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Automotive electrical and electromechanical system design

This document discusses the challenges of designing automotive electrical and electromechanical systems. It addresses multi-domain, multi-level, and multi-organizational design challenges. It promotes an integrated design environment to enable modeling of different domains, accuracy levels, and organizational interactions. Libraries of automotive-specific components are described to support electrical, hydraulic, and power system modeling.

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Automotive Electrical and Electromechanical System Design Dr.-Ing. Uwe Knorr Product Marketing Director Ansoft Corporation Pittsburgh, PA
Challenge #1: Multi-Domain Design Mechanical Electro- Chemical Hydraulic Electrical Controls Magnetic Pneumatic Thermal
Multi-Domain Design Multiple Domains are interconnected and influence each other The electrical content of vehicles increases More and more controls are involved Electrical systems closely interact with other domains Electro-Chemical Electro-Mechanical Electro-Magnetic Electro-Thermal
Challenge #2: Multi-Level Design Accuracy Complexity Details #ofComponents )()( )( )()( )()( )( )()( 1 1 111 1 1 111 ttp dt td Rtitv ttp dt td Rtitv d q qq q d dd ψω ψ ψω ψ ⋅⋅++⋅= ⋅⋅−+⋅= EQU X Y NL XY1 NL1 I_main sp vset vbus vbus := VM1.V D1 CONST CONST GAIN I LIMIT VBUS VSET ERR GAIN1 INTG1 SUM1 LIMIT1 + V VM1 I1 GAIN GAIN2 engine2generator INREG OUTREG GAIN GAIN3 GAIN GAIN4 VBUS<VSET VBUS>=VSET
Multi-Level Design Different analyses require different model accuracy levels Different analyses require different algorithms Different accuracy levels require different modeling languages Model exchange from one level to the next higher level requires model extraction Design information must be exchanged between different design groups
Challenge #3: Multi-Organizational Design Tier II Component Tier I Subsystem OEM System
Multi-Organizational Design Geometry, Material, Structure Fundamental Physics, DC, AC, TR, FEA, Stress TIER II Circuits, Block Diagrams, State Machines, C-Code, Lookup Tables Controls, Circuit Design, Statistical, Optimization, AC, Short Transients TIER I System Models with lookup tables minimum parameters Statistical, Worst Case, Drive Cycle, FMEA, Long Transients OEM ModelAnalysis
Design Challenges Today Control Electrical Mechanical Component Supplier System Integrator Tier 1 Supplier Circuit System Component Hydraulics Tier 2 Supplier Thermal Magnetic
Need for Integration Integration Control Electrical Mechanical Component Supplier System Integrator Tier 1 Supplier Circuit System Component Multi-Domain Multi-Level Multi-Organization
EM Design Environment SIMPLORER Simulation Data Bus Simulator Coupling Technology Circuit Simulator Block Diagram Simulator State Machine Simulator Simulink MathCad Maxwell2D/3D Electromagnetism Electro mechanics C/C++ Interface Model Database Electrical, Blocks, States, Machines, Automotive, Hydraulic, Mechanics, Power, Semiconductors… VHDL-AMS Simulator
Integrated Design Environment WIN/2000 WIN/XP WIN/NT Pentium >256MB
Compatibility MS-Office compatible Read and write Excel, Access Copy & Paste to and from Word, PowerPoint, Excel… Windows Printing Support Data Format compatible ASCII Access (*.mdb) Excel (*.xls) CSV (*.csv) Comtrade (*.cfg) SPICE (*.out) TEK – Oscilloscope data (*.dat)
Post Processing IEEE 488.2 Data Interface (GPIB) Graphical and numerical data analysis and representation Power Module Channel Calculator FFT Presentation Mode Matlab® and Mathcad® Integration
Component Characterization 2D, 3D, multi dimensional lookup table # L1 #C1 NL NL_Charact YZ X V3DLUT E1 Y t V_LUT M3 ~B A C IM1 Y t M_LUT1 • Characteristics • Stimuli • Loads Data Acquisition Data Transfer Data Processing
State Machines Behavioral Modeling Smart models, state dependent step size modification Event driven modification of topologies & parameters Online measurement of characteristic values
Relay Model com no drvm drvp Relay E1 R1 E2 S1 LCoil := 250m RSup := 680 ROn := 5m tdbrk := 8m tdmk := 12m VPULL := 7 VDROP := 2 RCoil := 3 CCoil := 40n E5 S3 E6 R3 Relay.Iin Relay.Iout t 14.00 -2.00 2.00 4.00 6.00 8.00 10.00 0 0.600.20 0.40 R1pNoRs1 Final Relay Model Relay Macro Symbol Editor
Relay Model Rsup LCoil RCoil ROn S1 drvp drvm no com ON_DIS DELAY_OFF_ON DELAY_ON_OFFLCoil.I >= IPULL LCoil.I <= IDROP lon loff OFF_DIS DEL: loff##tdbrk DEL: lon##tdmk EQU IPULL := VPULL/RCoil.R IDROP := VDROP/RCoil.R A + AM1 + V VM1 CCoil • Fast! • Easy model generation • Good numerical behavior
