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EV/HEV Value Chain

and Battery Design


Sandeep Sovani
Zed Tang
Mark Christini

January 26, 2011 ANSYS Sales Conference


2011 ANSYS, Inc. All rights reserved.

11

ANSYS, Inc. Proprietary

Outline
EV/HEV Market
Trends
Value Chain

EV/HEV Simulation

Integrated Simulation
Battery
Traction Motor
Power Electronics

Key Problems and Simulation Needs


ANSYS Solutions
Competition Analysis and Differentiators
R13 Advances
2011 ANSYS Targets

Success Stories
2011 Marketing Campaign
2011 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Market Trends
The automotive powertrain has changed for good

I.C. Engine
Powertrain

I.C. Engine
Powertrain

Augmented
with

Electric
Powertrain

Electric
Powertrain

Hybrid Powertrain
NEW

OLD

FUTURE

A once-in-a-lifetime landslide change


2011 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Market Trends
Why?
Environmental concerns in the west
Oil dependence concerns in the east

Ref:
Hazimeh,
PRTM
Consultants,
2011
ANSYS,
Inc. AllO.
rights
reserved.

50% Battery Cost Reduction, EV


MI, USA
ANSYS,
Inc. Proprietary
4 Battery Technology Conference, Sept 21-22, 2010, Troy,

Market Trends
Types of Hybrid Electric Vehicles

Micro
Hybrid
HEV

PHEV

ER-EV

BEV

FCEV

xEV = General term to reference all types of EVs


Ref: Bly, M. General Motors, Developing a Battery Value Chain, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA
2011 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Market Trends

Ref:
Hazimeh,
PRTM
Consultants,
2011
ANSYS,
Inc. AllO.
rights
reserved.

50% Battery Cost Reduction, EV


MI, USA
ANSYS,
Inc. Proprietary
6 Battery Technology Conference, Sept 21-22, 2010, Troy,

Market Trends

2011 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Market Trends
Electric Powertrain Power Flow
Control

Power
Source

Battery/BMS

Power
Electronics

Inverter/Busbar

Electric
Machine

Mechanical
Components

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

2011 ANSYS, Inc. All rights reserved.

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
2011 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Market Trends

Ref:
Bly, M.
General
Motors,
2011
ANSYS,
Inc.All
rights reserved.

Developing a Battery Value Chain, EV Battery


Technology Conference, Sept 21-22, 2010, Troy, MI,
USAInc. Proprietary
ANSYS,
10

Outline
EV/HEV Market
Trends
Value Chain

EV/HEV Simulation

Integrated Simulation
Battery
Traction Motor
Power Electronics

Key Problems and Simulation Needs


ANSYS Solutions
Competition Analysis and Differentiators
R13 Advances
2011 ANSYS Targets

Success Stories
2011 Marketing Campaigns
2011 ANSYS, Inc. All rights reserved.

11

ANSYS, Inc. Proprietary

EV/HEV Value Chain

Y2020 Estimates

Sample Business Initiatives

Ref: Hazimeh, O. PRTM Consultants, 50% Battery Cost Reduction, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA
2011 ANSYS, Inc. All rights reserved.

12

ANSYS, Inc. Proprietary

Battery Value Chain

Ref: Hazimeh, O. PRTM Consultants, 50% Battery Cost Reduction, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA
2011 ANSYS, Inc. All rights reserved.

13

ANSYS, Inc. Proprietary

EV/HEV Value Chain

Ref: Hazimeh, O. PRTM Consultants, 50% Battery Cost Reduction, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA
2011 ANSYS, Inc. All rights reserved.

14

ANSYS, Inc. Proprietary

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
2011 ANSYS, Inc. All rights reserved.

15

ANSYS, Inc. Proprietary

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
2011 ANSYS, Inc. All rights reserved.

16

ANSYS, Inc. Proprietary

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
2011 ANSYS, Inc. All rights reserved.

17

ANSYS, Inc. Proprietary

Outline
EV/HEV Market
Trends
Value Chain

EV/HEV Simulation

Integrated Simulation
Battery
Traction Motor
Power Electronics

Key Problems and Simulation Needs


ANSYS Solutions
Competition Analysis and Differentiators
R13 Advances
2011 ANSYS Targets

Success Stories
2011 Marketing Campaigns
2011 ANSYS, Inc. All rights reserved.

