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MODEL BASED DESIGN OF
HYBRID AND ELECTRIC POWERTRAINS
Sandeep Sovani, Ph.D.
ANSYS Inc.
October 22, 2013
SAE 2013 Hybrid Powertrain Complexity
And Maintainability Symposium
Acknowledgements:
Scott Stanton, Todd McDevitt, Eric Bantegnie,
Xiao Hu, ANSYS Inc.
SAE INTERNATIONAL
As mechanical, electrical, electronic and software systems in a vehicle are
getting ever more tightly integrated, three key necessities are arising
2
Mechanical/Fluid
Electrical &
Electronics
Software
Mechanical/Fluid
Software
Electrical &
Electronics
Mechatronics
Manage
Complexity
to design innovative,
market leading products
Early & Reliable
Verification
to deliver high quality
products to the market
faster
Coordinate
Interdisciplinary
Engineering
to reduce design changes
and development costs
SAE INTERNATIONAL
The hybrid electric powertrain is the most complex vehicle system
involving diverse interdisciplinary engineering
3
Predicting the behavior of a Hybrid Electric
Powertrain over a drive cycle requires
simulation of multiple domains:
• Mechanical, Hardware
• Electrical, Electronics
• Software
SAE INTERNATIONAL
Simulating the electric powertrain as a complete, interconnected system is
particularly challenging due to fragmentation of simulation tools and
methods at different stages of the product development process
4
System
Validation
Sub-System Integ. &
Verification
Component Integration
& Verification
Requirements and
Specifications
Component Design
System Functional &
Architectural Design
Mechanical Electrical Software
Customer Requirements: Adjust the speed
of my vehicle to keep it at a safe distance
behind the lead vehicle even in fog or heavy
rain
Functional Specification:
The car must adjust its speed
without users control
Alt. A:
Preview
Distance
Control
System
Alt. B
Radar
Cruise
Control
System
Alt. C
Dynamic Laser
Cruise Control
System
System Simulation Testing
Components Testing
Requirements Capture and
Management
Product
Structure
Optimal
Architecture
Mechanical Electrical Software
System Models
Systems Simulation
Detailed Design
& Optimization
Release Product
Manage
Complexity
Coordinate
Interdisciplinary
Engineering
Early & Reliable
Verification
SAE INTERNATIONAL
Systems functional engineering tools, software engineering tools, and
detailed 3D design tools need to be seamlessly integrated to create an
effective tool for handling the complexity of hybrid electric powertrains
5
System
Validation
Sub-System Integ.
& Verification
Component
Integration
& Verification
Requirements and
Specifications
Component Design
System Functional &
Architectural Design
Mechanical ElectricalSoftware
Detailed Design
& Optimization
Systems Functional Engineering
Functional
Allocations
Detailed Architecture
Architecture
Software Engineering
Detailed 3D Design and Simulation
SAE INTERNATIONAL
A multi-fidelity simulation toolset is essential to most effectively meet the
different design needs at different stages of the product development
process
6
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
500us0
Pos
true
false
t
0
500us
t
Pos
Pmax
Actuator
t
Pos
0 500us
t
Pos
Pmax
500us
Pmax
Pmax
SAE INTERNATIONAL
We are testing a comprehensive simulation platform comprised of in-depth
integrated tools to full system simulation of the hybrid electric powertrain
7
System
Design
System Architecture,
System Verification
Detailed
Component
Design
3D Simulations for Fluids,
Thermal, Mechanical,
Electrical, Magnetic
Effects
System &
Software
Lifecycle Mgmt
Certification Plans, Metrics,
Requirements, Configuration
Management,
Documentation
Generation
Circuit Design
and Control
Software Design
Prototyping, Design,
Verification, Qualified
Code Generation
SAE INTERNATIONAL
Requirements Mgmt and
Functional Design
Practices
Requirements analysis
Requirements traceability
Configuration management
Operational and usage analysis
Functional decomposition
Functional simulation
Architectural design & selection
Rapid prototyping
Behavior modeling (0D simulation)
At the highest level system design starts with requirements analysis,
