EV/HEV Value Chain and Battery Design

Size: px

Start display at page:

Download "EV/HEV Value Chain and Battery Design"

Beryl Susanna McCoy
6 years ago
Views:

2 Outline EV/HEV Market Trends Value Chain EV/HEV Simulation Integrated Simulation Battery Traction Motor Power Electronics Key Problems and Simulation Needs ANSYS Solutions Competition Analysis and Differentiators R13 Advances 2011 ANSYS Targets Success Stories 2011 Marketing Campaign 2011 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

3 Market Trends The automotive powertrain has changed for good I.C. Engine Powertrain I.C. Engine Powertrain Augmented with Electric Powertrain Electric Powertrain Hybrid Powertrain OLD NEW FUTURE A once-in-a-lifetime landslide change 2011 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary

4 Market Trends Why? Environmental concerns in the west Oil dependence concerns in the east Ref: Hazimeh, O. PRTM Consultants, 50% Battery Cost Reduction, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary

5 Market Trends Types of Hybrid Electric Vehicles Micro Hybrid HEV PHEV ER-EV BEV FCEV xev = General term to reference all types of EVs Ref: Bly, M. General Motors, Developing a Battery Value Chain, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary

6 Market Trends Ref: Hazimeh, O. PRTM Consultants, 50% Battery Cost Reduction, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary

Market Trends Electric Powertrain Power Flow Control Power Source Power Electronics Electric

http://commons.wikimedia.org/wiki/file:hitachij100a.

Electric Drive System Interim Report http://commons.wikimedia.org/wiki/file:ni-mh_battery_02.

8 Market Trends Electric Powertrain Power Flow Control Power Source Power Electronics Electric Machine Mechanical Components Battery/BMS Inverter/Busbar Traction Motor Drive Shaft Oakridge National Laboratory, ORNL/TM-2004/247, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System Interim Report Author {{:de:wiki:user DrJunge DrJunge}} ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary

9 Market Trends Ref: Hazimeh, O. PRTM Consultants, 50% Battery Cost Reduction, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary

10 Market Trends Ref: Bly, M. General Motors, Developing a Battery Value Chain, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary

11 Outline EV/HEV Market Trends Value Chain EV/HEV Simulation Integrated Simulation Battery Traction Motor Power Electronics Key Problems and Simulation Needs ANSYS Solutions Competition Analysis and Differentiators R13 Advances 2011 ANSYS Targets Success Stories 2011 Marketing Campaigns 2011 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary

12 EV/HEV Value Chain Y2020 Estimates Sample Business Initiatives Ref: Hazimeh, O. PRTM Consultants, 50% Battery Cost Reduction, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary

13 Battery Value Chain Ref: Hazimeh, O. PRTM Consultants, 50% Battery Cost Reduction, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary

14 EV/HEV Value Chain Ref: Hazimeh, O. PRTM Consultants, 50% Battery Cost Reduction, EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary

Commercialization EV Battery Technology Conference, Sept

15 Battery Value Chain Ref: Iyengar, J. Chrysler, EV Battery Business Analysis and Vision for Commercialization EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary

16 Battery Value Chain Ref: Iyengar, J. Chrysler, EV Battery Business Analysis and Vision for Commercialization EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary

17 Battery Value Chain Involvement of Different Types of Organizations in the Battery Value Chain Ref: Iyengar, J. Chrysler, EV Battery Business Analysis and Vision for Commercialization EV Battery Technology Conference, Sept 21-22, 2010, Troy, MI, USA 2011 ANSYS, Inc. All rights reserved. 17 ANSYS, Inc. Proprietary

18 Outline EV/HEV Market Trends Value Chain EV/HEV Simulation Integrated Simulation Battery Traction Motor Power Electronics Key Problems and Simulation Needs ANSYS Solutions Competition Analysis and Differentiators R13 Advances 2011 ANSYS Targets Success Stories 2011 Marketing Campaigns 2011 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary

19 EV/HEV Simulation Message to Executive Decision Makers Numerical Simulation will be a key differentiator in the electrification competition Numerical Simulation is particularly advantageous in electrification development Firms that strategically deploy numerical simulation will gain significant competitive advantage 2011 ANSYS, Inc. All rights reserved. 19 ANSYS, Inc. Proprietary

21 EV/HEV Simulation Challenges in developing disruptive innovations No precedence Many unknowns New paradigms Uncertainty Time pressure Last powertrain took ~100 years to develop New powertrain expected in ~10 years 2011 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary

22 EV/HEV Simulation Many Choices Many Decisions Cylindrical, Prismatic? Air Cooling, Liquid Cooling? Cell Chemistry? Established Demands Safety Reliability Cost Life Same as or surpassing current vehicle standards Multitude of ideas need to be generated, digested, validated, developed, tested, perfected, delivered, in a short time 2011 ANSYS, Inc. All rights reserved. 22 ANSYS, Inc. Proprietary

EV/HEV Simulation Multitude of ideas need to be generated, digested, validated, developed, tested, perfected, delivered, in a short time Numerical Simulation is particularly well suited for

23 EV/HEV Simulation Multitude of ideas need to be generated, digested, validated, developed, tested, perfected, delivered, in a short time Numerical Simulation is particularly well suited for this need; provides In-depth engineering insights Speedy design evaluation via virtual testing Enabler of fast, extensive design 2011 ANSYS, Inc. All rights reserved. 23 ANSYS, Inc. Proprietary

24 EV/HEV Simulation ANSYS Positioning Message Next Generation Simulation for Next Generation Vehicles Old Paradigms Component Simulation Single Physics Few Instances New Paradigms Integrated Simulation (Component and System) Multiphysics Simulation (Flow, thermal, structural, electrical, electrochem.) Extensive Automated Design Exploration Competitors Propositions ANSYS Differentiators 2011 ANSYS, Inc. All rights reserved. 24 ANSYS, Inc. Proprietary

25 Outline EV/HEV Market Trends Value Chain EV/HEV Simulation Integrated Simulation Battery Traction Motor Power Electronics Key Problems and Simulation Needs ANSYS Solutions Competition Analysis and Differentiators R13 Advances 2011 ANSYS Targets Success Stories 2011 Marketing Campaigns 2011 ANSYS, Inc. All rights reserved. 25 ANSYS, Inc. Proprietary

26 Integrated Simulation What is Integrated Simulation? Control Power Source Power Electronics Electric Machine Mechanical Components Battery/BMS Inverter/Busbar Traction Motor Drive Shaft Oakridge National Laboratory, ORNL/TM-2004/247, Evaluation of 2004 Toyota Prius Hybrid Electric Drive System Interim Report Author {{:de:wiki:user DrJunge DrJunge}} ANSYS, Inc. All rights reserved. 26 ANSYS, Inc. Proprietary

28 Integrated Simulation Why is Integrated Simulation critical for HEV? HEVs are all about fuel efficiency High level of optimization is needed Cannot be achieved by designing components and systems in isolation HEV components are by nature highly dependent on each other E.g. Battery Management System (controller) needs to dynamically change loads on battery cells to maintain temperature uniformity E.g. Traction Motor cannot run without being governed by advanced power electronics the two have to be designed together 2011 ANSYS, Inc. All rights reserved. 28 ANSYS, Inc. Proprietary

29 Integrated Simulation ANSYS Differentiator: No competitor can perform integrated simulation with the same multiphysics breadth and depth as ANSYS 2011 ANSYS, Inc. All rights reserved. 29 ANSYS, Inc. Proprietary

30 Outline EV/HEV Market Trends Value Chain EV/HEV Simulation Integrated Simulation Battery Traction Motor Power Electronics Key Problems and Simulation Needs ANSYS Solutions Competition Analysis and Differentiators R13 Advances 2011 ANSYS Targets Success Stories 2011 Marketing Campaigns 2011 ANSYS, Inc. All rights reserved. 30 ANSYS, Inc. Proprietary