18

ANSYS, Inc. Proprietary

EV/HEV Simulation
Message to Executive Decision Makers

Numerical Simulation will be a key differentiator


in the electrification competition
Numerical Simulation is particularly advantageous in
electrification development
Firms that strategically deploy numerical simulation will
gain significant competitive advantage

2011 ANSYS, Inc. All rights reserved.

19

ANSYS, Inc. Proprietary

EV/HEV Simulation

Why is Numerical Simulation


particularly advantageous in
electrification development?

2011 ANSYS, Inc. All rights reserved.

20

ANSYS, Inc. Proprietary

EV/HEV Simulation

Challenges in
developing disruptive
innovations
No precedence
Many unknowns
New paradigms
Uncertainty

Time pressure
Last powertrain took
~100 years to develop

New powertrain
expected in ~10 years
2011 ANSYS, Inc. All rights reserved.

21

ANSYS, Inc. Proprietary

EV/HEV Simulation
Many Choices
Many Decisions

Established Demands

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

Safety
Reliability
Cost
Life

Same as or surpassing
current vehicle standards

Multitude of ideas need to be generated, digested,


validated, developed, tested, perfected, delivered, in
a short time
2011 ANSYS, Inc. All rights reserved.

22

ANSYS, Inc. Proprietary

EV/HEV Simulation
Multitude of ideas need to be generated, digested,
validated, developed, tested, perfected, delivered, in a
short time

Numerical Simulation is particularly well


suited for this need; provides

In-depth engineering insights


Speedy design evaluation via virtual testing
Enabler of fast, extensive design

2011 ANSYS, Inc. All rights reserved.

23

ANSYS, Inc. Proprietary

EV/HEV Simulation
ANSYS Positioning Message
Next Generation Simulation for Next Generation Vehicles
Old Paradigms

New Paradigms

Component Simulation

Integrated Simulation
(Component and System)

Single Physics

Multiphysics Simulation
(Flow, thermal, structural,
electrical, electrochem.)

Few Instances

Extensive Automated
Design Exploration
ANSYS Differentiators

Competitors Propositions
2011 ANSYS, Inc. All rights reserved.

24

ANSYS, Inc. Proprietary

Outline
EV/HEV Market
Trends
Value Chain

EV/HEV Simulation

Integrated Simulation
Battery
Traction Motor
Power Electronics

Key Problems and Simulation Needs


ANSYS Solutions
Competition Analysis and Differentiators
R13 Advances
2011 ANSYS Targets

Success Stories
2011 Marketing Campaigns
2011 ANSYS, Inc. All rights reserved.

25

ANSYS, Inc. Proprietary

Integrated Simulation
What is Integrated Simulation?
Control

Power
Source

Battery/BMS

Power
Electronics

Inverter/Busbar

Electric
Machine

Mechanical
Components

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

2011 ANSYS, Inc. All rights reserved.

26

ANSYS, Inc. Proprietary

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

2011 ANSYS, Inc. All rights reserved.

27

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
2011 ANSYS, Inc. All rights reserved.

28

ANSYS, Inc. Proprietary

Integrated Simulation
ANSYS Differentiator: No competitor can perform
integrated simulation with the same multiphysics
breadth and depth as ANSYS

2011 ANSYS, Inc. All rights reserved.

29

ANSYS, Inc. Proprietary

Outline
EV/HEV Market
Trends
Value Chain

EV/HEV Simulation

Integrated Simulation
Battery
Traction Motor
Power Electronics

Key Problems and Simulation Needs


ANSYS Solutions
Competition Analysis and Differentiators
R13 Advances
2011 ANSYS Targets

Success Stories
2011 Marketing Campaigns
2011 ANSYS, Inc. All rights reserved.

