1 © 2015 ANSYS, Inc. ANSYS Confidential Simulation helps designing More Electric Aircraft Laurent Bracq ANSYS
1 © 2015 ANSYS, Inc. ANSYS Confidential
Simulation helps designing More Electric Aircraft
Laurent Bracq
ANSYS
2 © 2015 ANSYS, Inc. ANSYS Confidential
Aircraft Energy Consumption Key aircraft components and functions
High Medium Low
Presence of electrical power
Energy consumption
Flight control and operations Avionics, cockpit displays, navigation systems …
Power generation management Engine & generator management, fuel supply …
Configuration management Actuation of landing gear, brakes, deicing …
Passenger confort Lights, galleys, IFE, connectivity …
Air pressurization and conditioning Cabin ventilation, pressure systems …
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Aircraft electrical systems
Starter generators APU RAT
PEPDS SPDS Conversion Ventilation
Electrical braking system
Green taxiing system Reverser actuation system
Landing gear doors system
Power Generation
Distribution
Electrical Equipment
Wiring
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More Electric Aircraft Motivation
→Removal of hydraulic system • reduced system weight • ease maintenance
→“Bleedless” engine • improved efficiency
Reduced operating costs
Reduced fuel burn
Reduced environmental impact
→Controllability • power on demand
→Reconfigurability • maintain functionality during faults
→Advanced diagnostics / prognostics • more intelligent maintenance • increased aircraft availability
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Model-Based Systems Engineering (MBSE)
Detailed Design
Embedded Software, Electronics, Physics Hardware
Functional and Architectural Analysis
Modelling of functions and Architecture
Operational Analysis
Modelling of operational scenarios
Requirements Analysis
Manage textual requirements (Doors, Word, Excel…)
1
3
2
4
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Detailed Design 3D Multiphysics
Software Engineering
ANSYS Solution for MBSE System
Validation
Sub-System Integ. & Verification
Component Integration & Verification
Requirements and Specifications
Sub-System Design
System Functional & Architectural Design
Mechanical Electrical Software
Detailed Design & Optimization
Systems Functional Engineering
0D Physical Modeling
Electromagnetics Thermal Mechanical
EMC / EMI
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ANSYS Systems Solutions
SCADE System: Model-Based Systems Architectural and Functional Design Standards-based (SysML & Eclipse-based) System/Software Synchronisation
Simplorer: E/E systems simulation and virtual prototyping Adheres to physical laws 3D precision when needed Leader in power electronics and eletromechanical
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ANSYS Simplorer
Unmatched Versatility for E/E Systems Simulation Standard modeling languages, mixed digital and analog solver
technology, and standard cosimulation interfaces for simulation of electrical, electronics and embedded software systems
Adheres to Physical Laws Behind every modeling component is a corresponding
conservation law that ensures real-world physics are being respected
Systems
Leader in power electronics simulation Rich modeling libraries and design automation designed especially for high-
performance power electronics and electromechanical simulation
3-D Precision When You Need It Cosimulation with 3-D solvers and reduced-order modeling (ROM) captures complex multi-physics interactions when
precise system verification is required
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ANSYS SCADE System
Model-Based Systems Engineering Complete standards-based model-based systems
Engineering environment (SysML & Eclipse-based)
Functional and Architectural Design Supports industry and customer specific systems
engineering configurability (such as IMA) as well as model-based SE data management via open data
dictionary
System/Software Synchronization Enables modular system design and verification,
