop

    New powertrainexpected in ~10 years

    EV/HEV Simulation

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    Many ChoicesMany Decisions

    Cylindrical, Prismatic?Air Cooling, Liquid Cooling?Cell Chemistry?…

    Established Demands

    SafetyReliability

    Cost Life

    Same as or surpassingcurrent vehicle standards

    Multitude of ideas need to be generated, digested,validated, developed, tested, perfected, delivered, in

    a short time

    EV/HEV Simulation

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    Multitude of ideas need to be generated, digested,validated, developed, tested, perfected, delivered, in ashort time

    Numerical Simulation is particularly wellsuited for this need provides

    • In-depth engineering insights• Speedy design evaluation via virtual testing• Enabler of fast, extensive design

    EV/HEV Simulation

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    © 2011 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary

    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 AutomatedDesign Exploration

    EV/HEV Simulation ANSYS Positioning Message

    Competitors’ Propositions ANSYS Differentiators

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    © 2011 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary

    Outline

    • EV/HEV Market – Trends – Value Chain

    • EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics

    • Success Stories

    • 2011 Marketing Campaigns

    • Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators

    • R13 Advances• 2011 ANSYS Targets

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    © 2011 ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary

    Integrated Simulation

    PowerSource

    PowerElectronics

    ElectricMachine

    MechanicalComponents

    Control

    What is Integrated Simulation?

    Battery/BMS Inverter/Busbar Traction Motor Drive Shaft

    http://commons.wikimedia.org/wiki/File:HitachiJ100A.jpgOakridge National Laboratory, ORNL/TM-2004/247, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System Interim Reporthttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpg Author {{:de:wiki:user DrJunge|DrJunge}}.

    http://commons.wikimedia.org/wiki/File:HitachiJ100A.jpghttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpghttp://commons.wikimedia.org/wiki/File:Differentialgetriebe2.jpghttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:Ni-MH_Battery_02.JPGhttp://commons.wikimedia.org/wiki/File:HitachiJ100A.jpg

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    © 2011 ANSYS, Inc. All rights reserved. 27 ANSYS, Inc. Proprietary

    Integrated Simulation

    Integrated Simulation:Combining high-fidelity component simulation withsubsystem and system level simulation

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    © 2011 ANSYS, Inc. All rights reserved. 28 ANSYS, Inc. Proprietary

    Integrated 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

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    © 2011 ANSYS, Inc. All rights reserved. 29 ANSYS, Inc. Proprietary

    Integrated Simulation

    ANSYS Differentiator: No competitor can performintegrated simulation with the same multiphysicsbreadth and depth as ANSYS

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    © 2011 ANSYS, Inc. All rights reserved. 30 ANSYS, Inc. Proprietary

    Outline

    • EV/HEV Market – Trends – Value Chain

    • EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics

    • Success Stories

    • 2011 Marketing Campaigns

    • Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators

    • R13 Advances• 2011 ANSYS Targets

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    © 2011 ANSYS, Inc. All rights reserved. 31 ANSYS, Inc. Proprietary

    Battery: Key Problems

    CellManufacturing

    MaterialBehavior in Cell

    Assembly

    Ageing, Life

    Thermal Management(Temperature Uniformity)

    Safety, Crash, Abuse

    NVH, Durability

    Battery ManagementSystem and Algorithms

    BatteryPerformance inVehicle Level TestCycles

    Load Matching forChargingDischarging

    Overall Concerns:• Cost• Life• Safety• Power Density

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    © 2011 ANSYS, Inc. All rights reserved. 32 ANSYS, Inc. Proprietary

    Battery : ANSYS Solutions

    • Pack Level Simulation

    • Cell Level Simulation

    • System Level Simulation

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    © 2011 ANSYS, Inc. All rights reserved. 33 ANSYS, Inc. Proprietary

    Battery : ANSYS Solutions – Pack Level

    ANSYS Workbench – An Integrated Solution for Battery CFD Analysis

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    © 2011 ANSYS, Inc. All rights reserved. 34 ANSYS, Inc. Proprietary

    Build-in What-if Study in WB

    Battery : ANSYS Solutions – Pack Level

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    © 2011 ANSYS, Inc. All rights reserved. 35 ANSYS, Inc. Proprietary

    HEV Battery Thermal Management: Six Sigma Analysis

    Battery : ANSYS Solutions – Pack Level

    Ref: Valhinos et al, “Improving Battery Thermal Management Using Design for Six SigmaProcess”, 20 th Electric Vehicle Symposium, Long Beach, CA (November 15-18, 2003)

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    © 2011 ANSYS, Inc. All rights reserved. 36 ANSYS, Inc. Proprietary

