Meeting ng t the he e ele lectrification n cha halle lleng - - PowerPoint PPT Presentation

▶
meeting ng t the he e ele lectrification n cha halle
SMART_READER_LITE
LIVE PREVIEW

Meeting ng t the he e ele lectrification n cha halle lleng - - PowerPoint PPT Presentation

Feb 11, 2023 252 likes •406 views

Meeting ng t the he e ele lectrification n cha halle lleng nge w with s h simu mula lation n Steve H Hartridge Di Director, E , Ele lectric & & H Hyb ybrid V Vehi hicle les CD-a D-adapco Ele lectrification n

slide-1
SLIDE 1

Meeting ng t the he e ele lectrification n cha halle lleng nge w with s h simu mula lation n

Steve H Hartridge Di Director, E , Ele lectric & & H Hyb ybrid V Vehi hicle les CD-a D-adapco

slide-2
SLIDE 2

Compare t the he e evolu lution o n of t the he T Toyota Pr Priu ius

Ele lectrification n

A r result lt o

  • f i

improved c cooli ling ng and nd/or t the herma mal c l cont ntrol l

  • Source: E

: Evalu luation o n of t the he 2 2010 T Toyota Pr Priu ius h hyb ybrid syne ynergy d y drive s sys ystem - O m - Oak R k Ridge N Nationa nal la l labs

Power E Ele lectroni nics Ele lectric M Machi hine nes Battery y

slide-3
SLIDE 3

Pr Priu ius - E

  • Ele

lectroni nics C Cooli ling ng

“…….Although the power capability of the 2010 Prius bi-directional dc- dc converter increased by about 35% in comparison with the 2004 Prius, the mass only increased by about 6% and the volume decreased by about 6%.…”

“….a 58% decrease in length. Additionally, a solder layer and thermal paste layer has been eliminated, both of which have relatively low thermal conductivities (compared to aluminum) and therefore the overall thermal conductivity has greatly increased.’’’” Connecting the electrical response closer to the thermal

slide-4
SLIDE 4

Reduced w wire d diame meter – –

– Balancing higher voltage, higher speed with cooper reduction – Ohmic Losses

Pr Priu ius - E

  • Ele

lectric M Machi hine ne De Design n

– Improved torque profile – Lower mass – Iron losses

“…..The 2010 Prius rotor mass of 6.7 kg compares with 2004 Prius rotor mass of 10.2 kg….” Sophi histicated r rotor la lami mina nation d n design – n – ( (2010 Pr Priu ius R Rh s h side)

slide-5
SLIDE 5

Pr Priu ius – – B Battery De y Design n

Same me p package b but i inc ncreased p power r rating ng

– improved c cooli ling ng p performa manc nce – Rema mains ns N Nickel M l Metal H l Hyd ydride

Lithi hium i m ion w n will c ll come me i in t n the he Pr Priu ius V V

slide-6
SLIDE 6

IGB IGBT a ana nalys lysis w with S h STAR-C

  • CCM+

Ele lectroni nics C Cooli ling ng S Simu mula lation n

De Detaile led Simpli lified RC N Network k

Find nd o

  • ut mo

more: R : Ruben n Bons ns, s , session 1 n 19, 3 , 3pm , m , ‘T ‘Tren ends, i , implications & & el elec ectronics t ther ermal d des esign n need eeds d due t e to s system em el elec ectrification’ ’

slide-7
SLIDE 7

Addition o n of E Ele lectroma magne netic t to S STAR-C

  • CCM+

– Uniquely Flow, Thermal & Electromagnetics

Int Interface b between S n SPEED a D and nd S STAR-C

  • CCM+

– Removing repetition, joining the ‘designer’ with the ‘thermal analyst’

Ele lectric M Machi hine ne S Simu mula lation n

Find nd o

  • ut mo

more: M : Markus A And nders, s , session 1 n 13, 1 , 10;1 ;10am

slide-8
SLIDE 8

Battery S y Simu mula lation n

Addition o n of E Ele lectroche hemi mistry t y to S STAR-C

  • CCM+

– Uni niquely F ly Flo low, T , The herma mal & l & e ele lectroche hemi mistry y

Int Interface b between B n Battery De y Design S n Studio a and nd S STAR-C

  • CCM+

– Inc Increasing ng f fideli lity, jo , joini ning ng t the he ‘C ‘Cell d ll designe ner’ w ’ with t h the he ‘t ‘the herma mal a l ana nalys lyst’ ’

Find nd o

  • ut mo

more: : Ga Gaetan Da Damb mbla lanc nc & & R Robert Spotni nitz, B , Battery S y Simu mula lation 8 n 8am W m Wedne nesday

slide-9
SLIDE 9

Comparison of measured and simulated results

Temperature plots for two cells of the stack Averaged cell voltage Heat transported by coolant

Valida alidation ion on

  • n Module
  • dule Le

Level el

slide-10
SLIDE 10

Particle Model (1D and 3D) Unit Cell Physics Model (1D) Plate Cell Model (3D)

Pack Model(3D)

  • CAD
  • Fluid dynamics
  • Thermal
  • Electrical

Total Heat Generation

Battery S y Simu mula lation n

slide-11
SLIDE 11

Nissan – n – S Star Glo Global C l Conf nferenc nce 2 2012 FMC – – S Star Glo Global C l Conf nferenc nce 2 2012 GM GM E Europe – – S Star Glo Global C l Conf nferenc nce 2 2012 Hitachi hi M Maxell – ll – J Japane nese C Conf nferenc nce 2 2012 Hyu yund ndai Mo Mobis bis – – K Korean C n Conf nferenc nce 2 2012 Carne negie M Mello llon - n - INTERNATIONAL JOURNAL OF ENERGY RESEARCH + ma many u y users w world ldwide t tha hat a are no not na name med De Departme ment nt o

  • f E

Ene nergy y

– Co-funded project with JCI & A123 – $3M project – Software now available

Wide s spread a adoption o n of C CD-a D-adapco b battery mo y modeli ling ng me metho hods

Battery S y Simu mula lation Ind n Industry P y Present nters

slide-12
SLIDE 12

Us Use o

  • f C

CAE t tools ls f for a abuse s simu mula lations ns

slide-13
SLIDE 13

Us Use o

  • f C

CAE t tools ls f for a abuse s simu mula lations ns Heat P Propagation i n in a n a 1 10S-2

  • 2P mo

module le

slide-14
SLIDE 14

Ne New w Pr Priu ius mo models ls

– 7 seater enabled by reduced battery size – Other EV’s, PHEV,

  • Nissan Leaf, Ford Focus,

Wider A Automo motive E Ele lectrification n

– Hyundai Sonata, Ford Fusion, VW Jetta – Strong hybrids

Wider E Ele lectrification n

– Aircraft, boats, satellites,

CD-a D-adapco ha has a an a n active p program m

– Apply appropriate physics to the system – Links to design level tools

Conc nclu lusions ns

slide-15
SLIDE 15

Meeting ng t the he e ele lectrification n cha halle lleng nge w with s h simu mula lation n

Steve H Hartridge Di Director, E , Ele lectric & & H Hyb ybrid V Vehi hicle les CD-a D-adapco