Battery: Key Problems Overall Concerns: Cost Life Safety Power Density Cell Manufacturing Material Behavior in Cell Assembly Ageing, Life Thermal Management (Temperature Uniformity) Safety, Crash,

31 Battery: Key Problems Overall Concerns: Cost Life Safety Power Density Cell Manufacturing Material Behavior in Cell Assembly Ageing, Life Thermal Management (Temperature Uniformity) Safety, Crash, Abuse NVH, Durability Battery Management System and Algorithms Battery Performance in Vehicle Level Test Cycles Load Matching for Charging Discharging 2011 ANSYS, Inc. All rights reserved. 31 ANSYS, Inc. Proprietary

Battery : ANSYS Solutions Pack Level ANSYS Workbench An Integrated Solution for

Battery : ANSYS Solutions Pack Level Build-in What-if Study in

Battery : ANSYS Solutions Pack Level HEV Battery Thermal Management: Six Sigma Analysis Ref: Valhinos et al, Improving Battery Thermal Management Using Design

35 Battery : ANSYS Solutions Pack Level HEV Battery Thermal Management: Six Sigma Analysis Ref: Valhinos et al, Improving Battery Thermal Management Using Design for Six Sigma Process, 20 th Electric Vehicle Symposium, Long Beach, CA (November 15-18, 2003) 2011 ANSYS, Inc. All rights reserved. 35 ANSYS, Inc. Proprietary

Battery : ANSYS Solutions Pack Level Reduced Order Modeling

Battery : ANSYS Solutions Pack Level Reduced Order Model Extraction Process

Battery : ANSYS Solutions Pack Level LTI (Foster Network) vs ANSYS

training material exists for LTI method.

40 Battery : ANSYS Solutions Pack Level Battery Bus Bar Heating Multiphysics Simulation For steady (or low frequency) currents under temperature dependent conductivity 2011 ANSYS, Inc. All rights reserved. 40 ANSYS, Inc. Proprietary

Battery : ANSYS Solutions Pack Level Coupled Simulation in ANSYS

42 Battery : ANSYS Solutions Pack Level Other solutions at Pack Level Capabilities exist in standard ANSYS products but currently there are no demonstration cases NVH Fluid noise for air-cooled packs Crash, impact Durability 2011 HEV marketing campaign will create these demonstration cases 2011 ANSYS, Inc. All rights reserved. 42 ANSYS, Inc. Proprietary

Battery : ANSYS Solutions Cell Level Cell Manufacturing: Coating Analysis Courtesy:

Battery : ANSYS Solutions Cell Level Cell Manufacturing: Flow Inside Die Courtesy:

Battery : ANSYS Solutions Cell Level Cell Electrical Model: Simple enough for system level analysis Detailed electrochemistry models are too time consuming for system level analysis Accurate enough

46 Battery : ANSYS Solutions Cell Level Cell Electrical Model: Simple enough for system level analysis Detailed electrochemistry models are too time consuming for system level analysis Accurate enough for virtual prototyping Non-linear circuit voltage as a function of SOC Transient I-V performance Runtime prediction Discharge rate dependent capacity Temperature effect Accurate transient temperature prediction 2011 ANSYS, Inc. All rights reserved. 46 ANSYS, Inc. Proprietary

47 Battery : ANSYS Solutions Cell Level Single Cell Thermal Model Model based on: - Newman & Tidemann (1993); - Gu (1983) ; - Kim et al (2008)* 2011 ANSYS, Inc. All rights reserved. 47 ANSYS, Inc. Proprietary

Battery : ANSYS Solutions Cell Level Electrochemistry: Newman s 1D Model

Battery : ANSYS Solutions Cell Level 3D Electrochemistry

51 Battery: ANSYS Solutions System Level Pack Circuit Model 5 cells 60 Cells connected in matrix pack Packs are connected in matrix to final configuration 2011 ANSYS, Inc. All rights reserved. 51 ANSYS, Inc. Proprietary

