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1 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Optimizing Cell, Module, Pack and Controls Design with Comprehensive Simulation
Sandeep Sovani, Ph.D.
Director, Global Automotive Industry
ANSYS Inc, Detroit
Acknowledgements: Xiao Hu and Scott Stanton, ANSYS Inc.
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2 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Virtual Product Development
Concept & Design
Physical Prototype
Production
Simulation-Driven Product Development
Today’s norm for automotive product development
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3 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Largest Independent CAE simulation software company
Focused Simulation is all we do. Leading product technologies in all physics areas Largest development team focused on simulation
Capable 2,700 employees 60 locations, 40 countries
Trusted 96 of top 100 FORTUNE 500 industrials ISO 9001 and NQA-1 certified
Proven Recognized as one of the world’s most innovative and fastest-growing companies*
Independent Long-term financial stability
*BusinessWeek, FORTUNE
About ANSYS A Simulation Software Company
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4 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Fluid Dynamics Structural Mechanics
ANSYS Simplorer
ANSYS Engineering Knowledge Manager
ANSYS HPC ANSYS Workbench
Electromagnetics
ANSYS DesignXplorer
Systems and Multiphysics
ANSYS FLUENT
ANSYS CFX
ANSYS Icepak
ANSYS HFSS
ANSYS Maxwell
ANSYS Q3D
ANSYS Mechanical
ANSYS LS-DYNA
ANSYS nCode
ANSYS Acoustics
About ANSYS Advanced Physics Solvers
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5 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
A multi-fidelity simulation toolset is essential for complex systems such as batteries
Model Simulation Result
Requirement Req 23: On request, the valve should close in 500us
X
Functional simulation
System simulation (0D)
High fidelity simulation
(3D) - Open loop validation
System Validation
(0D-ROM-Ctrl)- Close loop validation
500us 0
Pos
true
false t
0
500us
t
Pos
Pmax
Actuator
t
Pos
0 500us
t
Pos
Pmax
500us
Pmax
Pmax
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6 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
A Total Li-Ion Battery Simulation Solution
Module/Pack
Thermal Mgt Durability NVH EMI/EMC
Electrode
Layout Process Life SEI
Molecular
Materials
Powertrain
System Integration
Smal
l Sca
le
Larg
e Sc
ale
Cell
Charging Discharging Heating Safety
ECM CFD ROM FEA
ECM CFD FEA
Electro-chemistry
ECM ROM
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7 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
A Total Li-Ion Battery Simulation Solution
Electric Circuit, System Model
High Fidelity Physics, Chemistry Models
Reduced Order Modeling (ROM)
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8 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Electrode Level - Electrochemistry
• Electrochemical Kinetics • Solid-State Li Transport • Electrolytic Li Transport
• Charge Conservation/Transport • (Thermal) Energy Conservation
Li+
e
Li+
Li+ Li+
LixC6 Lix-Metal-oxide
e
Jump
Li
eeee j
F
tcD
t
c
1)(
Impact of Discharge Rate on Capacity Charge Discharge Cycles Temperature Impact on Capacity
1/10 C 1/2 C 1 C 2 C 4 C 6 C 8 C 10 C
X. Hu, S. Lin, S. Stanton, SAE paper 2012-01-0665
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9 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
U.S. Department of Energy CAEBAT Project
DOE’s Computer-Aided Engineering for Electric Drive Vehicle Batteries (CAEBAT) program
ESim
Goals for the CAEBAT include:
• Developing standard battery engineering tools to design cells and battery packs
• Improving overall battery performance, safety, and predict battery life
CAEBAT Program: • DOE Funded program; $7.0 M Investment • Completion in August 2014
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10 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Newman P2D Electrochemistry Model in ANSYS-Fluent (CAEBAT project)
Domains
• negative electrode
• separator
• positive electrode
• spherical particles
L. Cai and R.E. White, “Reduction of Model Order Based on Proper Orthogonal Decomposition for Lithium-Ion Battery Simulations” J. of Electrochemical. Soc. 156(3) A154-A161 (2009).
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11 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Temperature Results Based on Electrochemistry
-110
-90
-70
-50
-30
-10
10
30
50
0 200 400 600 800 1000 1200 1400
Cu
rre
nt
(A)
Time (s)
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12 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Cell Level – CFD Thermal
Temperature Distribution
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13 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Cell Level –Electro-Thermal
Current Density Cathode Anode Current Density
J
)( UYJ ac
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14 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Cell Level – ECM
Battery Equivalent Circuit Model (ECM) Simulation Testing
X. Hu, L. Collins, S. Stanton, S. Jiang, "A Model Parameter Identification Method for Battery Applications", SAE 2013-01-1529.
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15 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
• 28 cells are connected in a module
• 4 modules are connected to the final configuration
Module/Pack Level – ECM
X. Hu, L. Collins, S. Stanton, S. Jiang, "A Model Parameter Identification Method for Battery Applications", SAE 2013-01-1529.