30

ANSYS, Inc. Proprietary

Battery: Key Problems

Overall Concerns:
Cost
Life
Safety
Power Density

2011 ANSYS, Inc. All rights reserved.

Cell
Manufacturing

Thermal Management
(Temperature Uniformity)

Material
Behavior in Cell
Assembly

Safety, Crash, Abuse

Ageing, Life

Battery Management
System and Algorithms

NVH, Durability

31

Battery
Performance in
Vehicle Level Test
Cycles
Load Matching for
Charging
Discharging
ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level Simulation

Cell Level Simulation

System Level Simulation

2011 ANSYS, Inc. All rights reserved.

32

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level
ANSYS Workbench An Integrated Solution for Battery CFD
Analysis

2011 ANSYS, Inc. All rights reserved.

33

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level

Build-in What-if Study in WB

2011 ANSYS, Inc. All rights reserved.

34

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level
HEV Battery Thermal Management: Six Sigma Analysis

Ref: Valhinos et al, Improving Battery Thermal Management Using Design for Six Sigma
Process, 20th Electric Vehicle Symposium, Long Beach, CA (November 15-18, 2003)
2011 ANSYS, Inc. All rights reserved.

35

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level

Reduced Order Modeling

2011 ANSYS, Inc. All rights reserved.

36

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level
Reduced Order Model Extraction Process Using Simplorer

2011 ANSYS, Inc. All rights reserved.

37

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level

LTI (Foster Network) vs ANSYS FLUENT

2011 ANSYS, Inc. All rights reserved.

38

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level

Additional
Information on LTI

Separate training
material exists for
LTI method.
2011 ANSYS, Inc. All rights reserved.

39

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level

Battery Bus Bar Heating Multiphysics Simulation


For steady (or low frequency) currents under
temperature dependent conductivity

2011 ANSYS, Inc. All rights reserved.

40

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level

Coupled Simulation in ANSYS FLUENT

2011 ANSYS, Inc. All rights reserved.

41

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level

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 create


these demonstration cases

2011 ANSYS, Inc. All rights reserved.

42

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level Simulation

Cell Level Simulation

System Level Simulation

2011 ANSYS, Inc. All rights reserved.

43

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Cell Level

Cell Manufacturing: Coating Analysis

2011 ANSYS, Inc. All rights reserved.

Courtesy: ANSYS Japan Technical Team


44

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Cell Level

Cell Manufacturing: Flow Inside Die

2011 ANSYS, Inc. All rights reserved.

Courtesy:
ANSYS Japan Technical Team
ANSYS, Inc. Proprietary
45

Battery : ANSYS Solutions


Cell Level

Cell Electrical Model:


Simple enough for system
level analysis
Detailed electrochemistry models
are too time consuming for system
level 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

2011 ANSYS, Inc. All rights reserved.

46

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Cell Level

Single Cell Thermal Model


Model based on:
- Newman &
Tidemann (1993);
- Gu (1983) ;
- Kim et al (2008)*

2011 ANSYS, Inc. All rights reserved.

47

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Cell Level

Electrochemistry: Newmans 1D Model in Simplorer

2011 ANSYS, Inc. All rights reserved.

48

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Cell Level

3D Electrochemistry Modeling

2011 ANSYS, Inc. All rights reserved.

49

ANSYS, Inc. Proprietary

Battery : ANSYS Solutions


Pack Level Simulation

Cell Level Simulation

System Level Simulation

2011 ANSYS, Inc. All rights reserved.

50

ANSYS, Inc. Proprietary

Battery: ANSYS Solutions


System Level

Pack Circuit Model

5
cells

60 Cells connected in matrix pack


Packs are connected in matrix to
final configuration
2011 ANSYS, Inc. All rights reserved.

51

ANSYS, Inc. Proprietary

Battery: ANSYS Solutions


System Level
Battery in Control System with Motor Controller

2011 ANSYS, Inc. All rights reserved.

52

ANSYS, Inc. Proprietary

Battery: Competition Analysis


CD-Adapco
Pack Level
CD-Adapco

ANSYS

Basic CFD needed for


Battery Simulation

Comparable to ANSYS

Comparable

Design Exploration

Rudimentary
parameterization

SpaceClaim and
DesignXplorer give
advantage

LTI Method

No comparable solution

Easy Simplorer based


solution

Please do no display this slide outside of the ANSYS and ANSYS Channel Partner Organizations
2011 ANSYS, Inc. All rights reserved.