operational and usage analysis, functional decomposition, architectural
design and basic behavioral modeling
8
SAE INTERNATIONAL
At the component design and verification level a data connector bus and
0D simulator forms the central core of the simulation platform
SAE INTERNATIONAL
The second key element at the component design and verification level is a
comprehensive control software development tool set that prototypes and
designs software models, verifies them, and generates certified code
SAE INTERNATIONAL
At the detailed component design level, 3D simulation tools help develop
and optimize the components from fluid, thermal, structural, electrical,
magnetic, acoustic, etc aspects
11
Fluid, Thermal
Simulation of a
Battery Module
Pre-Stressed
Structural Modal
Analysis of a Motor
Electrical Current and
Heating Simulation of
an IGBT
SAE INTERNATIONAL
Example 1:
Integrated power electronics and embedded controls development
12
SAE INTERNATIONAL
Example 1 . . . Continued
An incremental approach is used to design the system
13
SAE INTERNATIONAL
Example 1 . . . Continued
At level 1, open loop electric behavior is studied
14
SAE INTERNATIONAL
Example 1 . . . Continued
At level 1, system validation includes switching commands from embedded
code
15
Switching commands coming
from the Embedded Code
Angle and Torque on the load
SAE INTERNATIONAL
Example 1 . . . Continued
At level 4, closed loop control and detailed electric analysis is performed
16
SAE INTERNATIONAL
Example 1 . . . Continued
At level 4 system validation considers switching commands from
embedded code as well as feedback commands
17
Switching commands coming
from the Embedded Code
and feedback command
Angle and Torque on the load
SAE INTERNATIONAL
Example 2 . . . Continued
Hierarchical IGBT models suite different purposes: A dynamic IGBT model
is necessary for EMI analysis
18
DC core
A
Energy calculation
B
Thermal network
F
DC core
A C
Thermal network
F
Capacities C(V), C(I)
parasitics L, R, C
controlled sources
E
Full parameter excess
Maximum simulation speed:
• Accurate static behavior
• Accurate thermal response
• No voltage and current transients
• Suitable for system design analysis
Average IGBT Model Dynamic IGBT Model
Maximum simulation accuracy:
• Sophisticated semiconductor model
• Accurate dynamic and thermal behavior
• Accurate voltage and current waveforms
• Suitable for drive optimization, EMI/EMC
SAE INTERNATIONAL
Example 2 . . . Continued
Dynamic IGBT model accurately captures switching waveforms
19
Static IGBT for fast system simulations
SAE INTERNATIONAL
Example 2 . . . Continued
Detailed 3D thermal and electrical analysis of the IGBT further improves
waveform accuracy
20
EMI/EMC: Automatic L,R,C Extraction and Network
Model
The structure is meshed
using automatic and
adaptive meshing
Current Distribution
SAE INTERNATIONAL
Example 2 . . . Continued
The IGBT model couples seamlessly with detailed motor model to optimize
the sub-system in an integrated way
21
-22.50
60.00
0
25.00
50.00
0 240.00m100.00m
2DGraphSel1 NIGBT71.IC
Extract Power Loss
0
474.00m
200.00m
400.00m
100.00 1.00Meg1.00k 3.00k 10.00k 100.00k
2DGraphCon1
GS_I...FFT
SAE INTERNATIONAL
The battery pack is hierarchically simulated from the smallest electrode level scale
to the largest pack level scale and a behavioral model of the pack is extracted that
fits in the powertrain system level simulation
Example 3
Total battery simulation
Electrode
Level
•Electrode layout
•Heat source
calculation
•Aging
Molecular
Level
•Material
innovation
•Material
selection
Cell Level
•Charging, dischar-
ging profiles
•Cell level heat
distribution
•Swelling,
deformation
Pack Level
•BMS Logic
•Electrical System
•Cooling Channels
•Cooling Circuits
Powertrain and
Vehicle Level
•System Integration
SmallScale
LargeScale
SAE INTERNATIONAL
Example 3 . . . Continued
Electrochemistry at the cell electrode level is simulated with 1D and 3D
models
23
Impact of Temperature on
Concentration Distribution
Impact of Particle Shape on Capacity
Rate
0.1C
0.5C
1C
3C
5C
10C
Validation of Reduced Order Electrochemistry
[1] X. Hu, S. Stanton, L. Cai, R.E. White, J. Power Sources 214, 40-50, 2012.
