Because the electric powertrain is new and revolutionary technology, automotive industry engineers face the challenge of designing affordable, efficient, stable and reliable electric powertrain technologies almost entirely from scratch — and in an incredibly compressed time frame.
Engineering simulation helps to expedite and improve electric powertrain development, providing in-depth insights into complex components and systems that guide development through virtual prototyping and testing. Simulation software from ANSYS allows engineers to understand how a design performs under various real-life conditions even before prototyping takes place. Such usage of CAE may well separate the visionaries from the also-rans in the race to replace conventional powertrain technology.
Highly complex, electric vehicle (EV) and hybrid-electric vehicle (HEV) powertrains and their subsystems and components must work together in a coherent, tightly coupled way to maximize vehicle efficiency and performance.
The electric powertrain can be accurately simulated only with an integrated simulation platform. This allows developers to evaluate not only individual components and subsystems but also the interactions between them at the system level. Since components are subjected to multiple physics in the real world, simulation tools must accurately predict a wide range of forces, including structural mechanics, explicit dynamics, fluid dynamics, thermal physics, magnetics, electrochemistry, electromagnetic radiation and conductance (EMI/EMC). Innovative powertrain design also must include converting detailed component models into reduced-order models and connecting them to create circuit- and system-level models, which can then be used to optimize a subsystem or the entire electric powertrain.
Integrated component-and system-level simulation. Comprehensive physics simulation capabilities. As the world leader in Simulation Driven Product Development tools, ANSYS provides integrated software engineering simulation tools to solve key challenges in electric powertrain development:
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- Electrochemistry and cell design
- Battery thermal management: temperature uniformity, cold/hot start/stop
- Battery mechanical abuse: crash, crush, nail penetration
- Battery electrical abuse: overcharging/discharging, high current charging/discharging, external short
- NVH: flow noise, structural vibration
- Structural durability
- Cooling: developing dissipation paths for heat from electrical losses
- Control logic: for optimizing electric powertrain components and system under all driving conditions
- Optimizing magnetics design: speed, torque, losses
- Thermal management: accurate loss mapping
- Vibration: reducing motor noise
- System integration: optimizing motor and controls together
- Structural durability