Automatic I/O definition synchronization , Interface Control Documents production
and Team Collaboration support
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Aircraft Electrical Systems Library
• Complete set of blocks for modeling aircraft electrical power systems
• Over 70 models and examples
• Generators, converters, rectifiers, machines & drives, loads
• For a range of simulation studies:
• Power Quality
• System Stability
• Protection & Fusing
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Explore & Optimize System Performance
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ANSYS Solution for Power Systems
Power Distribution
(cable)
Power
Distribution -
fault protection, switchgear
Power Source
Power Conversion /
Inversion
Electrical Loads
Electro- Mechanical
Loads
13 © 2015 ANSYS, Inc. ANSYS Confidential
ANSYS Simplorer System Design
PP := 6
ICA:
A
A
A
GAIN
A
A
A
GAIN
A
JPMSYNCIA
IB
IC
Torque JPMSYNCIA
IB
IC
Torque
D2D
ANSYS Maxwell 2D/3D FEA Analysis
HF/SI
HFSS, Q3D, SIWave
RLCG Parasitics
ANSYS
Mechanical Thermal/Stress
ANSYS CFD Thermal
Model order Reduction
Co-simulation
Field Solution
FE Model Generation
Optimetrics
LS-DSO
SCADE Suite Control Systems
Embedded Design
Push Back Excitations
PExprt Magnetics
RMxprt Machine Design
ANSYS Solution for Power Systems
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ANSYS Solution for Power Systems
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Close loop control, Full Details
• Complete Software Controller
• Complete description of electric drive
• With detailed IGBTs
• Machine
• Cooling system
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IGBT device: Device Parameter Extraction
Infineon : eupec FZ600R12KE3
Simplorer Device Characterization Tool automatic parameter fitting from data sheet
0.00 1.00 2.00 3.00 4.00 5.00Vce.V [V]
0.00
200.00
400.00
600.00
800.00
1000.00
1200.00
Ic.I [A
]
x02_OutputOutput Char. @Tj=125c
Curve Info
Ic.ITR
Output Vce-Ic
Vg=17 15 11
9
Product Data sheet
Simplorer
Characterization Tool
Device Model
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Equivalent Thermal Circuit Model (IGBT&Diode)
IGBT Diode
25℃
特性抽出ツール
0 650.0 125.0 250.0 375.0 500.0 0
70.00
10.00
20.00
30.00
40.00
50.00
60.00
E=f(Ic)
Eon
Eoff
I [A]
E
[mJ]
1k * igbt_... 1k * igbt_...
Eon = f... Eoff = f...
20.0 140.0 40.0 60.0 80.0 100.0 120.0 15.00
40.00
17.50
20.00
22.50
25.00
27.50
30.00
32.50
35.00
37.50
E=f(Tc)
Eon
Eoff
E
[mJ]
Tc [C]
IGBT device: Thermal Impedance Extraction
Characterization Tool
Infineon : eupec FZ600R12KE3
Product Data sheet
Simplorer
Simplorer Device Characterization Tool automatic parameter fitting from data sheet
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EMI analysis by Q3D LRC extraction
Circuit Model ・DC or AC
Static
Circuit Model ・DC or AC
State Space Model ・Freq. Sweep
Dynamic
Equiv. Circuit
Project info.
R/L vs Freq.
DC Circuit Model
AC Circuit Model
State Space / IFFT Model
Q3D Simplorer
ANSYS Solution for RLC Extraction
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ANSYS Solution for RLC Extraction Cable Design Toolkit
Bounds Noise
Surge Noise
Geometry: 2D with skew
0
0
0
0
0 0 0000
00
0
0
E1
E2
E3
TFR3P6WL1
R4
R5
R6
armor_A
core_A_A
core_B_A
core_C_A
sheathA_A
sheathB_A
sheathC_A
armor_B
core_A_B
core_B_B
core_C_B
sheathA_B
sheathB_B
sheathC_B
R7 R8 R9R10R11R12
R13
R14
S1 R16
M3 ~
BA
C
IM1
MASS_ROT1S2
S3
S4
Q3D Simplorer
20 © 2015 ANSYS, Inc. ANSYS Confidential
ANSYS Solution for Electric Machines
Enter Design Parameters
and Evaluate Design
Tradeoffs
Sizing
Predict Design
Performances
Efficiency Optimization
Optimize Cooling,
Noise and Bearing Life
Thermal Vibration
Interactions with Power Electronics and Control
Drive Control System
21 © 2015 ANSYS, Inc. ANSYS Confidential
Electric Machines Design Flow
Enter Design Parameters
and Evaluate Design
Tradeoffs
Sizing
Predict Design
Performances
Efficiency
Optimize Cooling,
Noise and Bearing Life
Thermal Vibration
Interactions with Power Electronics and Control
