Funded by

Battery Simulation Evgeny Rudnyi Lucas Kostetzer Sreekanth Nallabolu

CADFEM GmbH Marktplatz 2 85567 Grafing Germany

gefördert vom: funded by

BMBF Project  „Zentrales Innovationsprogramm Mittelstand (ZIM)

 A project for 2 years  CADFEM

 ZSW 

Zentrum für Sonnenenergie- und Wasserstoff-Forschung (ZSW) Baden-Württemberg

 LionSmart

- 1-

gefördert vom: funded by

Multi-Level Physics in Battery simulation  1D System Level: Battery pack and power train  

Analyze individual systems and integrated performance Tool used: ANSYS Simplorer & MOR

Model Extraction

 3D Component level: Battery pack 

Charge/discharge cycle design, life, safety, cost, thermal management Tool used: ANSYS Mechanical & CFD

 1D Component level: Battery Cell  

- 2-

I-V characteristics, Electro-chemistry analysis Tool used: ANSYS Simplorer

Coupled physics + Control system

System level Mechanical



Component level

Physic solvers

gefördert vom: funded by

Content

 Vehicle Dynamic Simulation  Electrochemical Modeling of Liion Battery

 Thermal Model of Battery (1D CFD)

 Compact Thermal Models via Model Order Reduction

 Battery Pack Electrothermal Simulation at System Level

- 3-

gefördert vom: funded by

Complex interdependency of subsystems in HEV

Peak and mean power demand over time

• Power • Voltage • Energy

Battery

Maximum and mean electric power

Control Strategy Distribution of load to EM and ICE

Electric Machine (EM)

Downsizing due to EM Power and Torque

Engine (ICE) - 4-

Torque capability

Gearbox

Power Electronics

gefördert vom: funded by

Drive cycle

 Backward quasistatic simulation

Speed (m/s)

90

FTP

80 70

Speed request

60 50 40 30 20

10 0 0

200

400

600

800

1000

Time (sec)

- 5-

1200

1400

1600

1800

2000

gefördert vom: funded by

Hybrid Electric Vehicle Simulation @ CADFEM

 Series HEV model  Model to check the integrity of our semi-physical battery model  Model useful for component sizing  Model useful to test energy management startegies

- 6-

gefördert vom: funded by

Vehicle Dynamics and Wheel v

Faero

Linear acceleration Force

Ftrac

v Rolling Resistance force

Fgrad Aerodynamic drag force

mv·g

a

Froll

a

Gravitational Force

Rwheel Treq = FTR * Rwheel

Freq vreq

ωreq , Treq vreq , Freq - 7-

Treq ωreq = Vreq / Rwheel

ωreq

gefördert vom: funded by

Software for System Level Simulation: Simplorer Electrical circuits

Magnetics

Mechanics

Hydraulics, Thermal, ...

J A11 B11 C11

B12

M

C12

M(t)

A2

3~

B2

STF

MMF

C2

GND

A12

L

JA

+

ROT 1

ROT 2

-

F(t)

m STF

GND

ASMS

Q

H

Simplorer Simulation Data Bus / Simulator Coupling Technology CLK

ffj

INV

ffj

ffj

ffj

CLK

ffj

PST

State-space Models

Block Diagrams

State Graphs

Digital/ VHDL

J

Q

CLK

Flip flop QB CLR

CLK

CLK INV

state

transition EIN

SET: TSV1:=1 SET: TSV2:=0 SET: TSV3:=0 SET: TSV4:=1

x  Ax  Bu y  Cx 8

(R_LAST.I >= I_OGR)

AUS

(R_LAST.I