Block Diagrams Analog and Digital Controller Modeling CONTR_OUT op2 := 2.5 ymax2 := 1 op1 := -2.5 ymax1 := -1 -16.66m N"GSMP_1" LIMITER u_limit := 20 l_limit := 0 EXT P_GAIN KP := 50 I_GAIN KI := 20 P I LIMIT EXT CONST NSET 16.666667 Each block can be assigned an individual sampling time or run with system time step PI C/C++ Code NL
DC Motor Drive System L_R L_S L_T ET1 ET2 ET3 CD 1m R_R R_S R_T Yt LOAD CONTR_OUT THRES2 := 2.5 VAL2 := 1 THRES1 := -2.5 VAL1 := -1 -16.66m DCM.N P_GAIN KP := 50 I_GAIN KI := 20 LIMITER UL := 20 LL := 0 10m GAIN GAIN I LIMIT CONST N_REF 16.6667 0.3m M DCM RA := 1.2 LA := 9.5m KE := 0.544 J := 4m A + AM1D1 D2 D3 D4 D5 D6 D7 TR CONST CLOCK .1m Wiper System
Wiper System – Result Motor Torque and Load Torque Motor Speed N_REF N T 20.00 -10.00 -10.00 0 0 0 0 100.00m 100.00m 50.00m 50.00mT 15.00 0 0 10.00 10.00 0 0 100.00m 100.00m 50.00m 50.00m
Automotive Library Power Storages Wires Battery - Basic Model Battery Fuel Cell Wire - Thermal static Wire - Thermal dynamic Wire - Thermal dynamic II Wire with Thermal Pin Wire - Advanced Wire - Advanced II Gauge based Fuses Wire - Thermal static Wire - Thermal dynamic Wire - Thermal dynamic II Wire with Thermal Pin Wire - Advanced Wire - Advanced II Fuse - Single Element Fuse - Double Element Fuse - Advanced PPTC (Three RC combinations) PPTC (Two RC Combinations) Lamps Lamp - Filament Lamp - Single Filament Lamp - Double Filament Lamp - Advanced Relays Relay - Normally Open Relay - Normally Closed Relay - One Pole, Two Throws Relay - Two Poles, Two Throws Relay - Two Poles, Cross-Strap Spark Plugs Spark Plug Machines Alternator - Transient Model Alternator - Average Model Alternator - Current Source Starter DC Machine Mechanical Models Inertia Friction Fan Ideal Gearbox Gearbox with Losses PWM Models PWM PWM Switch PWM Load Flasher Switch Connectors Inline Terminal Pair Eyelet Terminal Engine Models Engine - Speed Source Engine - Dynamic Model Applications: • Electrical Distribution System of Vehicles • Power Management • Drive Cycle Analysis • FMEA • Statistical Analyses Industries: • Automotive Manufacturer • EV/EHV • Aerospace • Defense • Ship Building Industry Automotive System Library
Automotive Library Yt Y t Battery - + Engine Block Ground Chassis Ground To Hazzard Flasher To Head Lamp Switch Lamp Switch battery1 fuse1_5Amp fuse2_15Amp rlyno1 S1 TS1_HIGH_LOW_Beams_Switch Low High Low High High Low RH HeadLamp LH HeadLamp Tail Lamps Turn Signal Y t Y t QuickGraph1 N0161.V t 14.00 -2.00 2.00 6.00 10.00 0 60.0020.00 40.00 S2 S3 D1 D2 t 60s itp11 itp19 Probe1 t 7.50 -2.50 0 5.00 0 60.0025.00 50.00 Exterior Lighting System Inrush Currents Turn Signal Voltages
Automotive Library Benefits Easy to use and intuitive graphical modeling Easy parameterization using Wizard technology Statistical analyses, optimization and parameter variations Characterization tool for fuses Multiple model levels for components Web based example database with jump start projects Animated symbols for easy visual inspection
Electro-Chemical Components Lead Acid BatteryFuel Cell Fuel Cell +- Battery - +
EV/EHV – Charging System ST_r1 L1 0 0.1m RLoad RL TR1 D1 ICA: L1.I>=I_command ST_r1.VAL>=0.99 and L1.I<I_command On SET: cs:=1 Off SET: cs:=0 period := 20u Off2 SET: RL:=10 t>3m t>12m SET: RL:=5 SET: RL:=5 t>0.0025 SET: I_command:=10 SET: I_command:=15 VM1.V t 6.10 5.10 5.20 5.30 5.40 5.50 5.60 5.70 5.80 5.90 6.00 0 20.00m2.50m 5.00m 7.50m 10.00m 12.50m 15.00m + V VM1 L1.I t 16.00 0 2.00 4.00 6.00 8.00 10.00 12.00 14.00 0 20.00m2.50m 5.00m 7.50m 10.00m 12.50m 15.00m t0 20.00m2.50m 5.00m 7.50m 10.00m 12.50m 15.00m Output Voltage Input Voltage Inductor Current Transistor Control modeled using state machines Load resistance and reference current modification modeled using state machines Boost Converter Fuel Cell + - FUELCELL_A2 Battery -+ LBATT_A2
Multi-Domain Design • Hydraulics • VHDL-AMS • Mechanics • Electro Mechanical • Magnetics • …
Hydraulic Library 1 0 3 r1 pk_1 50
Hydraulic Library P1 PIPE Level1 PIPE1 Sharp-Edge Generic OR_SE1 VOL_ACT1 MASS_TRB1 LIMIT_TRB1 F LIMIT_TRB1.SUL MASS_TRB1.S t 15.00m 0 10.00m 0 1.000.50