[2] X. Hu, S. Stanton, L. Cai, R.E. White, J. Power Sources 218, 212-220, 2012.
SAE INTERNATIONAL
Example 3 . . . Continued
Cell electrical behavior is characterized by simulating electrical, flow and
temperature distributions in the cell in detail
24
Current DensityCathode Anode
  J 
)( UYJ ac  
Temperature
SAE INTERNATIONAL
Example 3 . . . Continued
Cell Equivalent Circuit Models are developed that account for detailed
thermal and electrical effects and are integrated into a module model
25
X. Hu, L. Collins, S. Stanton, S. Jiang, "A Model Parameter Identification Method for Battery Applications", SAE 2013-01-1529.
Battery Pack ECM Model
Simulation Results
Cell Equivalent Circuit
Model (ECM)
SAE INTERNATIONAL
State space based Linear Time Invariant Model
Example 3 . . . Continued
Module level detailed cooling models are developed and reduced to a
thermal reduced order model (ROM) which augments the ECM
26
ROM for the Battery Module
LTI
SAE INTERNATIONAL
Example 3 . . . Continued
Busbars are characterized with thermal, structural and electric simulation
and all components are integrated to create the pack model
27
Electromagnetic FEA Analysis for Busbar
RLC Network Extraction
Voc vs. SOC
Pulse Discharge
Battery Equivalent Circuit Model (ECM)
Battery Performance Data
Pack Level Battery ECM
SAE INTERNATIONAL
Summary:
Hierarchical multi-domain, multi-fidelity simulation provides the ability to
perform early and reliable verification while managing complexity, of
interdisciplinary H/EV powertrain engineering
28
Mechanical/Fluid
Software
Electrical &
Electronics
SAE INTERNATIONAL 29
29
System
Validation
Sub-System Integ. &
Verification
Component Integration
& Verification
Requirements and
Specifications
Component Design
System Functional &
Architectural Design
Detailed Design
& Optimization
SAE INTERNATIONAL
THANK YOU
SANDEEP.SOVANI@ANSYS.COM
30

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Model Based Design of Hybrid and Electric Powertrains

  • 1. MODEL BASED DESIGN OF HYBRID AND ELECTRIC POWERTRAINS Sandeep Sovani, Ph.D. ANSYS Inc. October 22, 2013 SAE 2013 Hybrid Powertrain Complexity And Maintainability Symposium Acknowledgements: Scott Stanton, Todd McDevitt, Eric Bantegnie, Xiao Hu, ANSYS Inc.
  • 2. SAE INTERNATIONAL As mechanical, electrical, electronic and software systems in a vehicle are getting ever more tightly integrated, three key necessities are arising 2 Mechanical/Fluid Electrical & Electronics Software Mechanical/Fluid Software Electrical & Electronics Mechatronics Manage Complexity to design innovative, market leading products Early & Reliable Verification to deliver high quality products to the market faster Coordinate Interdisciplinary Engineering to reduce design changes and development costs
  • 3. SAE INTERNATIONAL The hybrid electric powertrain is the most complex vehicle system involving diverse interdisciplinary engineering 3 Predicting the behavior of a Hybrid Electric Powertrain over a drive cycle requires simulation of multiple domains: • Mechanical, Hardware • Electrical, Electronics • Software
  • 4. SAE INTERNATIONAL Simulating the electric powertrain as a complete, interconnected system is particularly challenging due to fragmentation of simulation tools and methods at different stages of the product development process 4 System Validation Sub-System Integ. & Verification Component Integration & Verification Requirements and Specifications Component Design System Functional & Architectural Design Mechanical Electrical Software Customer Requirements: Adjust the speed of my vehicle to keep it at a safe distance behind the lead vehicle even in fog or heavy rain Functional Specification: The car must adjust its speed without users control Alt. A: Preview Distance Control System Alt. B Radar Cruise Control System Alt. C Dynamic Laser Cruise Control System System Simulation Testing Components Testing Requirements Capture and Management Product Structure Optimal Architecture Mechanical Electrical Software System Models Systems Simulation Detailed Design & Optimization Release Product Manage Complexity Coordinate Interdisciplinary Engineering Early & Reliable Verification