Battery: ANSYS Solutions System Level Battery in Control System with Motor

53 Battery: Competition Analysis CD-Adapco Pack Level CD-Adapco ANSYS Basic CFD needed for Battery Simulation Design Exploration Comparable to ANSYS Rudimentary parameterization Comparable SpaceClaim and DesignXplorer give advantage LTI Method No comparable solution Easy Simplorer based solution Please do no display this slide outside of the ANSYS and ANSYS Channel Partner Organizations 2011 ANSYS, Inc. All rights reserved. 53 ANSYS, Inc. Proprietary

54 Battery: Competition Analysis CD-Adapco Cell Level CD-Adapco ANSYS Cell Electrical Model Partnership with Battery Design LLC. Provides advantage in standard cell characteristics and cell material properties Simplorer based model. Needs cell properties as input. Cell Thermal Model Demonstrated examples Comparable capability 1D Electrochemistry 3D Electrochemistry No demonstrated solution Some demonstrated examples Simplorer based solution Some demonstrated examples Please do no display this slide outside of the ANSYS and ANSYS Channel Partner Organizations 2011 ANSYS, Inc. All rights reserved. 54 ANSYS, Inc. Proprietary

55 Battery: Competition Analysis CD-Adapco Multiphysics and System Level CD-Adapco ANSYS Multiphysics (E.g. bus bar deformation) No comparable solution ANSYS core advantage Durability, Impact, Abuse No direct solution ANSYS mechanical NVH Some acoustics models, no structural solution Broadband acoustics models in CFD, Structural NVH System Integration No direct solution Simplorer based solution Please do no display this slide outside of the ANSYS and ANSYS Channel Partner Organizations 2011 ANSYS, Inc. All rights reserved. 55 ANSYS, Inc. Proprietary

Battery: Competition Analysis Resources More information on automotive

Battery: 2011 Targets OEMs All major car, truck OEMs have ambitious electrification plans: All are targets Battery Suppliers Over 150 battery companies in the world Full list on Automotive Google

57 Battery: 2011 Targets OEMs All major car, truck OEMs have ambitious electrification plans: All are targets Battery Suppliers Over 150 battery companies in the world Full list on Automotive Google Site E.g. Saft, LG Chem Major concentration in China, Korea Other Suppliers (Integrators, Battery Management System) E.g. Continental, Magna 2011 ANSYS, Inc. All rights reserved. 57 ANSYS, Inc. Proprietary

58 Outline EV/HEV Market Trends Value Chain EV/HEV Simulation Integrated Simulation Battery Traction Motor Power Electronics Key Problems and Simulation Needs ANSYS Solutions Competition Analysis and Differentiators R13 Advances 2011 ANSYS Targets Success Stories 2011 Marketing Campaigns 2011 ANSYS, Inc. All rights reserved. 58 ANSYS, Inc. Proprietary

59 Traction Motor Key Problems and Simulation Needs Traction Motors: Optimization needs Efficiency (key importance for HEVs) Size and cost NVH; reliability and durability Technical Challenges Optimizing magnetics design (speed, torque, losses) Numerous variables have influence; virtually impossible to study effects through physical testing Thermal management (accurate loss mapping) Performance drops with temperature increase Noise and Vibration Motor is the biggest noise source in electric vehicles System integration (optimize motor and controls) Modern motor controls are highly complex; motor and controls have critical need to be designed together as one system 2011 ANSYS, Inc. All rights reserved. 59 ANSYS, Inc. Proprietary

60 Traction Motor Key Problems and Simulation Needs More Innovative and Complex Designs 19 machine types to choose from Different machine geometry templates 2011 ANSYS, Inc. All rights reserved. 60 ANSYS, Inc. Proprietary

integrated motor / electronics / control simulation is needed 172.00 100.00 Phase Current R A.I [A] R B.