Power Library Power Library Power System and Cable Models Single Phase Power Supply Ideal Three Phase Power Supply Three Phase Power Supply with Impedance WIRE - Gamma Model Wire T-Model Inverter Topologies Line-commutated Converters B2 Diode Bridge B2 Fully Controlled B2 Half-Controlled, Symmetrical B2 Half-Controlled, Asymmetrical B6 Diode Bridge Two Level Inverter Equivalent Circuit Three Phase Two Level Inverter Single Phase Two Level Inverter Three Phase Three Level Inverter Single Phase Three Level Inverter Control Algorithms Two Level Square Wave Two Level Natural Sampling Three Level Single Phase Three Level Three Phase Load Models Three Level Single Phase NS Three Level Three Phase NS Four Quadrant Current Control Four Quadrant Natural Sampling B6 Thyristor Bridge B6 Bridges - Inverse Parallel Connection B12 Diode Bridge B12 Thyristor Bridge Parallel Connection B12 Thyristor Bridge Cascade B24 Thyristor Bridge Single Phase A.C. Chopper Three Phase A.C. Chopper DC Link Three Phase RL Load Logic Dead Time Applications: • AC/DC Converters • Inverters (DC/AC) • Drive Systems • Power Quality • Alternative Power Industries: • Industrial Automation • Drives Manufacturers • EV/EHV • Power Conversion • Power Quality
Power Library Us1 Us2 Us3 Us1 Us2 Us3 M ω ω2 C J1 J2 ω1 M 1 M 2 + V CONST KONST1 SPR1 ein_aus 2L3_GTOS g_r1 g_r2 g_s1 g_s2 g_t1 g_t2 2L_NSAMP 2-level natural sampling Machine Characteristic 1.60k -200.00 0 200.00 400.00 600.00 800.00 1.00k 1.20k 1.40k -173.34 359.120 200.00 Stator Current asm_k_g22.Is_d asm_k_g22.Is_q t 200.00 -1.40k 0 -1.20k -1.00k -800.00 -600.00 -400.00 -200.00 0 1.501.00 Rotor Current asm_k_g22.Ir_d asm_k_g22.Ir_q t 1.40k -200.00 0 200.00 400.00 600.00 800.00 1.00k 1.20k 0 1.501.00 CONST Omega Uf Ua M ω Torque 350.00 -150.00 0 -100.00 100.00 200.00 300.00 0 1.501.00 Direct inverter driven squirrel cage induction machine with 2-level natural sampling control and mechanical load
Power Library Benefits Predefined macro models of frequently used power electronic topologies Includes common control algorithms Auxiliary elements, such as power grid models and loads System level models for rapid computation of overall system behavior, power quality and control algorithms Easy and intuitive graphical building blocks
Mechanical Elements Library Rotational Mass Translational Mass Coordinate Transformation Rotational-Rotational Rotational-Translational Translational-Rotational SYMP Synchronous Machine Permanent Excitation SYMP Synchronous Machine Permanent Excitation w Damper Electrical Machines DCMP DC-Machine Permanent Excitation ASMS Slip Ring Induction Machine Rigidity Rigidity Torque Source Ground Angular Velocity Source Velocity Source Ground Force Source Translational-Translational Mechanical Systems Applications: • Drive Trains • Electro-Hydraulic Systems • Electro-Mechanical Systems • Load Variations Industries: • Automotive Suppliers • Drive Manufacturers • Industrial Automation • Defense • Aerospace
Mechanical Elements Library ET1 Square_wave1.VAL M DCMP Dcmp1 J := 2m STF Stf1 M DCMP Dcmp2 J := 2m M DCMP Dcmp3 J := 2m STF Stf2 J Mas1 J := 10m Dcmp1.VA Dcmp2.VA Dcmp3.VA t 250.00 -250.00 0 -100.00 100.00 0 1.000.50 Dcmp1.OMEGA Dcmp2.OMEGA Dcmp3.OMEGA Mas1.OMEGA t 200.00 -200.00 0 -100.00 100.00 0 1.000.50 Mas1.MACX t 1.25k -1.25k 0 -500.00 500.00 0 1.000.50 Motor-generator combination driving a mass with limitations
Mechanical Elements Library Benefits Non-linear friction models incl. stick friction Non-linear rigidity models incl. backlash Fast computing 1D modeling approach based on SIMPLORER C-Code interface Electrical Machine model implementation with mechanical pins provide connectivity between electrical and mechanical world Schematic based graphical modeling with mechanical building blocks
VHDL-AMS Block Diagram Simulator State Flow Simulator SIMPLORER Simulation Data Bus MathCadSimulink Sim-Interface External Simulators Internal Simulators Multi-Organizational Design Digital Solver Circuit Elements Analog Solver AMS VHDL-AMS
VHDL-AMS Schematic Fully supported by SIMPLORER Schematic Embedded Editor with Syntax coloring allows to create models on sheet and in the ModelAgent
VHDL-AMS Code for a Resistor ENTITY Resistor IS PORT ( QUANTITY r : REAL := 1.0e+03; -- Default = 1 K TERMINAL p,m : ELECTRICAL); END ENTITY Resistor; ARCHITECTURE Rbehav1 OF Resistor IS QUANTITY voltage ACROSS current THROUGH p TO m; BEGIN current == voltage/r; END behav; mp Resistor r := 1.0e3 Rbehav1 r
Architecture 3 Architecture 2 Architecture 1 Entity and Architecture Entity Interface description of a subsystem or physical device Specifies input and output ports to the model Architecture Behavior description of the model Can be dataflow, structural, procedural, etc Modeling can deal with both analog (continuous) and digital (discrete) domains output ports input ports inout ports Architecture 2 Architecture 1 Entity
VHDL-AMS Basic Library OPEN!