53

ANSYS, Inc. Proprietary

Battery: Competition Analysis


CD-Adapco
Cell Level
CD-Adapco

ANSYS

Cell Electrical Model

Partnership with Battery


Design LLC. Provides
advantage in standard
cell characteristics and
cell material properties

Simplorer based model.


Needs cell properties as
input.

Cell Thermal Model

Demonstrated examples

Comparable capability

1D Electrochemistry

No demonstrated
solution

Simplorer based solution

3D Electrochemistry

Some demonstrated
examples

Some demonstrated
examples

Please do no display this slide outside of the ANSYS and ANSYS Channel Partner Organizations
2011 ANSYS, Inc. All rights reserved.

54

ANSYS, Inc. Proprietary

Battery: Competition Analysis


CD-Adapco
Multiphysics and System Level
CD-Adapco

ANSYS

Multiphysics (E.g. bus


bar deformation)

No comparable solution

ANSYS core advantage

Durability, Impact, Abuse

No direct solution

ANSYS mechanical

NVH

Some acoustics models,


no structural solution

Broadband acoustics
models 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
2011 ANSYS, Inc. All rights reserved.

55

ANSYS, Inc. Proprietary

Battery: Competition Analysis


Resources
More information on automotive google site:

https://sites.google.com/a/ansys.com/automotive/
https://sites.google.com/a/ansys.com/automotive/marketingmaterial/campaign-1/battery/general-references
2011 ANSYS, Inc. All rights reserved.

56

ANSYS, Inc. Proprietary

Battery: 2011 Targets


OEMs
All major car, truck OEMs have ambitious
electrification plans: All are targets
Battery Suppliers
Over 150 battery companies
in 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
2011 ANSYS, Inc. All rights reserved.

57

ANSYS, Inc. Proprietary

Outline
EV/HEV Market
Trends
Value Chain

EV/HEV Simulation

Integrated Simulation
Battery
Traction Motor
Power Electronics

Key Problems and Simulation Needs


ANSYS Solutions
Competition Analysis and Differentiators
R13 Advances
2011 ANSYS Targets

Success Stories
2011 Marketing Campaigns
2011 ANSYS, Inc. All rights reserved.

58

ANSYS, Inc. Proprietary

Traction Motor Key Problems


and 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 effects
through 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
2011 ANSYS, Inc. All rights reserved.

59

ANSYS, Inc. Proprietary

Traction Motor Key Problems


and Simulation Needs

More Innovative and Complex Designs

19 machine types to choose from


Different machine geometry templates

2011 ANSYS, Inc. All rights reserved.

60

ANSYS, Inc. Proprietary

Traction Motor Key Problems


and Simulation Needs
Integration with Controls and Power Electronics

Electric Machine does not work by itself;


two optimized components do not add up
to be an optimized system; integrated
motor / electronics / control simulation is
needed

Phase Current

17 2.00

R A.I [A]
R B.I [A]
R C .I [A]

10 0.00

- 10 0.00
- 17 2.00
74 .9 5m

2011 ANSYS, Inc. All rights reserved.

80 .0 0m

85 .0 0m

61

ANSYS, Inc. Proprietary

Traction Motor Key Problems


and Simulation Needs

Multiphysics Coupling
Thermal-Stress with Electromagnetic Force load

The electromagnetic force density


from Maxwell is used as load in
Structural
2011 ANSYS, Inc. All rights reserved.

Deformation of the stator

62

Deformation of coils

ANSYS, Inc. Proprietary

Traction Motor Key Problems


and Simulation Needs
Shorten Time to Market

Host

Nodes

Let computers work 24/7, freeing engineers


time for other important tasks

Parametric variations: 2,200


Solve time, one processor: 7.6 days
Solve time, distributed, 48 COREs: 4.5 hours

Speed improvement:
2011 ANSYS, Inc. All rights reserved.