    Reduced Order Modeling

    Battery : ANSYS Solutions – Pack Level

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    © 2011 ANSYS, Inc. All rights reserved. 37 ANSYS, Inc. Proprietary

    Reduced Order Model Extraction Process Using Simplorer

    Battery : ANSYS Solutions – Pack Level

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    © 2011 ANSYS, Inc. All rights reserved. 38 ANSYS, Inc. Proprietary

    LTI (Foster Network) vs ANSYS FLUENT

    Battery : ANSYS Solutions – Pack Level

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    © 2011 ANSYS, Inc. All rights reserved. 40 ANSYS, Inc. Proprietary

    Battery Bus Bar Heating Multiphysics Simulation• For steady (or low frequency) currents under

    temperature dependent conductivity

    Battery : ANSYS Solutions – Pack Level

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    © 2011 ANSYS, Inc. All rights reserved. 41 ANSYS, Inc. Proprietary

    Coupled Simulation in ANSYS FLUENT

    Battery : ANSYS Solutions – Pack Level

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    © 2011 ANSYS, Inc. All rights reserved. 42 ANSYS, Inc. Proprietary

    • 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 createthese demonstration cases

    Battery : ANSYS Solutions – Pack Level

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    © 2011 ANSYS, Inc. All rights reserved. 43 ANSYS, Inc. Proprietary

    Battery : ANSYS Solutions

    • Pack Level Simulation

    • Cell Level Simulation

    • System Level Simulation

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    © 2011 ANSYS, Inc. All rights reserved. 44 ANSYS, Inc. Proprietary

    Cell Manufacturing: Coating Analysis

    Courtesy: ANSYS Japan Technical Team

    Battery : ANSYS Solutions – Cell Level

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    © 2011 ANSYS, Inc. All rights reserved. 45 ANSYS, Inc. Proprietary

    Cell Manufacturing: Flow Inside Die

    Courtesy: ANSYS Japan Technical Team

    Battery : ANSYS Solutions – Cell Level

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    © 2011 ANSYS, Inc. All rights reserved. 46 ANSYS, Inc. Proprietary

    Cell Electrical Model:• Simple enough for systemlevel analysis

    – Detailed electrochemistry models

    are too time consuming for systemlevel 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

    Battery : ANSYS Solutions – Cell Level

    l

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    © 2011 ANSYS, Inc. All rights reserved. 47 ANSYS, Inc. Proprietary

    Single Cell Thermal Model

    - Newman &Tidemann (1993);

    - Gu (1983) ;- Kim et al (2008)*

    Model based on:

    Battery : ANSYS Solutions – Cell Level

    B ANSYS S l i

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    © 2011 ANSYS, Inc. All rights reserved. 48 ANSYS, Inc. Proprietary

    Electrochemistry: Newman’s 1D Model in Simplorer

    Battery : ANSYS Solutions – Cell Level

    B ANSYS S l i

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    © 2011 ANSYS, Inc. All rights reserved. 49 ANSYS, Inc. Proprietary

    3D Electrochemistry Modeling

    Battery : ANSYS Solutions – Cell Level

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    © 2011 ANSYS, Inc. All rights reserved. 50 ANSYS, Inc. Proprietary

    Battery : ANSYS Solutions –

    • Pack Level Simulation

    • Cell Level Simulation

    • System Level Simulation

    B tt ANSYS S l ti

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    © 2011 ANSYS, Inc. All rights reserved. 51 ANSYS, Inc. Proprietary

    Battery: ANSYS Solutions – System Level

    • 60 Cells connected in matrix pack• Packs are connected in matrix to

    final configuration

    5cells

    Pack Circuit Model

    B tt ANSYS S l ti

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    © 2011 ANSYS, Inc. All rights reserved. 52 ANSYS, Inc. Proprietary

    Battery in Control System with Motor Controller

    Battery: ANSYS Solutions – System Level

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    © 2011 ANSYS, Inc. All rights reserved. 53 ANSYS, Inc. Proprietary

    Battery: Competition Analysis

    • CD-AdapcoPack Level –CD-Adapco ANSYS

    Basic CFD needed forBattery Simulation

    Comparable to ANSYS Comparable

    Design Exploration Rudimentaryparameterization

    SpaceClaim andDesignXplorer giveadvantage

    LTI Method No comparable solution Easy Simplorer based

    solution

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

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    © 2011 ANSYS, Inc. All rights reserved. 54 ANSYS, Inc. Proprietary

    Battery: Competition Analysis

    • CD-AdapcoCell Level –CD-Adapco ANSYS

    Cell Electrical Model Partnership with BatteryDesign LLC. Providesadvantage in standardcell characteristics andcell material properties

    Simplorer based model.Needs cell properties asinput.