61 Traction Motor Key Problems and Simulation Needs Integration with Controls and Power Electronics Electric Machine does not work by itself; two optimized components do not add up to be an optimized system; integrated motor / electronics / control simulation is needed Phase Current R A.I [A] R B.I [A] R C.I [A] m 80.00m 85.00m 2011 ANSYS, Inc. All rights reserved. 61 ANSYS, Inc. Proprietary

62 Traction Motor Key Problems and Simulation Needs Multiphysics Coupling Thermal-Stress with Electromagnetic Force load The electromagnetic force density from Maxwell is used as load in Structural Deformation of the stator Deformation of coils 2011 ANSYS, Inc. All rights reserved. 62 ANSYS, Inc. Proprietary

63 Traction Motor Key Problems and Simulation Needs Shorten Time to Market Host Nodes Let computers work 24/7, freeing engineers time for other important tasks Parametric variations: 2,200 Solve time, one processor: 7.6 days Solve time, distributed, 48 COREs: 4.5 hours Speed improvement: 43.2X 2011 ANSYS, Inc. All rights reserved. 63 ANSYS, Inc. Proprietary

64 Traction Motor Competition Analysis and Differentiators ANSYS Simulation Driven Product Development Electric Machine Design Methodology ANSYS offers Functionality Competition Maxwell Simplorer ANSYS Mechanical/CFD Q3D DX, MPO, DSO RMxprt Electromagnetic Finite Element Solvers Circuit/System Simulator Stress, Thermal Parasitics Extraction Design Automation & Optimization Closed-form analytical solution, quickly reduce design space JMag, FLUX, MagNet, Saber, PSpice, Matlab/SIMULINK, Abaqus, STAR-CD, SPEED, MotorSolve 2011 ANSYS, Inc. All rights reserved. 64 ANSYS, Inc. Proprietary

65 Traction Motor Competition Analysis and Differentiators ANSYS offers Functionality Competition ANSYS Maxwell Simplorer Electric ANSYS Simulation Driven Product Development Electric Machine Design Methodology Electromagnetic Finite Element Solvers Circuit/System Simulator JMag, FLUX, MagNet, Saber, PSpice, Matlab/SIMULINK, Mechanical/CFD Stress, Thermal Abacus, STAR-CD, Machine Q3D DX, MPO, DSO Design RMxprt Methodology Fully Integrated Electric Mechine System Design Parasitics Extraction Design Automation & Optimization Closed-form analytical solution, quickly reduce design space NONE! SPEED, MotorSolve 2011 ANSYS, Inc. All rights reserved. 65 ANSYS, Inc. Proprietary

66 Traction Motor ANSYS 13.0 Advances Ansoft Tools inside ANSYS Workbench Easier and more efficient coupling Using DM for geometry Using DX for optimization/statistical study Maxwell TAU Meshing More robust and efficient Can use MP license More Robust DSO Easier to set up Speed, scalability getting even better 2011 ANSYS, Inc. All rights reserved. 66 ANSYS, Inc. Proprietary

67 Traction Motor 2011 ANSYS Targets General Trends It takes years for major auto OEMs to realize that they have to control their own destiny in terms of designing traction motors by themselves. For example, GM. Ford is starting to realize that. It also takes years for motor suppliers to realize that they need to re-design a motor for auto traction application ANSYS, Inc. All rights reserved. 67 ANSYS, Inc. Proprietary

68 Traction Motor 2011 ANSYS Targets Maintain Success and Expand Use success story in one OEM and apply to more GM -> Ford -> Chrysler Use success story in one physics and apply to more Magnetics design -> Structural/Thermal -> Electronics Use success story in traction motor and apply to other applications Battery, electronics, system integration, EMI/EMC 2011 ANSYS, Inc. All rights reserved. 68 ANSYS, Inc. Proprietary

69 Traction Motor 2011 ANSYS Targets Expand Success to Major Suppliers and Commercial Vehicles/Off-highway Vehicles Suppliers Want to do More too Commercial Vehicle companies have huge interest in HEV/EV too Eaton Trucks, Prestolite, ArvinMeritor, etc. Off-highway industry also starts looking into HEV/EV CAT, John Deere, Cummins, etc ANSYS, Inc. All rights reserved. 69 ANSYS, Inc. Proprietary