VHDL – Digital Systems A.val B.val C.val SUM.y CARRY.y t0 40m2m 4m 6m 8m 10m 12m 14m 16m 18m 20m 22m 24m 26m 28m 30m 32m 34m 36m 38m CLK A CLK B CLK C XOR2 XOR2 AND2 AND2 AND2 Two bit adder with Carry Sum Carry OR3
VHDL – Digital Systems Complete Automotive System Analysis across Domains • ASICs • Micro Controller • FPGAs … ECU PTCU MCU VHDL
VHDL-AMS Multi Domain Design L dia := 1 len := 1/4 rho := MATH_PI vol := 1 b := 1 k := 10 EQU crank_radius:= 0.2 pipe_area:= 0.05 Fluidic torque force pressure flow_meter rhyd1 lhyd1 chyd1 spring_rotb damp_rotb T fm_rotb ω + vm_rotb ω + v_rotb mass_rotb CONST CONST 1/pipe_areacrank_radius P Spped damp_rotb.omega t [s] 40 -40 0 -25 25 0 0.1k50 QuickGraph2 flow_meter.q t [s] 1Meg -1Meg 0 0 0.1k50 Mechanic
VHDL-AMS Component Providers Subsystem Providers - Suppliers OEM System Simulation Drive Cycles Fuel Economy Multi Organization Design Power Train Electrical System Sensors … VHDL - AMS VHDL - AMS Solenoids, Motors, Battery, Sensors, Semiconductors, Fuse …
DC Drive – VHDL-AMS Controller L_R 0.3m L_S L_T ET1 ET2 ET3 R_R 10m R_S R_T t [s] 4.00e+001 0 2.00e+001 0 0 0.2 0.2 0.1 0.1 t [s] 1.50e+003 0 1.00e+003 0 0 0.2 0.2 0.1 0.1 motor current speed and reference speed LIMIT LIMITER LL := 0 UL := 20 GAIN CONTR_OUT THRES1 := -2.5 VAL1 := -1 THRES2 := 2.5 VAL2 := 1 CONST N_REF 1000 M DCM J := 4m LA := 9.5m RA := 1.2 KE := 0.544 A AM1 t [s] 1.00e+003 0 5.00e+002 0 0 0.2 0.2 0.1 0.1 DCM.MI [N·m] TLoad.VAL t [s] 2.00e+001 -1.00e+001 0 0 0 0.2 0.2 0.1 0.1 motor torque and load torque DC Link Voltage and Current D7 TR TLoad 3 Bridge1 PIC VHDL-AMS
DC Drive – VHDL-AMS Controller
ODE Non- Electrical Elements External Simulators Electrical Components µ-Controller Code C/C++ Interface
C/C++ Interface ® System Simulation The Multi Domain Simulator C/C++ make Dynamic Link Library .dll Symbol Library Symbol Editor
DC Drive – C-Code Controller L_R 0.3m L_S L_T ET1 ET2 ET3 R_R 10m R_S R_T DCM.IA [A] t [s] 3.00e+001 0 2.00e+001 0 0 0.2 0.2 0.1 0.1 DCM.N [rpm] N_REF.VAL t [s] 1.50e+003 0 1.00e+003 0 0 0.2 0.2 0.1 0.1 motor current speed and reference speed LIMIT LIMITER LL := 0 UL := 20 GAIN CONTR_OUT THRES1 := -2.5 VAL1 := -1 THRES2 := 2.5 VAL2 := 1 CONST N_REF 1000 M DCM J := 4m LA := 9.5m RA := 1.2 KE := 0.544 A AM1 Bridge1.Vout [V] Bridge1.Iout [A] t [s] 1.00e+003 0 5.00e+002 0 0 0.2 0.2 0.1 0.1 DCM.MI [N·m] TLoad.VAL t [s] 2.00e+001 -1.00e+001 0 0 0 0.2 0.2 0.1 0.1 motor torque and load torque DC Link Voltage and Current D7 TR TLoad 3 Bridge1 PIC PIC1 IGain := 2 PGain := 3 C-Code
DC Drive – C-Code Controller
SIM2SIM SIMPLORER to Simulink Interface SIMPLORER Simulink • Co-Simulation Interface • Link blocks in both packages • Using SIMPLORER's external simulator integration interface and S-function in Matlab • Co-Simulation Interface is an open API that can be used for other simulation packages
Drive System Control L_R 0.3m L_S L_T ET1 ET2 ET3 R_R 10m R_S R_T GAIN P_GAIN KP := 3 I I_GAIN KI := 2 LIMIT LIMITER LL := 0 UL := 20 CONTR_OUT THRES1 := -2.5 VAL1 := -1 THRES2 := 2.5 VAL2 := 1 CONST N_REF 1000 M DCM J := 4m LA := 9.5m RA := 1.2 KE := 0.544 A + AM1 D7 TR CONST CLOCK .1m 3 Bridge1 TLoad
Drive System Control L_R 0.3m L_S L_T ET1 ET2 ET3 R_R 10m R_S R_T M DCM J := 4m LA := 9.5m RA := 1.2 KE := 0.544 D7 TR 3 Bridge1 TLoad SiM2SiMSIMPLORER Link Interface  SiM2SiM 50 SIM2SIM1 SIM2SIM1.CS
Drive System Control
Complete Vehicle Simulation
SIMPLORER – Advisor Link
SIMPLORER – Advisor Link SIMPLORER Single Voltage Electrical Automobile System Template voltage regulator curve Regulator Generator p mGeneratorPower p m BatteryPower RearDefrost FrontHVAC Engine BrakeLightsMisc ExternalLights HeatedSeats FrontWipers RearWipers Radio TurnSignalRadiatorFan RearHVAC generic generator generator Battery Loads Starter p m ® Simulation properties: Step width max 100m Step width min 100u Simulation end time 1369 GAIN Battery -+ pm LoadPower + V VM1 A + AM1 generic generator generator1 SiM2SiMSIMPLORER Link Interface  SiM2SiM 50
Results Generator Current AM1.I t 100.00 -50.00 0 0 793.91500.00 Speed in RPM Speed t 4.00k -2.00k 0 2.50k 0 793.91500.00 Bus Voltage VM1.V t 13.00 11.50 12.00 0 793.91500.00 Load Power LoadPower t 500.00 -1.50k 0 -1.00k 0 793.91500.00
Complete Set of Analyses DC Analysis NINV INV OUT + - NSC_LM_7411 NINV INV OUT + - NSC_LM_7412 NINV INV OUT + - NSC_LM_7413 R1 10k R2 10k R3 10k R4 10k Rp 15916 R1p 10k C1 100p C2 1n E1 + V VM Rfp 30k R9 30k R 15916 OP: -0.00100994 V OP: -0.00405477 V OP: -7.9752e-006 V OP: 0.999992 V OP: 0.998936 V OP: 3.99573 V OP: 0.000980576 V OP: -3.98873 V OP: 1 V