  • 5. SAE INTERNATIONAL Systems functional engineering tools, software engineering tools, and detailed 3D design tools need to be seamlessly integrated to create an effective tool for handling the complexity of hybrid electric powertrains 5 System Validation Sub-System Integ. & Verification Component Integration & Verification Requirements and Specifications Component Design System Functional & Architectural Design Mechanical ElectricalSoftware Detailed Design & Optimization Systems Functional Engineering Functional Allocations Detailed Architecture Architecture Software Engineering Detailed 3D Design and Simulation
  • 6. SAE INTERNATIONAL A multi-fidelity simulation toolset is essential to most effectively meet the different design needs at different stages of the product development process 6 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 500us0 Pos true false t 0 500us t Pos Pmax Actuator t Pos 0 500us t Pos Pmax 500us Pmax Pmax
  • 7. SAE INTERNATIONAL We are testing a comprehensive simulation platform comprised of in-depth integrated tools to full system simulation of the hybrid electric powertrain 7 System Design System Architecture, System Verification Detailed Component Design 3D Simulations for Fluids, Thermal, Mechanical, Electrical, Magnetic Effects System & Software Lifecycle Mgmt Certification Plans, Metrics, Requirements, Configuration Management, Documentation Generation Circuit Design and Control Software Design Prototyping, Design, Verification, Qualified Code Generation
  • 8. SAE INTERNATIONAL Requirements Mgmt and Functional Design Practices Requirements analysis Requirements traceability Configuration management Operational and usage analysis Functional decomposition Functional simulation Architectural design & selection Rapid prototyping Behavior modeling (0D simulation) At the highest level system design starts with requirements analysis, operational and usage analysis, functional decomposition, architectural design and basic behavioral modeling 8
  • 9. SAE INTERNATIONAL At the component design and verification level a data connector bus and 0D simulator forms the central core of the simulation platform
  • 10. SAE INTERNATIONAL The second key element at the component design and verification level is a comprehensive control software development tool set that prototypes and designs software models, verifies them, and generates certified code
  • 11. SAE INTERNATIONAL At the detailed component design level, 3D simulation tools help develop and optimize the components from fluid, thermal, structural, electrical, magnetic, acoustic, etc aspects 11 Fluid, Thermal Simulation of a Battery Module Pre-Stressed Structural Modal Analysis of a Motor Electrical Current and Heating Simulation of an IGBT
  • 12. SAE INTERNATIONAL Example 1: Integrated power electronics and embedded controls development 12
  • 13. SAE INTERNATIONAL Example 1 . . . Continued An incremental approach is used to design the system 13
  • 14. SAE INTERNATIONAL Example 1 . . . Continued At level 1, open loop electric behavior is studied 14
  • 15. SAE INTERNATIONAL Example 1 . . . Continued At level 1, system validation includes switching commands from embedded code 15 Switching commands coming from the Embedded Code Angle and Torque on the load
  • 16. SAE INTERNATIONAL Example 1 . . . Continued At level 4, closed loop control and detailed electric analysis is performed 16
  • 17. SAE INTERNATIONAL Example 1 . . . Continued At level 4 system validation considers switching commands from embedded code as well as feedback commands 17 Switching commands coming from the Embedded Code and feedback command Angle and Torque on the load