70 Traction Motor 2011 ANSYS Targets Expand Success to other Motor Areas Power Steering, Electric Pumps, Wind Shields, etc. These applications have the same physics (motor, controller, power source/electronics, mechanical components) HEV/EVs need new designs for these applications because requirements are very different from traditional vehicles 2011 ANSYS, Inc. All rights reserved. 70 ANSYS, Inc. Proprietary

71 Outline EV/HEV Market Trends Value Chain EV/HEV Simulation Integrated Simulation Battery Traction Motor Power Electronics Key Problems and Simulation Needs ANSYS Solutions Competition Analysis and Differentiators ANSYS 13.0 Advances 2011 ANSYS Targets Success Stories 2011 Marketing Campaigns 2011 ANSYS, Inc. All rights reserved. 71 ANSYS, Inc. Proprietary

72 HEV Power Electronics Key Problems and Simulation Needs Energy Management High Power Distribution Systems Systems Typical HEV System Charging Systems (internal use only) 2011 ANSYS, Inc. All rights reserved. 72 ANSYS, Inc. Proprietary

74 HEV Power Electronics ANSYS Solutions ANSYS is the only provider of a complete power electronics design solution for Hybrid Electric Vehicles! Simulink Simplorer Co Simulation Mathcad ModelSIM 2011 ANSYS, Inc. All rights reserved. 74 ANSYS, Inc. Proprietary

HEV Power Electronics ANSYS Solutions ANSYS Complete Power Electronics Design Solution Can assist engineers in designing and analyzing power systems, drives, and components for HEV market Provides

75 HEV Power Electronics ANSYS Solutions ANSYS Complete Power Electronics Design Solution Can assist engineers in designing and analyzing power systems, drives, and components for HEV market Provides true multi-physics coupled solutions for electrical, magnetic, mechanical, fluid, and thermal simulations Integrates electromagnetic, circuit, and system engineering using a common desktop environment Three Basic Simulation types on same schematic: Circuits Block Diagrams State Machines Co-simulation with Maxwell and Simulink Couples directly to: EM tools (Maxwell, PExprt, Q3D, RMxprt, HFSS) Thermal tools (ANSYS CFD, ANSYS Icepak) Optimization and Statistical analysis VHDL-AMS capability 2011 ANSYS, Inc. All rights reserved. 75 ANSYS, Inc. Proprietary

HEV Power Electronics ANSYS System Solutions

Electromagnetic Thermal Fluidic Mechanical

76 HEV Power Electronics ANSYS System Solutions System Circuit Subsystem Q3D, Xprt Tools Simplorer Maxwell, HFSS FEA solvers ANSYS Mechanical, CFD, Icepak Component Electromagnetic Thermal Fluidic Mechanical 2011 ANSYS, Inc. All rights reserved. 76 ANSYS, Inc. Proprietary

77 D2D GAIN J HEV Power Electronics ANSYS Coupled Solutions ANSYS CFD Thermal Simplorer System Design RMxprt Motor Design IA PMSYNC Torque A IB ICA: A A IC PP := 6 A Q3D Parasitics Icepak PExprt Magnetics ANSYS Mechanical Thermal/Stress Maxwell Electromagnetic Components Model order Reduction Co-simulation Field Solution Model Generation 2011 ANSYS, Inc. All rights reserved. 77 ANSYS, Inc. Proprietary