E1 1 R1 500m L1 R2 16 L2 C1 132.6u 31.83m 3.18m OP: 0 V OP: 0.969697 V OP: 0.969697 V OP: 1 V Complete Set of Analyses Bode C1.VGain Phase 100 100 1k 1k 200 200 300 300 400 400 500 500 600 600 700 700 800 800 900 900 100 100 1k 1k 200 200 300 300 400 400 500 500 600 600 700 700 800 800 900 900 -28.01 -20.00 0.00 20.00 -28.01 -20.00 0.00 20.00 0.00 0.79 1.57 2.36 3.14 0.00 0.79 1.57 2.36 3.14 f [Hz] f [Hz] [dB] [rad] AC Analysis
Experiments 1D, 2D & 3D Parameter Sweep Monte Carlo Sensitivity Worst Case Optimization Simplex Algorithm Successive Approximation Genetic Algorithms
Electrical Mechanical ThermalMagneticLogic Hydraulic Component Circuit Sub-System System OEM Supplier VHDL-AMS Block Diagrams/State Machines FEA Disconnected Technologies Circuits
FEA VHDL-AM S Circuits Block D iagram s/ State M achines Integrated Technologies Simulator Coupling Matlab/ Simulink MathCAD Co-Simulation Advisor …
Integrated Design Environment Efficiency Com m unication Accuracy Standards

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Automotive electrical and electromechanical system design

  • 1.
    Automotive Electrical and ElectromechanicalSystem Design Dr.-Ing. Uwe Knorr Product Marketing Director Ansoft Corporation Pittsburgh, PA
  • 2.
  • 3.
    Multi-Domain Design Multiple Domainsare interconnected and influence each other The electrical content of vehicles increases More and more controls are involved Electrical systems closely interact with other domains Electro-Chemical Electro-Mechanical Electro-Magnetic Electro-Thermal
  • 4.
    Challenge #2: Multi-Level Design Accuracy Complexity Details #ofComponents )()( )( )()( )()( )( )()( 1 1 111 1 1 111 ttp dt td Rtitv ttp dt td Rtitv d q qq q d dd ψω ψ ψω ψ ⋅⋅++⋅= ⋅⋅−+⋅= EQU XY NL XY1 NL1 I_main sp vset vbus vbus := VM1.V D1 CONST CONST GAIN I LIMIT VBUS VSET ERR GAIN1 INTG1 SUM1 LIMIT1 + V VM1 I1 GAIN GAIN2 engine2generator INREG OUTREG GAIN GAIN3 GAIN GAIN4 VBUS<VSET VBUS>=VSET
  • 5.
    Multi-Level Design Different analysesrequire different model accuracy levels Different analyses require different algorithms Different accuracy levels require different modeling languages Model exchange from one level to the next higher level requires model extraction Design information must be exchanged between different design groups
  • 6.
    Challenge #3: Multi-Organizational Design TierII Component Tier I Subsystem OEM System
  • 7.
    Multi-Organizational Design Geometry, Material, Structure FundamentalPhysics, DC, AC, TR, FEA, Stress TIER II Circuits, Block Diagrams, State Machines, C-Code, Lookup Tables Controls, Circuit Design, Statistical, Optimization, AC, Short Transients TIER I System Models with lookup tables minimum parameters Statistical, Worst Case, Drive Cycle, FMEA, Long Transients OEM ModelAnalysis
  • 8.
    Design Challenges Today Control Electrical Mechanical Component Supplier System Integrator Tier1 Supplier Circuit System Component Hydraulics Tier 2 Supplier Thermal Magnetic
  • 9.
    Need for Integration Integration Control Electrical Mechanical Component Supplier System Integrator Tier1 Supplier Circuit System Component Multi-Domain Multi-Level Multi-Organization
  • 10.
    EM Design Environment SIMPLORERSimulation Data Bus Simulator Coupling Technology Circuit Simulator Block Diagram Simulator State Machine Simulator Simulink MathCad Maxwell2D/3D Electromagnetism Electro mechanics C/C++ Interface Model Database Electrical, Blocks, States, Machines, Automotive, Hydraulic, Mechanics, Power, Semiconductors… VHDL-AMS Simulator
  • 11.
  • 12.
    Compatibility MS-Office compatible Read andwrite Excel, Access Copy & Paste to and from Word, PowerPoint, Excel… Windows Printing Support Data Format compatible ASCII Access (*.mdb) Excel (*.xls) CSV (*.csv) Comtrade (*.cfg) SPICE (*.out) TEK – Oscilloscope data (*.dat)
  • 13.
    Post Processing IEEE 488.2Data Interface (GPIB) Graphical and numerical data analysis and representation Power Module Channel Calculator FFT Presentation Mode Matlab® and Mathcad® Integration
  • 14.
    Component Characterization 2D, 3D,multi dimensional lookup table # L1 #C1 NL NL_Charact YZ X V3DLUT E1 Y t V_LUT M3 ~B A C IM1 Y t M_LUT1 • Characteristics • Stimuli • Loads Data Acquisition Data Transfer Data Processing
  • 15.