Drive Control System
→ Optimal Motor Dimensions → Coil Arrangements → Machine Performance Metrics
→ Rapid Sizing of Motors/Generators → Parameterize any of the over 50 Inputs → 30%-40% Time Savings Compared to Traditional Method
22 © 2015 ANSYS, Inc. ANSYS Confidential
Electric Machines Design Flow
Enter Design Parameters
and Evaluate Design
Tradeoffs
Efficiency Optimization
Predict Design
Performances
Efficiency
Optimize Cooling,
Noise and Bearing Life
Thermal Vibration
Interactions with Power Electronics and Control
Drive Control System
→ Minimise Losses → Minimize Magnet Size → Reduce Cogging and Ripple Torque
→ Advanced Magnetic Material Modeling → 20% of Rare Earth Magnet Size Reduction → Automated Prediction of Efficiency Maps
23 © 2015 ANSYS, Inc. ANSYS Confidential
Electric Machines Design Flow
Enter Design Parameters
and Evaluate Design
Tradeoffs
Thermal Vibration
Predict Design
Performances
Efficiency
Optimize Cooling,
Noise and Bearing Life
Thermal Vibration
Interactions with Power Electronics and Control
Drive Control System
→ Optimize Cooling → Reduce Noise → Increase bearing life
→ 20% More Accurate Over Single Physics Approach → Reduce NVH Profile by 40% → Increase Bearing Life by 150%
24 © 2015 ANSYS, Inc. ANSYS Confidential
Electric Machines Design Flow
Enter Design Parameters
and Evaluate Design
Tradeoffs
Drive Control System
Predict Design
Performances
Efficiency
Optimize Cooling,
Noise and Bearing Life
Thermal Vibration
Interactions with Power Electronics and Control
Drive Control System
→ Simulate Entire Drive System With Controls
→ Dynamic Performances
→ Integrated Circuit and 2D/3D Simulations → Reduce Late Stage Changes → Reduce Warranty Cost By 40%
25 © 2015 ANSYS, Inc. ANSYS Confidential
Requirement
Req 23: On request, the valve should close in 500us
Functional simulation
500us 0
Pos
true
false t
Behavorial simulation (0D)
t
Pos
0 500us
Virtual Prototyping
t
Pos
500us
Prototypes and Testing
Pmax
500us t
Pos
High fidelity 3D Design
Electronics Design Embedded Software Design
Magnetics Thermal 0.20 0.40 0.60 0.80 1.00
Stroke (Normalized Distance)
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
Y1
TRW / Ansoft Force vs Stroke
Curve Info
ArmStepHeight1='0mm' ArmStepRad1='2
ArmStepHeight1='0.000130288001891299
500us
t
ANSYS Simulation for Actuators
26 © 2015 ANSYS, Inc. ANSYS Confidential
ANSYS Simulation for Actuators
0
0
0
0 0
S
+
SM_TRB1
F
F_TRB2
MASS_TRB1
V0=0m_per_sec
S0=0.5mm
M=1gram
F
F_TRB1
Ide
al
STOP
LOWER_LIM=0.01mm
UPPER_LIM=0.195mm
F
F_mag
F
F_Plunger
F
F_spring
SPRING_TRB1
C=333
S+
S_TRB1
VALUE=0.185mm
E1
R1
T1
T2T3
T4
smpl_lift
cfd_force
S1
CTRL=S1
D1
Electromagnetics Fluid
0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]
0.00
100.00
200.00
300.00
400.00
500.00
Po
sitio
n [u
m]
0.00
0.01
0.02
0.03
0.04
0.05
0.06
Co
il C
urr
en
t [A
]
-20.00
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
20.00
Plu
ng
er
Fo
rce
[n
ew
ton
]
02_CoSim_MAgnetic_CFDTransient Switching with CFD ANSOFT
Curve Info Y Axis
Current Current
Plunger Force Plunger Force
Position w. CFD Y3
Position w/o CFD Y3
System
Magnetic Flux Density vs Time Includes Magnetic Diffusion Coil Temperature
Deformation
27 © 2015 ANSYS, Inc. ANSYS Confidential
ANSYS Solution for Batteries C
ELL
Elec
tro
chem
istr
y C
ELL
& M
OD
ULE
Th
erm
al
PA
CK
Th
erm
o-E
lect
ric
• Electrochemistry models, Geometry Soc, Voltage, Ohm losses, temp
• Data (Voc vs SoC, V under discharge) Equivalent Circuit Model
• Cooling, Cells connections Temperatures
Thermal Model
Thermo-electric Model
DATA
ROM
Assembly Mgt
3D 0D
28 © 2015 ANSYS, Inc. ANSYS Confidential
ANSYS Solution for Batteries
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ANSYS Solution for Cockpit
Structural & Fatigue & Explicit Thermal
Electrical
Acoustics
Software & System
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ANSYS Solution for Direct Strike
Current flowing on cables, here at 1MHz
Plot PeakH vs. distance along the whole cable length for each frequency.
