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 � Compare t the he e evolu lution o n of t the he T Toyota Pr Priu ius � A r result lt o of i improved c cooli ling ng and nd/or t the herma mal c l cont ntrol l Power E Ele lectroni nics Ele lectric M Machi hine nes Battery y 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
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%.…” Connecting the electrical response closer to the thermal “….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.’’’”
Priu Pr ius - E - Ele lectric M Machi hine ne De Design n � Reduced w wire d diame meter – – – Balancing higher voltage, higher speed with cooper reduction – Ohmic Losses � Sophi histicated r rotor la lami mina nation d n design – n – ( (2010 Pr Priu ius R Rh s h side) – 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….”
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
Ele lectroni nics C Cooli ling ng S Simu mula lation n � IGB IGBT a ana nalys lysis w with S h STAR-C -CCM+ Simpli lified Detaile De led RC N Network k � Find nd o out 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’ ’
Ele lectric M Machi hine ne S Simu mula lation n � 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’ � Find nd o out mo more: M : Markus A And nders, s , session 1 n 13, 1 , 10;1 ;10am
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 out 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
Valida alidation ion on on Module odule Le Level el Comparison of measured Temperature plots for two cells of the stack and simulated results Averaged cell voltage Heat transported by coolant
Battery S y Simu mula lation n Pack Model(3D) Unit Cell Physics Model • CAD (1D) • Fluid dynamics • Thermal Plate Cell Model • Electrical (3D) Total Heat Generation Particle Model (1D and 3D)
Battery S y Simu mula lation Ind n Industry P y Present nters � 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 of 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
Us Use o of C CAE t tools ls f for a abuse s simu mula lations ns
Us Use o of 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
Conc nclu lusions ns � 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
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
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