    Cell Thermal Model Demonstrated examples Comparable capability

    1D Electrochemistry No demonstratedsolution

    Simplorer based solution

    3D Electrochemistry Some demonstratedexamples

    Some demonstratedexamples

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

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    © 2011 ANSYS, Inc. All rights reserved. 55 ANSYS, Inc. Proprietary

    Battery: Competition Analysis

    • CD-AdapcoMultiphysics and System Level –

    CD-Adapco ANSYS

    Multiphysics (E.g. busbar deformation)

    No comparable solution ANSYS core advantage

    Durability, Impact, Abuse No direct solution ANSYS mechanical

    NVH Some acoustics models,no structural solution

    Broadband acousticsmodels in CFD,Structural NVH

    System Integration No direct solution Simplorer based solution

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

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    © 2011 ANSYS, Inc. All rights reserved. 56 ANSYS, Inc. Proprietary

    Battery: Competition Analysis

    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-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/marketing-material/campaign-1/battery/general-referenceshttps://sites.google.com/a/ansys.com/automotive/

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    © 2011 ANSYS, Inc. All rights reserved. 57 ANSYS, Inc. Proprietary

    Battery: 2011 Targets

    • OEMs – All major car, truck OEMs have ambitious

    electrification plans: All are targets• Battery Suppliers

    – Over 150 battery companiesin 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

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    © 2011 ANSYS, Inc. All rights reserved. 58 ANSYS, Inc. Proprietary

    Outline

    • EV/HEV Market – Trends – Value Chain

    • EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics

    • Success Stories

    • 2011 Marketing Campaigns

    • Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators

    • R13 Advances• 2011 ANSYS Targets

    Traction Motor – Key Problems

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    © 2011 ANSYS, Inc. All rights reserved. 59 ANSYS, Inc. Proprietary

    Traction Motor – Key Problemsand 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 effectsthrough 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

    Traction Motor – Key Problems

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    © 2011 ANSYS, Inc. All rights reserved. 60 ANSYS, Inc. Proprietary

    Traction Motor Key Problemsand Simulation Needs

    • More Innovative and Complex Designs

    19 machine types to choose from

    Different machine geometry templates

    Traction Motor – Key Problems

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    © 2011 ANSYS, Inc. All rights reserved. 61 ANSYS, Inc. Proprietary

    Traction Motor Key Problemsand Simulation Needs

    • 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 upto be an optimized system; integratedmotor / electronics / control simulation is

    needed

    Traction Motor – Key Problems

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    Traction Motor Key Problemsand Simulation Needs

    • Multiphysics Coupling

    Deformation of the stator Deformation of coilsThe electromagnetic force densityfrom Maxwell is used as load inStructural

    Thermal-Stress with Electromagnetic Force load

    Traction Motor – Key Problems

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    Traction Motor Key Problemsand Simulation Needs

    • 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

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    Traction Motor CompetitionAnalysis and Differentiators

    ANSYS offers Functionality Competition

    Maxwell Electromagnetic FiniteElement Solvers

    JMag, FLUX, MagNet,…

    Simplorer Circuit/SystemSimulator Saber, PSpice,Matlab /SIMULINK, …

    ANSYSMechanical/CFD

    Stress, Thermal Abaqus, STAR- CD, …

    Q3D Parasitics Extraction

    DX, MPO, DSO Design Automation &Optimization

    RMxprt

    Closed-form analyticalsolution, quickly reducedesign space

    SPEED, MotorSolve …

    ANSYS Simulation Driven Product DevelopmentElectric Machine Design Methodology

    Traction Motor – Competition

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    Traction Motor CompetitionAnalysis and Differentiators

    ANSYS offers Functionality Competition

    Maxwell Electromagnetic FiniteElement Solvers

    JMag, FLUX, MagNet,…

    Simplorer Circuit/SystemSimulator Saber, PSpice,Matlab /SIMULINK, …

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

    Q3D Parasitics Extraction

    DX, MPO, DSO Design Automation &Optimization

    RMxprt

    Closed-form analyticalsolution, quickly reducedesign space

    SPEED, MotorSolve …

    ANSYS Simulation Driven Product DevelopmentElectric Machine Design Methodology

    ANSYS

    Electric

    Machine

    Design

    Methodology

    FullyIntegratedElectricMechine

    SystemDesign

    NONE!