43.2X
63

ANSYS, Inc. Proprietary

Traction Motor Competition


Analysis and Differentiators
ANSYS Simulation Driven Product Development
Electric Machine Design Methodology
ANSYS offers

Functionality

Competition

Electromagnetic Finite
Element Solvers

JMag, FLUX, MagNet,

Simplorer

Circuit/System
Simulator

Saber, PSpice,
Matlab/SIMULINK,

ANSYS
Mechanical/CFD

Stress, Thermal

Abaqus, STAR-CD,

Maxwell

Q3D

Parasitics Extraction

DX, MPO, DSO

Design Automation &


Optimization

RMxprt

2011 ANSYS, Inc. All rights reserved.

Closed-form analytical
solution, quickly reduce
design space

64

SPEED, MotorSolve

ANSYS, Inc. Proprietary

Traction Motor Competition


Analysis and Differentiators
ANSYS Simulation Driven Product Development
Electric Machine Design Methodology
ANSYS offers
Maxwell
ANSYS
Simplorer

Electric
Mechanical/CFD

Machine
Q3D
DX, MPO, DSO

Design
RMxprt

Methodology
2011 ANSYS, Inc. All rights reserved.

Functionality

Competition

Electromagnetic Finite
Element Solvers

JMag, FLUX, MagNet,

Fully
Integrated
Stress, Thermal
Electric
Mechine
Parasitics
Extraction
System
Design
Automation &
Optimization
Design
Circuit/System
Simulator

Closed-form analytical
solution, quickly reduce
design space

65

Saber, PSpice,
Matlab/SIMULINK,
Abacus, STAR-CD,

NONE!
SPEED, MotorSolve

ANSYS, Inc. Proprietary

Traction Motor ANSYS 13.0


Advances

Ansoft Tools inside ANSYS Workbench


Easier and more efficient coupling
Using DM for geometry
Using DX for optimization/statistical study
Maxwell TAU Meshing
More robust and efficient
Can use MP license
More Robust DSO
Easier to set up
Speed, scalability getting even better
2011 ANSYS, Inc. All rights reserved.

66

ANSYS, Inc. Proprietary

Traction Motor 2011 ANSYS


Targets
General Trends
It takes years for major auto OEMs to realize
that they have to control their own destiny in
terms of designing traction motors by
themselves. For example, GM. Ford is
starting to realize that.
It also takes years for motor suppliers to
realize that they need to re-design a motor for
auto traction application.

2011 ANSYS, Inc. All rights reserved.

67

ANSYS, Inc. Proprietary

Traction Motor 2011 ANSYS


Targets
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 to


more
Magnetics design -> Structural/Thermal -> Electronics

Use success story in traction motor and apply to


other applications
Battery, electronics, system integration, EMI/EMC

2011 ANSYS, Inc. All rights reserved.

68

ANSYS, Inc. Proprietary

Traction Motor 2011 ANSYS


Targets
Expand Success to Major Suppliers and
Commercial Vehicles/Off-highway Vehicles
Suppliers Want to do More too
Commercial Vehicle companies have huge interest
in HEV/EV too
Eaton Trucks, Prestolite, ArvinMeritor, etc.

Off-highway industry also starts looking into


HEV/EV
CAT, John Deere, Cummins, etc.

2011 ANSYS, Inc. All rights reserved.

69

ANSYS, Inc. Proprietary

Traction Motor 2011 ANSYS


Targets
Expand Success to other Motor Areas
Power Steering, Electric Pumps, Wind
Shields, etc.
These applications have the same physics
(motor, controller, power source/electronics,
mechanical components)
HEV/EVs need new designs for these
applications because requirements are very
different from traditional vehicles

2011 ANSYS, Inc. All rights reserved.

70

ANSYS, Inc. Proprietary

Outline
EV/HEV Market
Trends
Value Chain

EV/HEV Simulation

Integrated Simulation
Battery
Traction Motor
Power Electronics

Key Problems and Simulation Needs


ANSYS Solutions
Competition Analysis and Differentiators
ANSYS 13.0 Advances
2011 ANSYS Targets

Success Stories
2011 Marketing Campaigns
2011 ANSYS, Inc. All rights reserved.