Battery Pack ECM
Simulation Results
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16 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential X. Hu, L. Collins, S. Stanton, S. Jiang, "A Model Parameter Identification Method for Battery Applications", SAE 2013-01-1529.
Cell Level – ECM Extraction Tool
ECM Extraction Toolkit
ECM Model Workflow
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17 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Module Level – CFD Thermal
Temperature Distribution
Velocity Distribution
Initial Optimized
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18 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Motivation of Reduced Order Model(ROM)
CFD as a general thermal analysis tool is accurate.
Can be computationally expensive for system level analysis
ROM can significantly reduce the model size and simulation time.
ROM is an import tool for system level simulation.
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19 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Battery Thermal Behavior via ROM
Type 1: Thermal Network
• Careful calculation and calibration needed
• Accuracy compromises
Type 2: LTI – state space
• Can be as accurate as CFD
• No calibration
LTI t t Step Input
Step Response
1
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20 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
LTI ROM gives the same results as CFD. LTI ROM runs in less than 2 seconds while the CFD runs 2 hours on one single CPU.
X. Hu, S. Lin, S. Stanton, W. Lian, “A Foster Network Thermal Model for HEV/EV Battery Modeling,” IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 47, NO. 4, JULY/AUGUST 2011 X. Hu, S. Lin, S. Stanton, W. Lian, “A State Space Thermal Model for HEV/EV Battery Modeling", SAE 2011-01-1364
Heat Profile
LTI ROM for General Motors Battery Module
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21 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Module Level – ROM for Thermal
ROM vs CFD ROM for the Battery Module
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22 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
SVD = Singular Value Decomposition
SVD ROM technology allows for quick temperature distribution calculation in addition to average temperature calculation.
Using a heat source from GM, SVD ROM is applied to the GM 16 cell case.
SVD ROM : General Motors 16 Cell Test Case
Heat source used
S. Asgari, X. Hu, M. Tsuk, S. Kaushik, “Application of POD plus LTI ROM to Battery Thermal Modeling: SISO Case,” SAE 2014.-01-1843 X. Hu, S. Asgari, I. Yavuz, S. Stanton, C-C Hsu, Z. Shi, B. Wang, H-K Chu, “A Transient Reduced Order Model for Battery Thermal Management Based on Singular Value Decomposition,“ Submitted to ECCE 2014.
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23 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
SVD ROM Validation: GM 16 Cell Test Case
CFD (200 sec)
SVD ROM (200 sec)
CFD (400 sec) CFD (600 sec) CFD (800 sec)
SVD ROM (400 sec)
SVD ROM (600 sec)
SVD ROM (800 sec)
X. Hu, S. Asgari, I. Yavuz, S. Stanton, C-C Hsu, Z. Shi, B. Wang, H-K Chu, “A Transient Reduced Order Model for Battery Thermal Management Based on Singular Value Decomposition,“ Submitted to ECCE 2014.
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24 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Temperature Distribution - Animation
Temperature calculated from CFD. 7 hr simulation time with 6 CPUs.
Temperature calculated from SVD ROM. 0.5 hr simulation time with 1 CPU.
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26 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
ECM calculates heat source and sends it to the two ROMs.
LTI ROM calculates average temperature and sends it to ECM.
SVD ROM calculates temperature distribution.
GM Battery Module – ECM Coupled with ROMs
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27 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
ROMs/ECM Coupled Results
LTI ROM calculates average temperature.
SVD ROM calculates temperature field. – Needs to be post-processed back in FLUENT.
ECM calculates electrical performance.
Average Cell Temperature Battery Voltage as a Function of Time
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28 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Module/Pack Level – Bus Bar Model
Electromagnetic FEA Analysis for Busbar RLC Network Extraction
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29 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Full Battery Simulation
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)
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30 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
System Assembly
Battery ROM Inverter ROM Machine ROM
Embedded Software
Behavioral Models
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31 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
HIL
PIL
SIL
MIL
Plant Model Embedded Controller
Control Software Development
C code
Desig
n Im
plem
entatio
n
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32 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Control Software Development Bringing Aerospace Safety Best Practices to Automotive SCADE = Safety Critical Application Development Environment Certified Automatic Embedded Code Generation
Certified Embedded Code Generation: ISO 26262 certification up to ASIL D
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33 © 2014 ANSYS, Inc. August 21, 2014 ANSYS Confidential
Summary
Effective virtual product development of batteries needs combination of
High fidelity physics and chemistry models
Circuit/system level models
Reduced Order Methods (ROMs) are key enablers for combining high fidelity and system models
Such high accuracy, fast-running models can be used for many development purposes, including controller software development
Bringing Aerospace best practices, to improve development of automotive embedded systems