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    Traction Motor – 2011 ANSYS

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    Traction Motor 2011 ANSYSTargets

    • General Trends• It takes years for major auto OEMs to realizethat they have to control their own destiny interms of designing traction motors bythemselves. For example, GM. Ford isstarting to realize that.• It also takes years for motor suppliers to

    realize that they need to re-design a motor forauto traction application.

    Traction Motor – 2011 ANSYS

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    Traction Motor 2011 ANSYSTargets

    • 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 tomore• Magnetics design -> Structural/Thermal -> Electronics

    • Use success story in traction motor and apply toother applications

    • Battery, electronics, system integration, EMI/EMC

    Traction Motor – 2011 ANSYS

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    Targets

    • Expand Success to Major Suppliers andCommercial Vehicles/Off-highway Vehicles

    • Suppliers Want to do More too

    • Commercial Vehicle companies have huge interestin HEV/EV too• Eaton Trucks, Prestolite, ArvinMeritor, etc.

    • Off-highway industry also starts looking intoHEV/EV

    • CAT, John Deere, Cummins, etc.

    Traction Motor – 2011 ANSYS

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    Targets

    • Expand Success to other Motor Areas• Power Steering, Electric Pumps, WindShields, etc.

    • These applications have the same physics(motor, controller, power source/electronics,mechanical components)• HEV/EVs need new designs for theseapplications because requirements are verydifferent from traditional vehicles

    O li

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    Outline

    • EV/HEV Market – Trends – Value Chain

    • EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics

    • Success Stories

    • 2011 Marketing Campaigns

    • Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators• ANSYS 13.0 Advances• 2011 ANSYS Targets

    HEV Power Electronics – Key

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    yProblems and Simulation Needs

    Charging SystemsHigh Power Distribution SystemsEnergy

    ManagementSystems

    Typical HEV System

    (internal use only)

    HEV Power Electronics – Key

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    System

    Control

    Thermal

    Digital

    yProblems and Simulation Needs

    HEV Power Electronics

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    Simplorer

    Simulink

    MathcadCo Simulation

    ModelSIM

    ANSYS Solutions

    ANSYS is the only providerof a complete powerelectronics design solutionfor Hybrid Electric Vehicles!

    HEV Power Electronics

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    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

    HEV Power Electronics

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    ThermalElectromagnetic MechanicalFluidicComponent

    CircuitSubsystem

    System

    ANSYS

    Mechanical,CFD, Icepak

    Q3D,Xprt Tools

    Simplorer

    Maxwell, HFSSFEA solvers

    ANSYS System Solutions

    HEV Power Electronics

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    Simplorer

    System Design

    PP:=6

    ICA:

    A

    A

    A

    GAIN

    A

    A

    A

    GAIN

    A

    JPMSYNCIA

    IB

    IC

    Torque JPMSYNCIA

    IB

    IC

    TorqueD2D

    MaxwellElectromagnetic Components

    PExprtMagnetics

    RMxprtMotor Design

    Q3DParasitics

    ANSYSMechanicalThermal/Stress

    ANSYS CFDThermal

    Model order Reduction

    Co-simulation

    Field Solution

    Model Generation

    Icepak

    ANSYS Coupled Solutions

    HEV Power Electronics

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    Competitive Differentiators

    ANSYS offers Functionality DifferentiatorsSimplorer Circuit/System Simulator Multi-domain, multi-physics

    Maxwell Electromagnetic Finite ElementSolvers 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 FEARMxprt Closed-form analytical solution

    for Motors and GeneratorsCouples to Simplorer andMaxwell for complete FEA

    Q3D R,L,C,G parasitic extraction forwiring harnesses andinterconnects

    Frequency dependent modelcoupled to Simplorer

    ANSYSMechanical

    Basic Stress and ThermalAnalysis

    Couples directly to Maxwell viaWorkbench

    ANSYS CFD Thermal analysis using fluid flow Couples directly to Maxwell

    ANSYS Icepak Electronics Cooling Couples directly to Simplorer

    HEV Power Electronics

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    Simplorer v8.1 and v9 Advances

    • Integrated with the ANSYS

    Workbench interface. Can becreated and launched from WB

    • Improved co-simulation capabilitieswith Maxwell 3D

    • Enhanced IGBT ParameterizationWizard with more accurate fittingalgorithm – important for EMC/EMIanalysis

    • 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

    HEV Power Electronics

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    2011 ANSYS Target #1

    • Expand Success to other Major Suppliersof HEV components and systems such asXYZ Corp.