    State Machines Behavioral Modeling Smartmodels, state dependent step size modification Event driven modification of topologies & parameters Online measurement of characteristic values
  • 16.
    Relay Model com no drvm drvp Relay E1 R1 E2 S1 LCoil:= 250m RSup := 680 ROn := 5m tdbrk := 8m tdmk := 12m VPULL := 7 VDROP := 2 RCoil := 3 CCoil := 40n E5 S3 E6 R3 Relay.Iin Relay.Iout t 14.00 -2.00 2.00 4.00 6.00 8.00 10.00 0 0.600.20 0.40 R1pNoRs1 Final Relay Model Relay Macro Symbol Editor
  • 17.
    Relay Model Rsup LCoil RCoil ROn S1 drvp drvm no com ON_DIS DELAY_OFF_ON DELAY_ON_OFFLCoil.I >=IPULL LCoil.I <= IDROP lon loff OFF_DIS DEL: loff##tdbrk DEL: lon##tdmk EQU IPULL := VPULL/RCoil.R IDROP := VDROP/RCoil.R A + AM1 + V VM1 CCoil • Fast! • Easy model generation • Good numerical behavior
  • 18.
    Block Diagrams Analog andDigital Controller Modeling CONTR_OUT op2 := 2.5 ymax2 := 1 op1 := -2.5 ymax1 := -1 -16.66m N"GSMP_1" LIMITER u_limit := 20 l_limit := 0 EXT P_GAIN KP := 50 I_GAIN KI := 20 P I LIMIT EXT CONST NSET 16.666667 Each block can be assigned an individual sampling time or run with system time step PI C/C++ Code NL
  • 19.
    DC Motor DriveSystem L_R L_S L_T ET1 ET2 ET3 CD 1m R_R R_S R_T Yt LOAD CONTR_OUT THRES2 := 2.5 VAL2 := 1 THRES1 := -2.5 VAL1 := -1 -16.66m DCM.N P_GAIN KP := 50 I_GAIN KI := 20 LIMITER UL := 20 LL := 0 10m GAIN GAIN I LIMIT CONST N_REF 16.6667 0.3m M DCM RA := 1.2 LA := 9.5m KE := 0.544 J := 4m A + AM1D1 D2 D3 D4 D5 D6 D7 TR CONST CLOCK .1m Wiper System
  • 20.
    Wiper System –Result Motor Torque and Load Torque Motor Speed N_REF N T 20.00 -10.00 -10.00 0 0 0 0 100.00m 100.00m 50.00m 50.00mT 15.00 0 0 10.00 10.00 0 0 100.00m 100.00m 50.00m 50.00m
  • 21.
    Automotive Library Power Storages Wires Battery- Basic Model Battery Fuel Cell Wire - Thermal static Wire - Thermal dynamic Wire - Thermal dynamic II Wire with Thermal Pin Wire - Advanced Wire - Advanced II Gauge based Fuses Wire - Thermal static Wire - Thermal dynamic Wire - Thermal dynamic II Wire with Thermal Pin Wire - Advanced Wire - Advanced II Fuse - Single Element Fuse - Double Element Fuse - Advanced PPTC (Three RC combinations) PPTC (Two RC Combinations) Lamps Lamp - Filament Lamp - Single Filament Lamp - Double Filament Lamp - Advanced Relays Relay - Normally Open Relay - Normally Closed Relay - One Pole, Two Throws Relay - Two Poles, Two Throws Relay - Two Poles, Cross-Strap Spark Plugs Spark Plug Machines Alternator - Transient Model Alternator - Average Model Alternator - Current Source Starter DC Machine Mechanical Models Inertia Friction Fan Ideal Gearbox Gearbox with Losses PWM Models PWM PWM Switch PWM Load Flasher Switch Connectors Inline Terminal Pair Eyelet Terminal Engine Models Engine - Speed Source Engine - Dynamic Model Applications: • Electrical Distribution System of Vehicles • Power Management • Drive Cycle Analysis • FMEA • Statistical Analyses Industries: • Automotive Manufacturer • EV/EHV • Aerospace • Defense • Ship Building Industry Automotive System Library
  • 22.
    Automotive Library Yt Y t Battery -+ Engine Block Ground Chassis Ground To Hazzard Flasher To Head Lamp Switch Lamp Switch battery1 fuse1_5Amp fuse2_15Amp rlyno1 S1 TS1_HIGH_LOW_Beams_Switch Low High Low High High Low RH HeadLamp LH HeadLamp Tail Lamps Turn Signal Y t Y t QuickGraph1 N0161.V t 14.00 -2.00 2.00 6.00 10.00 0 60.0020.00 40.00 S2 S3 D1 D2 t 60s itp11 itp19 Probe1 t 7.50 -2.50 0 5.00 0 60.0025.00 50.00 Exterior Lighting System Inrush Currents Turn Signal Voltages
  • 23.
    Automotive Library Benefits Easy touse and intuitive graphical modeling Easy parameterization using Wizard technology Statistical analyses, optimization and parameter variations Characterization tool for fuses Multiple model levels for components Web based example database with jump start projects Animated symbols for easy visual inspection
  • 24.
    Electro-Chemical Components Lead AcidBatteryFuel Cell Fuel Cell +- Battery - +
  • 25.