78 HEV Power Electronics Competitive Differentiators ANSYS offers Functionality Differentiators Simplorer Circuit/System Simulator Multi-domain, multi-physics Maxwell PExprt RMxprt Q3D ANSYS Mechanical Electromagnetic Finite Element Solvers for components Closed-form analytical solution for Transformers and Inductors Closed-form analytical solution for Motors and Generators R,L,C,G parasitic extraction for wiring harnesses and interconnects Basic Stress and Thermal Analysis Automatic adaptive meshing, 3D transient w/ circuits, motion Couples to Simplorer and Maxwell for complete FEA Couples to Simplorer and Maxwell for complete FEA Frequency dependent model coupled to Simplorer Couples directly to Maxwell via Workbench ANSYS CFD Thermal analysis using fluid flow Couples directly to Maxwell ANSYS Icepak Electronics Cooling Couples directly to Simplorer 2011 ANSYS, Inc. All rights reserved. 78 ANSYS, Inc. Proprietary

79 HEV Power Electronics Simplorer v8.1 and v9 Advances Integrated with the ANSYS Workbench interface. Can be created and launched from WB Improved co-simulation capabilities with Maxwell 3D Enhanced IGBT Parameterization Wizard with more accurate fitting algorithm important for EMC/EMI analysis Direct link with ANSYS Icepak Q3D State-Space Model from S- Parameters State-space model to simulate multi-domain state-space models Dynamic plot updates and numeric displays while simulating 2011 ANSYS, Inc. All rights reserved. 79 ANSYS, Inc. Proprietary

80 HEV Power Electronics 2011 ANSYS Target #1 Expand Success to other Major Suppliers of HEV components and systems such as XYZ Corp. XYZ Corporation in Detroit is a Tier 1,2 supplier (traditionally seating) for major automotive OEMs Previously owned ANSYS Mechanical and ANSYS Icepak Made a strategic decision several years ago to move into the automotive power electronics market Currently developing a high voltage power supply for a HEV battery charging system Over the past 2 years, XYZ has acquired: Maxwell, PExprt, Simplorer, Q3D, and HFSS Team of (8) engineers using this software today Currently evaluating SIwave 2011 ANSYS, Inc. All rights reserved. 80 ANSYS, Inc. Proprietary

Potential Areas for Simulation 2011 ANSYS, Inc.

82 HEV Power Electronics 2011 ANSYS Target #2 Expand Success to Major Automotive OEM s for radiated EMC/EMI analysis of power supplies IGBT Module Pack 3D accurate model Parameters Extraction Design and Couplings Model IGBT Model Far Field Study Tridimensional IGBT pack model and EM study Parasitic model extraction IGBT circuit model Electromagnetic (EM) study Far Field Study for Electric Field EM 2011 ANSYS, Inc. All rights reserved. 82 ANSYS, Inc. Proprietary

83 Analysis Methodology Using Different Techniques FEA / Boundary Element Method System Simulation Finite Element Method Finite Element Method Tridimensional IGBT pack model and EM study Parasitic model extraction IGBT circuit model Far Field Study for Electric Field EM 2011 ANSYS, Inc. All rights reserved. 83 ANSYS, Inc. Proprietary

86 HEV Power Electronics 2011 ANSYS Target #2 Expand Success to Major Automotive OEM s for conducted EMC/EMI analysis of power supplies Characterize and reduce EMI emissions from Switched Mode Power Supply (SMPS) by: - Model SMPS - Determine critical components in system - Determine noise attenuating techniques Detailed Procedure: Model: Actives and Passives (discrete components and interconnects) Use simulations to find critical paths Focus attention on these paths to mitigate noise 2011 ANSYS, Inc. All rights reserved. 86 ANSYS, Inc. Proprietary

90 Outline EV/HEV Market Trends Value Chain EV/HEV Simulation Integrated Simulation Battery Traction Motor Power Electronics Key Problems and Simulation Needs ANSYS Solutions Competition Analysis and Differentiators R13 Advances 2011 ANSYS Targets Success Stories 2011 Marketing Campaigns 2011 ANSYS, Inc. All rights reserved. 90 ANSYS, Inc. Proprietary

91 Success Story 1 Company #1 Car Manufacturer What did they buy? DSO, Optimetrics, Maxwell ANSYS CFD, ANSYS Mechanical, DM, DX What are they using it for? Electric Motors, Battery, Power electronics 2011 ANSYS, Inc. All rights reserved. 91 ANSYS, Inc. Proprietary

