Agenda
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2 ©2020 ANSYS, Inc.
Challenges in Electric Vehicle (Power) Development
• Mileage/Range
Performance • Charge Times
• Operational Life Span
• Crash Worthiness – Passenger
Safety
Safety • Operational Conditions
• Thermal Management (Batteries,
etc.)
• Production
Cost • Warranty/Recall (Reliability)
• Maintenance
ANSYS Platform for EV Powertrain Development
5 ©2020 ANSYS, Inc.
3D CFD Based Modeling Approach in FLUENT
Multi-Scale Physics in Li+ Battery modeled using (MSMD) framework
material electrode pair cell, pack
Separato
Negative
electrod
Positive
electrod
e
e
r
10-9~10-8 10-6~10-4 10-2~100
Multi-Scale Multi-Dimensional (MSMD) Approach
Electrode layer structure is a sub-grid-scale model, not
resolved by mesh
G-H Kim et al, “Multi-Domain Modeling of Lithium-Ion Batteries Encompassing Multi-Physics in Varied length Scales” J.
of Electrochemical. Soc. 158 (8) A955-A969 (2011).
Electrochemistry Models
NTGK Model Newman P2D
− Newman & Tidemann: 1D − Doyle, Fuller & Newman
− Gu: 1D − Physics Based Model
− Kim et al: 2D − Solves for Charge and Mass
− ANSYS: 3D Transport Equations at a
− Semi-Empirical Model Particle/Electrolyte Level
− Relies on Battery’s Discharge − Physical Parameters Required
curves at different C rates and
under different temperature
conditions
ECM Model
− Chen & Rincon-Mora
− Equivalent Circuit Model
− HPPC Testing Data
✔ U.S. Kim et al, “Modeling the Dependence of the Discharge behavior of a Lithium-Ion Battery on the Environmental
Temperature” J. Electrochem. Soc., 158(5), A611-A618 (2001)
✔ M. Chen and G. A. Rincon-Mora, “Accurate Electrical Battery Model Capable of Predicting Runtime and I-V Performance” IEEE
Trans. On Energy Conversion, Vol. 21. No.2 (2006)
✔ M. Doyle, T.F. Fuller and J. Newman. “Modeling of Galvanostatic Charge and Discharge of the Lithium/Polymer/Insertion
Cell”. J. of Electrochemical Soc.. Vol 140, No. 6. 1526-1533 (1993)
Battery Modeling Examples
Battery Module Simulation
Multiphysics Simulation - Thermal Abuse
•
Battery Thermal Abuse Simulation
Structural Impact Damage Zone Electrochemical-Therm
Analysis Characterization al Analysis
(LS-DYNA) (ANSYS Fluent) (ANSYS Fluent)
Decrease in Contact
Deformation Thermal Runaway
Resistance
ANSYS Simulation Platform
…
Electrical & Thermal Perspectives
•
•
Electrical/Electrochemistry Model
Thermal Model
Language-based/Behavioral Language-based/Behavioral
Models Models
- VHDL-AMS, Modelica, C++, - VHDL-AMS, Modelica, C++,
etc. etc.
Equivalent Circuit
- Thermal Network Equivalent Circuit
- Foster Network
ROMs ROMs
-LTI, SVD, etc. -LTI, SVD, etc.
Co-Simulation Co-Simulation
Electrical & Thermal Perspectives
•
•
Electrical/Electrochemistry Model
Thermal Model
Language-based/Behavioral Language-based/Behavioral
Models Models
- VHDL-AMS, Modelica, C++, - VHDL-AMS, Modelica, C++,
etc. etc.
Equivalent Circuit
- Thermal Network Equivalent Circuit
- Foster Network
ROMs ROMs
-LTI, SVD, etc. -LTI, SVD, etc.
Co-Simulation Co-Simulation
ANSYS Battery Design Toolkit (ACT Extension)
Submod
Unit Group Module Pack
el
ANSYS Battery Design Toolkit (ACT Extension)
Submod
Unit Group Module Pack
el
ANSYS Battery Design Toolkit (ACT Extension)
Submod
Unit Group Module Pack
el
ANSYS Battery Design Toolkit (ACT Extension)
Submod
Unit Group Module Pack
el
Validation: Test Data vs. ABDT Twin Builder Model
Pack Voltage of 24-Cell Module during
Five Consecutive US06 Driving
Schedules.
Yen, C., Han, T., Kaushik, S., and Khalighi, B.,
"Application of CAEBAT System Approach for
a Liquid-Cooled Automotive Battery Pack,"
SAE Technical Paper 2016-01-1205, 2016,
doi:10.4271/2016-01-1205.
System-Level Simulation with ABDT in ANSYS Twin Builder
ABDT based Battery Module Model can
be plugged into EV System Model to
estimate range of Battery Module
What is Reduced-Order Modeling (ROM)?
A Reduced-Order Model (ROM) Fluent CFD Simulation:
3 hours on 12 cores
is a simplification of a
high-fidelity dynamical model
that preserves essential behavior
and dominant effects, for the
purpose of reducing solution
time or storage capacity required
ROM Simulation:
for the more complex
TECHNIQUES model.
FOR RANGE OF Real-time
PHYSICS
Fluid Flow, Thermal, Mechanical,
EM SOLVES IN SECONDS (vs.
HOURS)
ROM Techniques Linear Case (Static & Dynamic)
•
Applications
• Electronics/Battery Cooling
• Mechanical vibrations
• • Conducted EMI
• EM actuators & machines
• …
•
ROM Generation Process
ROM preparation
Create the CFD/FEA
model
Stage 1 Input #1 Input #2 Input #n
(step input) (step input) … (step input)
CFD/FEA CFD/FEA
solving solving
System
System response System response
response
to input #2 … to input #n
to input #1
ROM simulation
Actual inputs ROM solution
Stage 2
(for 1, 2, … n) ROM ROM
to actual
inputs
solving
ROM Generation Process
ROM preparation
Create the CFD/FEA
model
Stage 1 Input #1 Input #2 Input #n
(step input) (step input) … (step input)
CFD/FEA CFD/FEA
solving solving
System
System response System response
response
to input #2 … to input #n
to input #1
ROM simulation
Actual inputs ROM solution
Stage 2
(for 1, 2, … n) ROM ROM
to actual
inputs
solving
ROM Step Response A CT’s & Extraction Toolkits
•
Heat Profile
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,“ ECCE 2014.
Battery Model - ECM Coupled with Thermal ROMs
•
•
• Electrical ECM calculates
heat generation rates, which
are passed to the ROMs
Calculated
Temperatures passed
from the ROMs to the
Electrical ECM.
30 ©2020 ANSYS, Inc. / Confidential
Battery Modeling – Systems-Level Perspective
Battery Modeling Toolset Summary
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