    EV/EHV – ChargingSystem ST_r1 L1 0 0.1m RLoad RL TR1 D1 ICA: L1.I>=I_command ST_r1.VAL>=0.99 and L1.I<I_command On SET: cs:=1 Off SET: cs:=0 period := 20u Off2 SET: RL:=10 t>3m t>12m SET: RL:=5 SET: RL:=5 t>0.0025 SET: I_command:=10 SET: I_command:=15 VM1.V t 6.10 5.10 5.20 5.30 5.40 5.50 5.60 5.70 5.80 5.90 6.00 0 20.00m2.50m 5.00m 7.50m 10.00m 12.50m 15.00m + V VM1 L1.I t 16.00 0 2.00 4.00 6.00 8.00 10.00 12.00 14.00 0 20.00m2.50m 5.00m 7.50m 10.00m 12.50m 15.00m t0 20.00m2.50m 5.00m 7.50m 10.00m 12.50m 15.00m Output Voltage Input Voltage Inductor Current Transistor Control modeled using state machines Load resistance and reference current modification modeled using state machines Boost Converter Fuel Cell + - FUELCELL_A2 Battery -+ LBATT_A2
  • 26.
    Multi-Domain Design • Hydraulics •VHDL-AMS • Mechanics • Electro Mechanical • Magnetics • …
  • 27.
  • 28.
  • 29.
    Power Library Power Library PowerSystem and Cable Models Single Phase Power Supply Ideal Three Phase Power Supply Three Phase Power Supply with Impedance WIRE - Gamma Model Wire T-Model Inverter Topologies Line-commutated Converters B2 Diode Bridge B2 Fully Controlled B2 Half-Controlled, Symmetrical B2 Half-Controlled, Asymmetrical B6 Diode Bridge Two Level Inverter Equivalent Circuit Three Phase Two Level Inverter Single Phase Two Level Inverter Three Phase Three Level Inverter Single Phase Three Level Inverter Control Algorithms Two Level Square Wave Two Level Natural Sampling Three Level Single Phase Three Level Three Phase Load Models Three Level Single Phase NS Three Level Three Phase NS Four Quadrant Current Control Four Quadrant Natural Sampling B6 Thyristor Bridge B6 Bridges - Inverse Parallel Connection B12 Diode Bridge B12 Thyristor Bridge Parallel Connection B12 Thyristor Bridge Cascade B24 Thyristor Bridge Single Phase A.C. Chopper Three Phase A.C. Chopper DC Link Three Phase RL Load Logic Dead Time Applications: • AC/DC Converters • Inverters (DC/AC) • Drive Systems • Power Quality • Alternative Power Industries: • Industrial Automation • Drives Manufacturers • EV/EHV • Power Conversion • Power Quality
  • 30.
    Power Library Us1 Us2 Us3 Us1 Us2 Us3 M ω ω2 C J1J2 ω1 M 1 M 2 + V CONST KONST1 SPR1 ein_aus 2L3_GTOS g_r1 g_r2 g_s1 g_s2 g_t1 g_t2 2L_NSAMP 2-level natural sampling Machine Characteristic 1.60k -200.00 0 200.00 400.00 600.00 800.00 1.00k 1.20k 1.40k -173.34 359.120 200.00 Stator Current asm_k_g22.Is_d asm_k_g22.Is_q t 200.00 -1.40k 0 -1.20k -1.00k -800.00 -600.00 -400.00 -200.00 0 1.501.00 Rotor Current asm_k_g22.Ir_d asm_k_g22.Ir_q t 1.40k -200.00 0 200.00 400.00 600.00 800.00 1.00k 1.20k 0 1.501.00 CONST Omega Uf Ua M ω Torque 350.00 -150.00 0 -100.00 100.00 200.00 300.00 0 1.501.00 Direct inverter driven squirrel cage induction machine with 2-level natural sampling control and mechanical load
  • 31.
    Power Library Benefits Predefined macromodels of frequently used power electronic topologies Includes common control algorithms Auxiliary elements, such as power grid models and loads System level models for rapid computation of overall system behavior, power quality and control algorithms Easy and intuitive graphical building blocks
  • 32.
    Mechanical Elements Library Rotational Mass Translational Mass CoordinateTransformation Rotational-Rotational Rotational-Translational Translational-Rotational SYMP Synchronous Machine Permanent Excitation SYMP Synchronous Machine Permanent Excitation w Damper Electrical Machines DCMP DC-Machine Permanent Excitation ASMS Slip Ring Induction Machine Rigidity Rigidity Torque Source Ground Angular Velocity Source Velocity Source Ground Force Source Translational-Translational Mechanical Systems Applications: • Drive Trains • Electro-Hydraulic Systems • Electro-Mechanical Systems • Load Variations Industries: • Automotive Suppliers • Drive Manufacturers • Industrial Automation • Defense • Aerospace
  • 33.
    Mechanical Elements Library ET1 Square_wave1.VAL M DCMP Dcmp1 J:= 2m STF Stf1 M DCMP Dcmp2 J := 2m M DCMP Dcmp3 J := 2m STF Stf2 J Mas1 J := 10m Dcmp1.VA Dcmp2.VA Dcmp3.VA t 250.00 -250.00 0 -100.00 100.00 0 1.000.50 Dcmp1.OMEGA Dcmp2.OMEGA Dcmp3.OMEGA Mas1.OMEGA t 200.00 -200.00 0 -100.00 100.00 0 1.000.50 Mas1.MACX t 1.25k -1.25k 0 -500.00 500.00 0 1.000.50 Motor-generator combination driving a mass with limitations
  • 34.
    Mechanical Elements Library Benefits Non-linearfriction models incl. stick friction Non-linear rigidity models incl. backlash Fast computing 1D modeling approach based on SIMPLORER C-Code interface Electrical Machine model implementation with mechanical pins provide connectivity between electrical and mechanical world Schematic based graphical modeling with mechanical building blocks
  • 35.
    VHDL-AMS Block Diagram Simulator State Flow Simulator SIMPLORERSimulation Data Bus MathCadSimulink Sim-Interface External Simulators Internal Simulators Multi-Organizational Design Digital Solver Circuit Elements Analog Solver AMS VHDL-AMS
  • 36.