92 Success Story 1 Company #1 Car Manufacturer What did they prefer ANSYS? Motors: very fast analysis of 1000s of designs using DSO Battery: WB workflow integrating multiple physics Future growth potential Structural mechanics & explicit Simplorer EKM? 2011 ANSYS, Inc. All rights reserved. 92 ANSYS, Inc. Proprietary

93 Success Story 2 Company #2 Battery Manufacturer Who are they? A prominent U.S. battery company What did they buy? CFD (Fluent) What are they using it for? Battery Simulation 2011 ANSYS, Inc. All rights reserved. 93 ANSYS, Inc. Proprietary

94 Success Story 2 Company #2 Battery Manufacturer What did they prefer ANSYS? They replaced CD-Adapco that was in use for 2 years Preferred ANSYS due to Workbench Opinion about ANSYS leadership in battery simulation Expert onsite visits, presentations, reference materials Prior FLUENT use by key engineering manager 2011 ANSYS, Inc. All rights reserved. 94 ANSYS, Inc. Proprietary

95 Success Story 3 Company #3 Car Manufacturer What did they buy? Maxwell 2D/3D + RMxprt + Optimetrics + ANSYS FLUENT + DesignXplorer What are they using it for? Departments: (a) R&D (b) Production) Applications Verify performance map of supplier produced motor Simplorer co-simulation for circuit and system level Battery cooling 2011 ANSYS, Inc. All rights reserved. 95 ANSYS, Inc. Proprietary

96 Success Story 3 Company #3 Car Manufacturer What did they prefer ANSYS? Competitors beaten CEDRAT, CD-Adapco Preffered ANSYS due to Single vendor for battery, motor, electronics Simulation workflow (from CATIA V5 thru DX/DOE) Coupling Maxwell & FLUENT ROM of Maxwell & FLUENT into Simplorer ANSYS more stable company compared to CEDRAT Excellent support Future growth potential DSO, Q3D 2011 ANSYS, Inc. All rights reserved. 96 ANSYS, Inc. Proprietary

97 Success Story 4 Company #3 Multinational Parts Supplier What did they buy? Q3D + ANSYS FLUENT + ANSYS Mechanical What are they using it for? Micro-hybrid systems (start-stop alternator, electronics) Mechatronics simulation Thermal FLUENT Structural Acoustics ANSYS Mechanical Electromagnetics Maxwell Co-Simulation Simplorer 2011 ANSYS, Inc. All rights reserved. 97 ANSYS, Inc. Proprietary

98 Success Story 4 Company #3 Multinational Parts Supplier What did they prefer ANSYS? Competitors beaten CEDRAT, CST, Dassault, CD-Adapco Corporate focus on simulation at Valeo Why did they prefer ANSYS ANSYS Vision for Hybrid Electric Vehicles Workbench workflow Multiphysics Integrated simulation 2011 ANSYS, Inc. All rights reserved. 98 ANSYS, Inc. Proprietary

99 Success Story 5 Company #5 Car Manufacturer HEV related sale Maxwell - Motor Design CFD - Battery Design See details in Day 4 presentation by Greg Fallon and Tom Smithyman 2011 ANSYS, Inc. All rights reserved. 99 ANSYS, Inc. Proprietary

100 Outline EV/HEV Market Trends Value Chain EV/HEV Simulation Integrated Simulation Battery Traction Motor Power Electronics Key Problems and Simulation Needs ANSYS Solutions Competition Analysis and Differentiators R13 Advances 2011 ANSYS Targets Success Stories 2011 Marketing Campaigns 2011 ANSYS, Inc. All rights reserved. 100 ANSYS, Inc. Proprietary

Realize Your Product Promise. Simplorer

Realize Your Product Promise. Simplorer Realize Your Product Promise Simplorer Simplify multidomain simulation from detailed components to the system level, all within a single design environment. When you trust complex systems design to ANSYS