  • 18. SAE INTERNATIONAL Example 2 . . . Continued Hierarchical IGBT models suite different purposes: A dynamic IGBT model is necessary for EMI analysis 18 DC core A Energy calculation B Thermal network F DC core A C Thermal network F Capacities C(V), C(I) parasitics L, R, C controlled sources E Full parameter excess Maximum simulation speed: • Accurate static behavior • Accurate thermal response • No voltage and current transients • Suitable for system design analysis Average IGBT Model Dynamic IGBT Model Maximum simulation accuracy: • Sophisticated semiconductor model • Accurate dynamic and thermal behavior • Accurate voltage and current waveforms • Suitable for drive optimization, EMI/EMC
  • 19. SAE INTERNATIONAL Example 2 . . . Continued Dynamic IGBT model accurately captures switching waveforms 19 Static IGBT for fast system simulations
  • 20. SAE INTERNATIONAL Example 2 . . . Continued Detailed 3D thermal and electrical analysis of the IGBT further improves waveform accuracy 20 EMI/EMC: Automatic L,R,C Extraction and Network Model The structure is meshed using automatic and adaptive meshing Current Distribution
  • 21. SAE INTERNATIONAL Example 2 . . . Continued The IGBT model couples seamlessly with detailed motor model to optimize the sub-system in an integrated way 21 -22.50 60.00 0 25.00 50.00 0 240.00m100.00m 2DGraphSel1 NIGBT71.IC Extract Power Loss 0 474.00m 200.00m 400.00m 100.00 1.00Meg1.00k 3.00k 10.00k 100.00k 2DGraphCon1 GS_I...FFT
  • 22. SAE INTERNATIONAL The battery pack is hierarchically simulated from the smallest electrode level scale to the largest pack level scale and a behavioral model of the pack is extracted that fits in the powertrain system level simulation Example 3 Total battery simulation Electrode Level •Electrode layout •Heat source calculation •Aging Molecular Level •Material innovation •Material selection Cell Level •Charging, dischar- ging profiles •Cell level heat distribution •Swelling, deformation Pack Level •BMS Logic •Electrical System •Cooling Channels •Cooling Circuits Powertrain and Vehicle Level •System Integration SmallScale LargeScale
  • 23. SAE INTERNATIONAL Example 3 . . . Continued Electrochemistry at the cell electrode level is simulated with 1D and 3D models 23 Impact of Temperature on Concentration Distribution Impact of Particle Shape on Capacity Rate 0.1C 0.5C 1C 3C 5C 10C Validation of Reduced Order Electrochemistry [1] X. Hu, S. Stanton, L. Cai, R.E. White, J. Power Sources 214, 40-50, 2012. [2] X. Hu, S. Stanton, L. Cai, R.E. White, J. Power Sources 218, 212-220, 2012.
  • 24. SAE INTERNATIONAL Example 3 . . . Continued Cell electrical behavior is characterized by simulating electrical, flow and temperature distributions in the cell in detail 24 Current DensityCathode Anode   J  )( UYJ ac   Temperature
  • 25. SAE INTERNATIONAL Example 3 . . . Continued Cell Equivalent Circuit Models are developed that account for detailed thermal and electrical effects and are integrated into a module model 25 X. Hu, L. Collins, S. Stanton, S. Jiang, "A Model Parameter Identification Method for Battery Applications", SAE 2013-01-1529. Battery Pack ECM Model Simulation Results Cell Equivalent Circuit Model (ECM)
  • 26. SAE INTERNATIONAL State space based Linear Time Invariant Model Example 3 . . . Continued Module level detailed cooling models are developed and reduced to a thermal reduced order model (ROM) which augments the ECM 26 ROM for the Battery Module LTI
  • 27. SAE INTERNATIONAL Example 3 . . . Continued Busbars are characterized with thermal, structural and electric simulation and all components are integrated to create the pack model 27 Electromagnetic FEA Analysis for Busbar RLC Network Extraction Voc vs. SOC Pulse Discharge Battery Equivalent Circuit Model (ECM) Battery Performance Data Pack Level Battery ECM
  • 28. SAE INTERNATIONAL Summary: Hierarchical multi-domain, multi-fidelity simulation provides the ability to perform early and reliable verification while managing complexity, of interdisciplinary H/EV powertrain engineering 28 Mechanical/Fluid Software Electrical & Electronics
  • 29. SAE INTERNATIONAL 29 29 System Validation Sub-System Integ. & Verification Component Integration & Verification Requirements and Specifications Component Design System Functional & Architectural Design Detailed Design & Optimization