71

ANSYS, Inc. Proprietary

HEV Power Electronics Key


Problems and Simulation Needs
Energy
High
Power
Distribution
Management
Typical
HEV
SystemSystems
Systems

Charging Systems

(internal use only)


2011 ANSYS, Inc. All rights reserved.

72

ANSYS, Inc. Proprietary

HEV Power Electronics Key


Problems and Simulation Needs

Control

Thermal
System
Digital

2011 ANSYS, Inc. All rights reserved.

73

ANSYS, Inc. Proprietary

HEV Power Electronics


ANSYS Solutions
ANSYS is the only provider
of a complete power
electronics design solution
for Hybrid Electric Vehicles!
Simulink
Simplorer

Co Simulation

Mathcad
ModelSIM

2011 ANSYS, Inc. All rights reserved.

74

ANSYS, Inc. Proprietary

HEV Power Electronics


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
2011 ANSYS, Inc. All rights reserved.

75

ANSYS, Inc. Proprietary

HEV Power Electronics


ANSYS System Solutions

System

Simplorer
Circuit
Subsystem

Q3D,
Xprt Tools
ANSYS
Maxwell, HFSS
Mechanical,
FEA solvers
CFD, Icepak

Component

2011 ANSYS, Inc. All rights reserved.

Thermal Fluidic

Electromagnetic

76

Mechanical

ANSYS, Inc. Proprietary

HEV Power Electronics


ANSYS Coupled Solutions
ANSYS CFD
Thermal

Simplorer
System Design

RMxprt
Motor Design

PMSYNC

IA
A

Torque
A

IB

D2D

ICA:

IC

PP := 6

GAIN

Q3D
Parasitics

ANSYS
Mechanical
Thermal/Stress

Icepak

PExprt
Magnetics

Maxwell
Electromagnetic Components
Model order Reduction
Co-simulation
Field Solution
Model Generation

2011 ANSYS, Inc. All rights reserved.

77

ANSYS, Inc. Proprietary

HEV Power Electronics


Competitive Differentiators
ANSYS offers Functionality

Differentiators

Circuit/System Simulator

Multi-domain, multi-physics

Maxwell

Electromagnetic Finite Element


Solvers 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 FEA

RMxprt

Closed-form analytical solution


for Motors and Generators

Couples to Simplorer and


Maxwell for complete FEA

Q3D

R,L,C,G parasitic extraction for


wiring harnesses and
interconnects

Frequency dependent model


coupled to Simplorer

ANSYS
Mechanical

Basic Stress and Thermal


Analysis

Couples directly to Maxwell via


Workbench

ANSYS CFD

Thermal analysis using fluid flow

Couples directly to Maxwell

Simplorer

ANSYS Icepak Electronics Cooling


2011 ANSYS, Inc. All rights reserved.

Couples directly to Simplorer


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HEV Power Electronics


Simplorer v8.1 and v9 Advances
Integrated with the ANSYS
Workbench interface. Can be
created and launched from WB
Improved co-simulation capabilities
with Maxwell 3D
Enhanced IGBT Parameterization
Wizard with more accurate fitting
algorithm important for EMC/EMI
analysis
Direct link with ANSYS Icepak
Q3D State-Space Model from SParameters
State-space model to simulate
multi-domain state-space models
Dynamic plot updates and numeric
displays while simulating
2011 ANSYS, Inc. All rights reserved.

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HEV Power Electronics


2011 ANSYS Target #1
Expand Success to other Major Suppliers
of HEV components and systems such as
XYZ Corp.
XYZ Corporation in Detroit is a Tier 1,2 supplier (traditionally
seating) for major automotive OEMs
Previously owned ANSYS Mechanical and ANSYS Icepak
Made a strategic decision several years ago to move into the
automotive power electronics market
Currently developing a high voltage power supply for a HEV
battery 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
2011 ANSYS, Inc. All rights reserved.

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Potential Areas for Simulation

2011 ANSYS, Inc. All rights reserved.

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HEV Power Electronics


2011 ANSYS Target #2
Expand Success to Major Automotive OEMs for radiated
EMC/EMI analysis of power supplies

IGBT Module

Pack 3D
accurate model

Parameters
Extraction

Design and Couplings


Model

IGBT Model

Far Field Study

Tridimensional IGBT pack model and EM study


Parasitic model extraction
IGBT circuit model
Far Field Study for Electric Field EM
Electromagnetic
(EM) study
2011 ANSYS, Inc. All rights reserved.

