1 - EMobility Compose Activate EATC 2017 v10 Electric Machines Track Noi

System-Driven Simulation for e-Mobility
EATC, June 2017

Electrical Machines Track
Andrew Dyer, Abdessamed Soualmi

adyer@altair.com, asoualmi@altair.com
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda: e-Mobility
• e-Mobility challenges and solutions
• Use Cases
• Supervisory control of HEV
• Motor design/control – Flux/FluxMotor
• Model-Based Design using

solidThinking Compose and Activate,
integration with other Altair products
2
Takeaways for Today’s Presentation
• e-Mobility systems are complex and require a

range of fidelity 1D system models to design:
• Physical models
• Control models
• Supervisory control (high-level) and

component (subsystem) control systems
must all work together to achieve design goals
• System integration, including 3D

HyperWorks tools, is key to driving innovation
4
e-Mobility Challenges
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. © 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Electric, hybrids, plug-in and fuel cell systems

require sub-system integration and
modeling/analysis
• Energy storage and conversion systems
• Mechanical
• Electrical machines
• Controls to direct and optimize performance…
efficiency depends heavily on control strategy
• E.g., Optimal control to balance fuel economy, performance,
drivability
16
• Need improvements to:

• Batteries and energy storage devices
• Motors/Generators (electric machines)
• Power electronics
• Thermal management of electrical systems, electric machines, batteries
• Complex controllers – supervisory & component
• Embedded software
• Emissions
• Charging infrastructure, micro and smart grid interface systems
• Coordinating these with traditional design goals for chassis/mechanical light-weighting, safety,
durability, handling, etc…
 Requires SYSTEM INTEGRATION and MODEL-BASED DEVELOPMENT
17
Model-Based Design/System Modeling

Model Based Development
Design Testing
System Certification
Requirements
System
Model
System Testing
Concept
Design
Component Component
Design Testing
Physical Parts
19
Altair’s Simulation Solutions for e-Mobility
Math & Systems

• Compose, Activate, Embed
Electromagnetics
• Feko, Flux
Thermal
• AcuSolve
Structural
• OptiStruct & RADIOSS
Multibody Systems
• MotionSolve, CarSim (APA)
21
Compose Activate Embed
Concept Studies | Control Design | System Performance Optimization | Controller Implementation
22
HEV/EV Powertrain Metrics

e-Mobility Powertrain Metrics
Acceleration
• Objective and quantitative
• Fuel economy Typical ICE-only
powertrain
• Powertrain Performance
• Drivability Fuel
Economy
• Emissions
• Safety
• Traction/Handling Performance
• … Acceleration
e-Mobility
• e-Mobility technologies/topologies are allowing
Fuel
Economy
system performance to be improved over
traditional designs
25
e-Mobility Powertrain Control
• Many improvements depend on proper control of systems!
• Requires control-oriented models
• Balance fidelity to evaluate control criteria with enough detail but not so much that
burdens control development
• Complexity/content depends on application
26
Use Case – Detailed HEV Supervisory Controller

Prius – Toyota Hybrid System (THS)
31
Prius HEV – Activate Model Summary
• Component abstraction:
• Look-up tables (engine & motor torque, efficiency)
• Physics based (vehicle, planetary gear set)
• Used to explore:
• Supervisory controller design
• Minimize fuel consumption, battery usage
• Performance (straight-line acceleration, braking, etc.)
• Component selection: engine, battery, motor, etc.
• Power needs
• Efficiencies of system  effects on fuel consumption
35
Inputs and Key Results
Inputs:
Drive Cycles
• E.g., EPA Urban Drive cycle
• > 1200 seconds runs in < 10 simulation seconds
Initial Battery State-of-Charge (SOC)
Outputs:
• Fuel Economy, Battery SOC
• Power Demands – Engine, Electric Machines
55
Prius – Toyota Hybrid System (THS)
56
Use Case – Electric Machine Control & Design with Flux

Prius Hybrid System Improvements (THS  THS II)
• How was better fuel economy AND acceleration achieved in next

generation design?
Acceleration
• Battery – Smaller, lighter, internal resistance reduced by
connecting cells from one spot to two spots  more
efficiency
Fuel
Economy
• Inverter – Boosted nominal battery from 201.6 to 500V 
more power
• Electric Machines (MG1, MG2) – More powerful…