Transient Thermal
31 © 2015 ANSYS, Inc. ANSYS Confidential *BusinessWeek, FORTUNE
ANSYS Strengths
FOCUSED This is all we do. Leading product technologies in all physics areas Largest development team focused on simulation
CAPABLE 2,600+
75
40
employees
locations
countries
TRUSTED
FORTUNE 500 Industrials 96 of the top 100
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
CAD agnostic
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OEMs Airbus Boeing Embraer Bombardier Alenia COMAC IRKUT Tupolev Northrop Grumman Aerospace Systems Lockheed Martin Aerospace Systems General Atomics Bell Sikorsky Eurocopter Agusta Westland
NASA JAXA SpaceX Astrobotic Astrium SP Korolev Rocket and Space Corporation Ampac ISP NEC Toshiba Space Systems Orbital Sciences United Launch Alliance United Space Alliance
Engines GE Aviation Pratt and Whitney Honeywell Rolls Royce MTU Aero Engines ITP Snecma
Suppliers GE Aviation Honeywell UTC Aerospace Systems Safran GKN Meggitt Moog
Northrop Grumman Lockheed Martin Aerospace Systems Thales L-3 Rockwell Collins Raytheon Harris BAE Sagem General Dynamics Cobham Elbit Systems
US Army US Air Force US Navy US DOD DGA AWE DSTL DRDC Lockheed Martin Boeing Northrop Grumman General Dynamics JPL JHU APL Wyle Labs SAIC QinetiQ Raytheon DRS General Dynamics Textron
MBDA Aerojet Rafael Remington Sturm Ruger ATK Roketsan Ruag Diehl BGT
Top Aerospace and Defense Companies Rely on ANSYS Tools
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ANSYS System Solutions @ Airbus
SCADE Suite & SCADE Display have been used in the following A380 systems:
Flight Warning System
Electrical Load Management System
Cockpit Display System
ATSU (Board / Ground communications)
Braking and Steering System
Flight Control System
Anti Icing System
FADEC (Engine Control)
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ANSYS provides market-leading depth and breadth of capabilities in one discipline, while allowing for integrated simulation across all disciplines
Products Overview: Leaders in the Field
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ANSYS solutions deliver value across a wide range of aerodynamic, aeroacoustic and multidisciplinary design optimization applications
Drag prediction workshop
Aeroelasticity prediction workshop
High lift prediction workshop
Aero-acoustics
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ANSYS solutions deliver value across a wide range of aerostructural, composite material and aerothermal applications
Building block simulations from coupons to airframes
Impact (e.g. bird strike)
Optimization and multifunctional simulations for composites
Integrated aero-thermal-structural simulations
Lightning
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ANSYS solutions deliver value across a wide range of aircraft systems applications
Environmental control systems
Avionics and Embedded code
- Control - Display - Requirements Management - Auto-generation of certified code
-ARINC 661 compliant -DO 178B Level A -DO 178C ready -Def Stan 00-56 -FACE Consortium
ANSYS solutions in place on: -Airbus (A318 Elite, A340, A380, A350, A320 Neo -Boeing (787, 747-8) -COMAC (C919) -Irkut-OAK MS 21 -Bombardier CRJ1000, C Series -Embraer Phenom 100/300 -Eurocopter AS350, EC 135/145/155/225 -Sikorsky S76D
Mechanical/Hydraulic systems
De-icing systems
Passenger safety
Mechantronics for the “More Electric Aircraft”
*Courtesy of Parker Aerospace
Batteries and power electronics