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Analysis Methodology Using


Different Techniques
FEA / Boundary
Element Method

Finite Element Method

System Simulation

Finite Element
Method

Tridimensional IGBT pack model and EM study


Parasitic model extraction
IGBT circuit model
Far Field Study for Electric Field EM

2011 ANSYS, Inc. All rights reserved.

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IGBT Characterization

SheetScan

2011 ANSYS, Inc. All rights reserved.

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Simplorer to HFSS Radiated Field

E-field @ 100 MHz, Power = 10kW

2011 ANSYS, Inc. All rights reserved.

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HEV Power Electronics


2011 ANSYS Target #2
Expand Success to Major Automotive OEMs for
conducted EMC/EMI analysis of power supplies
Characterize and reduce EMI emissions from Switched
Mode Power Supply (SMPS) by:
- Model SMPS
- Determine critical components in system
- Determine noise attenuating techniques
Detailed Procedure:
Model: Actives and Passives (discrete components
and interconnects)
Use simulations to find critical paths
Focus attention on these paths to mitigate noise
2011 ANSYS, Inc. All rights reserved.

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Modeling Process

Proprietary
Material has
been removed

2011 ANSYS, Inc. All rights reserved.

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System Simulation

Proprietary
Material has
been removed

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Reduction of Conducted EMI

Proprietary
Material has
been removed

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Outline
EV/HEV Market
Trends
Value Chain

EV/HEV Simulation

Integrated Simulation
Battery
Traction Motor
Power Electronics

Key Problems and Simulation Needs


ANSYS Solutions
Competition Analysis and Differentiators
R13 Advances
2011 ANSYS Targets

Success Stories
2011 Marketing Campaigns
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Success Story 1

Company #1
Car Manufacturer

What did they buy?


DSO, Optimetrics, Maxwell
ANSYS CFD, ANSYS Mechanical, DM, DX
What are they using it for?
Electric Motors, Battery, Power electronics

2011 ANSYS, Inc. All rights reserved.

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Success Story 1

Company #1
Car Manufacturer

What did they prefer ANSYS?


Motors: very fast analysis of 1000s of designs
using DSO
Battery: WB workflow integrating multiple
physics
Future growth potential
Structural mechanics & explicit
Simplorer
EKM?
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Success Story 2

Company #2
Battery Manufacturer

Who are they?


A prominent
U.S. battery company
What did they buy?
CFD (Fluent)
What are they using
it for?
Battery Simulation
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Success Story 2

Company #2
Battery Manufacturer

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

2011 ANSYS, Inc. All rights reserved.

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Success Story 3

Company #3
Car Manufacturer

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
2011 ANSYS, Inc. All rights reserved.

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Success Story 3

Company #3
Car Manufacturer

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
2011 ANSYS, Inc. All rights reserved.

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Success Story 4

Company #3
Multinational Parts Supplier

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

2011 ANSYS, Inc. All rights reserved.

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Success Story 4

Company #3
Multinational Parts Supplier

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

2011 ANSYS, Inc. All rights reserved.

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Success Story 5

Company #5
Car Manufacturer

HEV related sale


Maxwell - Motor Design
CFD - Battery Design

See details in Day 4


presentation by Greg Fallon
and Tom Smithyman

2011 ANSYS, Inc. All rights reserved.

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Outline
EV/HEV Market
Trends
Value Chain

EV/HEV Simulation

Integrated Simulation
Battery
Traction Motor
Power Electronics

Key Problems and Simulation Needs


ANSYS Solutions
Competition Analysis and Differentiators
R13 Advances
2011 ANSYS Targets

Success Stories
2011 Marketing Campaigns
2011 ANSYS, Inc. All rights reserved.

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Marketing Campaigns

Proprietary
Material has
been removed

2011 ANSYS, Inc. All rights reserved.

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Thank you!

2011 ANSYS, Inc. All rights reserved.

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