“Regardless of model complexity and size, we can now solve computations of hour-long drive cycles in close to real time, while simpler models can take just minutes. The inclusion of a virtual battery pack also helped our team identify and eliminate potential problems in battery design, including design issues early on in the development process.”
— David Singer Simulation Engineer for Multiphysics / KTM R&D
In the spirit of no-trace off-road adventure, KTM, a European motorcycle manufacturer, is focused on taking electrification to the trails with its E-Ride dirt bike. With support from Ansys’ channel partner CADFEM, KTM leveraged Ansys Twin Builder and Ansys Mechanical to develop a simulation workflow and a full 3D model useful in the virtual design, validation, and verification of a traction battery with optimized thermal properties.
KTM has a previous history in the solitary use of simulation. An added challenge for the team was creating an entire workflow around battery optimization that used various tools to simultaneously analyze thermal interactions as they relate to thermal hotspot avoidance, temperature distribution, and charging efficiency. KTM needed to be able to use their own code to generate the lookup tables, then used Ansys simulation to tune the parameters and scale up from cells to modules.
An electrical lumped model was used to predict the heat generation per cell as a function of each cell’s temperature and its state of charge (SOC). Resulting values were then fed into a compact thermal model derived from 3D finite element method (FEM) models that calculate the battery’s temperature distribution. A third submodule was then created based on computational fluid dynamics (CFD) analysis to calculate thermal dissipation of the battery housing resulting from convection and radiation. Mechanical was used to create and mesh the high-dimensional FEM model.