How?...
63
Prius Hybrid System Improvements (THS  THS II)

Improved Torque via
Original Design new control method
Improved Design
Motor Torque
New “V”-
shaped
magnet
Motor Speed
• Permanent magnet structure changed to V shape, better power and torque (e.g., Flux/FluxMotor)
• MG2 Control - new over-modulation control for medium speed range, also increased MG1 RPM max
for better charging – (e.g., Activate/Embed)
64
Flux Coupling with Activate
• Flux: Low-frequency, electromagnetic and thermal simulations, finite element model (2D and 3D)
• Study non-linear effects not captured by standard “Park” equation model

• Detailed physics via co-simulation
• Transient analysis, both 2D and 3D solvers
• Complete FE model
• Fast analysis
• Quasi-static: Generate look-up tables to represent motor
• Study effects:
• Control system/system behavior
• Saturation
• Losses – thermal, eddy currents, friction,
stray loads, permanent magnet
65
Flux Coupling with Activate
• FluxMotor – for early design (Pre-design)

• Take advantage of catalogs to quickly explore designs
• Extensive parameterization available, fast analysis
• Table Generation for Activate; Export to models to Flux
• Flux – Full 2D or 3D FE models, for later, detailed design
66
Model-Based Development Workflows (1D, 3D integration)
Activate + Flux support of Model-Based Development

Work with different levels of fidelity depending on your analysis needs
• Motor Design/Control
• Supervisory HEV Control
67
PMSM Modeling Approaches

• Methodologies to set a model of a PMSM with Activate
• Analytic approach (Park equation model)
• Full Co-simulation Flux/Activate
• Reduced-order model with finite element table representation
• Why implement different methodologies to represent the behavior of a magnetic component?
 Speed vs. Accuracy!
69
PMSM Modeling Methods

• Analytic approaches (Park model) – Activate only(no Flux)
• FAST! Least accurate…
« abc » reference
« dq » reference
Ld, Lq and Phi_PM are calculated using Flux or by physical testing
70

• Full co-simulation Flux + Activate
• BEST ACCURACY! But slowest…
Link to FE Motor model

Activate Flux
Output:
• Current
• Speed
• Torque…
Voltage to fed the

motor
71
• Table-based model from finite element results– FAST and IMPROVED ACCURACY vs. Park
Flux in a, b, c axis and magnetic torque

are computed in term of Id, Iq and rotor
position using Flux 2D
72
Park Equations Example

• Example : PMSM used for HEV power train
• Park model Vector control of IPM
Park model of IPM
74
Co-Simulation (Flux + Activate) Example

• Full co-simulation model Vector control of IPM
Inputs
Outputs
Flux details
Component coupling with FE

model
75
Co-Simulation (Flux/Activate) Example
• Flux model includes electrical circuit as well
• Co-simulation block: Palettes > Activate > CoSimulation
76
Tables (Flux  Activate) Example

• Table model
77
Tables (Flux  Activate) Example

• Table model
• Modelica used to model motor electrical circuit
78
PMSM Example, Comparison – Motor Torque

• Comparison
79
PMSM Example, Comparison – Motor Speed

• Comparison
80
Motor Design/Control
• (1D, 3D  1D) Use fast solutions, Park and/or Flux table methods to investigate
control strategies
• (1D + 3D) Once control strategy refined, use co-simulation of detailed model to
investigate losses and dynamic effects
• (1D  3D) Can also get driving inputs from Activate and use Flux standalone to
investigate thermal effects and losses
• (1D) Model fidelity: can continue to add accuracy via detailed inverter, etc. in Activate
• Leverage Modelica libraries for physical components (electrical, thermal, etc.)
81
Supervisory Control (3D  1D)

• Simplified tables generated by Flux or FluxMotor to represent salient behavior for
system design (review battery usage/longevity, etc.)
• Torque vs. Speed
• Efficiency
• …
82
Electric Machine Design Process

System Analysis – solidThinking Activate
Prototype & tests
Specifications
Control implementation -
solidThinking Embed
Analytical
computations
Compose Optimization
HyperStudy
Motor topology selection

& fast analysis
FluxMotor
Refined design
Flux2D / 3D
Thermal analysis Advanced NVH

Multiphysics Thermal analysis
Flux2D OptiStruct
AcuSolve
83
Summary
Altair Solutions for e-Mobility
• System models with Activate + Compose:

• Control system design/evaluation
• Supervisory HEV Control
• Motor design/control development
• Modelica Libraries for physical subsystems
• Mechanical, electrical, thermal, motors, batteries, etc.
• Systems Integration – Native co-simulation and FMI
• Working the design “V” - leverage 3D tools with 1D system tools

• 1D + 3D, 1D  3D:
• Co-sim for more detailed analysis (Flux, MotionSolve, CarSim, VI-GradeRealTime, Prescan, etc…), or
• Sequentially generate system-level inputs to 3D tools
• 3D  1D: Use 3D tools to create 1-D model data, validate 1D results
105
Thanks! References
• Professor Huei Peng, University of Michigan

• Flux team, especially Abdessamed, Vincent
• Activate team – Ramine, Franck, Michael
• Other Altarians: Wei-Hung Ko, Steve Ho, Vijay
Singla, Richard Yen, Brian Brothers
References for more information:

• “Automotive Control Systems”, Ulsoy, Peng, Cakmakci
• "Modeling and Analysis of the Toyota Hybrid System", Jinming Liu, Huei Peng and Zoran Filipi,
Proceedings of the 2005 IEEE/ASME International Conference on Advanced Intelligent Mechatronics
Monterey, California, USA, 24-28 July, 2005
• "Modeling and Control of a Power-Split Hybrid Vehicle", Jinming Liu and Huei Peng, IEEE
TRANSACTIONS ON CONTROL SYSTEMS TECHNOLOGY, VOL. 16, NO. 6, NOVEMBER 2008
106
http://learn.solidThinking.com/
107
Das Ende - Driving Innovation Through Simulation
108

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System-Driven Simulation for e-Mobility

EATC, June 2017

Andrew Dyer, Abdessamed Soualmi

• e-Mobility challenges and solutions

• Model-Based Design using

Takeaways for Today’s Presentation

• e-Mobility systems are complex and require a

• Supervisory control (high-level) and

• System integration, including 3D

• Electric, hybrids, plug-in and fuel cell systems

• Need improvements to:

 Requires SYSTEM INTEGRATION and MODEL-BASED DEVELOPMENT

Model-Based Design/System Modeling

Model Based Development

Altair’s Simulation Solutions for e-Mobility

Math & Systems

Compose Activate Embed

Concept Studies | Control Design | System Performance Optimization | Controller Implementation

HEV/EV Powertrain Metrics

e-Mobility Powertrain Metrics

e-Mobility Powertrain Control

• Many improvements depend on proper control of systems!

• Requires control-oriented models

• Complexity/content depends on application

Use Case – Detailed HEV Supervisory Controller

Prius – Toyota Hybrid System (THS)

Prius HEV – Activate Model Summary

Inputs and Key Results

Initial Battery State-of-Charge (SOC)

Prius – Toyota Hybrid System (THS)

Use Case – Electric Machine Control & Design with Flux

Prius Hybrid System Improvements (THS  THS II)

• How was better fuel economy AND acceleration achieved in next

• Electric Machines (MG1, MG2) – More powerful…

Prius Hybrid System Improvements (THS  THS II)

Flux Coupling with Activate

• Study non-linear effects not captured by standard “Park” equation model

Flux Coupling with Activate

• FluxMotor – for early design (Pre-design)

Model-Based Development Workflows (1D, 3D integration)

Activate + Flux support of Model-Based Development

PMSM Modeling Approaches

• Analytic approach (Park equation model)

• Full Co-simulation Flux/Activate

• Reduced-order model with finite element table representation

• Why implement different methodologies to represent the behavior of a magnetic component?

 Speed vs. Accuracy!

PMSM Modeling Methods

Ld, Lq and Phi_PM are calculated using Flux or by physical testing

PMSM Modeling Methods

Link to FE Motor model

Voltage to fed the

PMSM Modeling Methods

Flux in a, b, c axis and magnetic torque

Park Equations Example

Park model of IPM

Co-Simulation (Flux + Activate) Example

Component coupling with FE

Co-Simulation (Flux/Activate) Example

• Flux model includes electrical circuit as well

• Co-simulation block: Palettes > Activate > CoSimulation

Tables (Flux  Activate) Example

Tables (Flux  Activate) Example

PMSM Example, Comparison – Motor Torque