    − XYZ Corporation in Detroit is a Tier 1,2 supplier (traditionallyseating) for major automotive OEMs− Previously owned ANSYS Mechanical and ANSYS Icepak− Made a strategic decision several years ago to move into theautomotive power electronics market− Currently developing a high voltage power supply for a HEVbattery 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

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    Potential Areas for Simulation

    HEV Power Electronics

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    IGBT Module Pack 3Daccurate model

    ParametersExtraction

    Electromagnetic(EM) study

    Design and CouplingsModel

    IGBT Model

    • Tridimensional IGBT pack model and EM study

    • Parasitic model extraction

    • IGBT circuit model

    Far Field Study

    • Far Field Study for Electric Field EM

    2011 ANSYS Target #2

    • Expand Success to Major Automotive OEM’s for radiated

    EMC/EMI analysis of power supplies

    Analysis Methodology Using

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    • Tridimensional IGBT pack model and EM study

    • Parasitic model extraction

    • IGBT circuit model

    • Far Field Study for Electric Field EM

    Finite Element Method

    Finite ElementMethodFEA / BoundaryElement Method System Simulation

    Different Techniques

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    Simplorer to HFSS Radiated Field

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    E-field @ 100 MHz, Power = 10kW

    p

    HEV Power Electronics

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    2011 ANSYS Target #2

    • Expand Success to Major Automotive OEM’s for

    conducted EMC/EMI analysis of power supplies

    Characterize and reduce EMI emissions from SwitchedMode Power Supply (SMPS) by:

    - Model SMPS- Determine critical components in system- Determine noise attenuating techniques

    Detailed Procedure:

    − Model: Actives and Passives (discrete componentsand interconnects)− Use simulations to find critical paths− Focus attention on these paths to mitigate noise

    Modeling Process

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    g

    ProprietaryMaterial has

    been removed

    System Simulation

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    y

    Proprietary

    Material hasbeen removed

    Reduction of Conducted EMI

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    Proprietary

    Material hasbeen removed

    Outline

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    Outline

    • EV/HEV Market – Trends – Value Chain

    • EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics

    • Success Stories

    • 2011 Marketing Campaigns

    • Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators• R13 Advances• 2011 ANSYS Targets

    Success Story 1 Company #1Car Manufacturer

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    • 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 1 Car Manufacturer

    Success Story 1 Company #1Car Manufacturer

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    • What did they prefer ANSYS? – Motors: very fast analysis of 1000s of designs

    using DSO –

    Battery: WB workflow integrating multiplephysics• Future growth potential

    – Structural mechanics & explicit – Simplorer – EKM?

    Success Story 1 Car Manufacturer

    Success Story 2 Company #2Battery Manufacturer

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    • Who are they? – A prominent

    U.S. battery company

    • What did they buy? – CFD (Fluent)

    • What are they usingit for?

    – Battery Simulation

    Success Sto y Battery Manufacturer

    Success Story 2 Company #2Battery Manufacturer

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    • What did they prefer ANSYS? – 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

    y Battery Manufacturer

    Success Story 3 Company #3Car Manufacturer

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    • What did they buy? – Maxwell 2D/3D + RMxprt + Optimetrics +

    ANSYS FLUENT + DesignXplorer

    • What are they using it for? – Departments: (a) R&D (b) Production) – Applications

    • Verify performance map of supplier produced motor • Simplorer co-simulation for circuit and system level• Battery cooling

    y Car Manufacturer

    Success Story 3 Company #3Car Manufacturer

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    • What did they prefer ANSYS? – 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

    y Car Manufacturer

    Success Story 4 Company #3Multinational Parts Supplier

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    • What did they buy? – Q3D + ANSYS FLUENT + ANSYS Mechanical

    • What are they using it for?

    – Micro-hybrid systems (start-stop alternator,electronics) – Mechatronics simulation• Thermal – FLUENT• Structural Acoustics – ANSYS Mechanical

    • Electromagnetics – Maxwell• Co-Simulation – Simplorer

    y Multinational Parts Supplier

    Success Story 4 Company #3Multinational Parts Supplier

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    • What did they prefer ANSYS? – 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

    y Multinational Parts Supplier

    Success Story 5 Company #5Car Manufacturer

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    y

    HEV related sale

    Maxwell - Motor DesignCFD - Battery Design

    See details in Day 4presentation by Greg Fallonand Tom Smithyman

    Car Manufacturer

    Outline

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    • EV/HEV Market – Trends – Value Chain

    • EV/HEV Simulation – Integrated Simulation – Battery – Traction Motor – Power Electronics

    • Success Stories

    • 2011 Marketing Campaigns

    • Key Problems and Simulation Needs• ANSYS Solutions• Competition Analysis and Differentiators• R13 Advances• 2011 ANSYS Targets

    Marketing Campaigns

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    Proprietary

    Material hasbeen removed

    Thank you!

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