    VHDL-AMS Schematic Fully supported by SIMPLORER Schematic Embedded Editorwith Syntax coloring allows to create models on sheet and in the ModelAgent
  • 37.
    VHDL-AMS Code fora Resistor ENTITY Resistor IS PORT ( QUANTITY r : REAL := 1.0e+03; -- Default = 1 K TERMINAL p,m : ELECTRICAL); END ENTITY Resistor; ARCHITECTURE Rbehav1 OF Resistor IS QUANTITY voltage ACROSS current THROUGH p TO m; BEGIN current == voltage/r; END behav; mp Resistor r := 1.0e3 Rbehav1 r
  • 38.
    Architecture 3 Architecture 2 Architecture1 Entity and Architecture Entity Interface description of a subsystem or physical device Specifies input and output ports to the model Architecture Behavior description of the model Can be dataflow, structural, procedural, etc Modeling can deal with both analog (continuous) and digital (discrete) domains output ports input ports inout ports Architecture 2 Architecture 1 Entity
  • 39.
  • 40.
    VHDL – DigitalSystems A.val B.val C.val SUM.y CARRY.y t0 40m2m 4m 6m 8m 10m 12m 14m 16m 18m 20m 22m 24m 26m 28m 30m 32m 34m 36m 38m CLK A CLK B CLK C XOR2 XOR2 AND2 AND2 AND2 Two bit adder with Carry Sum Carry OR3
  • 41.
    VHDL – DigitalSystems Complete Automotive System Analysis across Domains • ASICs • Micro Controller • FPGAs … ECU PTCU MCU VHDL
  • 42.
    VHDL-AMS Multi DomainDesign L dia := 1 len := 1/4 rho := MATH_PI vol := 1 b := 1 k := 10 EQU crank_radius:= 0.2 pipe_area:= 0.05 Fluidic torque force pressure flow_meter rhyd1 lhyd1 chyd1 spring_rotb damp_rotb T fm_rotb ω + vm_rotb ω + v_rotb mass_rotb CONST CONST 1/pipe_areacrank_radius P Spped damp_rotb.omega t [s] 40 -40 0 -25 25 0 0.1k50 QuickGraph2 flow_meter.q t [s] 1Meg -1Meg 0 0 0.1k50 Mechanic
  • 43.
    VHDL-AMS Component Providers Subsystem Providers - Suppliers OEM System Simulation DriveCycles Fuel Economy Multi Organization Design Power Train Electrical System Sensors … VHDL - AMS VHDL - AMS Solenoids, Motors, Battery, Sensors, Semiconductors, Fuse …
  • 44.
    DC Drive –VHDL-AMS Controller L_R 0.3m L_S L_T ET1 ET2 ET3 R_R 10m R_S R_T t [s] 4.00e+001 0 2.00e+001 0 0 0.2 0.2 0.1 0.1 t [s] 1.50e+003 0 1.00e+003 0 0 0.2 0.2 0.1 0.1 motor current speed and reference speed LIMIT LIMITER LL := 0 UL := 20 GAIN CONTR_OUT THRES1 := -2.5 VAL1 := -1 THRES2 := 2.5 VAL2 := 1 CONST N_REF 1000 M DCM J := 4m LA := 9.5m RA := 1.2 KE := 0.544 A AM1 t [s] 1.00e+003 0 5.00e+002 0 0 0.2 0.2 0.1 0.1 DCM.MI [N·m] TLoad.VAL t [s] 2.00e+001 -1.00e+001 0 0 0 0.2 0.2 0.1 0.1 motor torque and load torque DC Link Voltage and Current D7 TR TLoad 3 Bridge1 PIC VHDL-AMS
  • 45.
    DC Drive –VHDL-AMS Controller
  • 46.
  • 47.
    C/C++ Interface ® System Simulation TheMulti Domain Simulator C/C++ make Dynamic Link Library .dll Symbol Library Symbol Editor
  • 48.
    DC Drive –C-Code Controller L_R 0.3m L_S L_T ET1 ET2 ET3 R_R 10m R_S R_T DCM.IA [A] t [s] 3.00e+001 0 2.00e+001 0 0 0.2 0.2 0.1 0.1 DCM.N [rpm] N_REF.VAL t [s] 1.50e+003 0 1.00e+003 0 0 0.2 0.2 0.1 0.1 motor current speed and reference speed LIMIT LIMITER LL := 0 UL := 20 GAIN CONTR_OUT THRES1 := -2.5 VAL1 := -1 THRES2 := 2.5 VAL2 := 1 CONST N_REF 1000 M DCM J := 4m LA := 9.5m RA := 1.2 KE := 0.544 A AM1 Bridge1.Vout [V] Bridge1.Iout [A] t [s] 1.00e+003 0 5.00e+002 0 0 0.2 0.2 0.1 0.1 DCM.MI [N·m] TLoad.VAL t [s] 2.00e+001 -1.00e+001 0 0 0 0.2 0.2 0.1 0.1 motor torque and load torque DC Link Voltage and Current D7 TR TLoad 3 Bridge1 PIC PIC1 IGain := 2 PGain := 3 C-Code
  • 49.
    DC Drive –C-Code Controller
  • 50.
    SIM2SIM SIMPLORER to SimulinkInterface SIMPLORER Simulink • Co-Simulation Interface • Link blocks in both packages • Using SIMPLORER's external simulator integration interface and S-function in Matlab • Co-Simulation Interface is an open API that can be used for other simulation packages
  • 51.
    Drive System Control L_R 0.3m L_S L_T ET1 ET2 ET3 R_R 10m R_S R_T GAIN P_GAIN KP:= 3 I I_GAIN KI := 2 LIMIT LIMITER LL := 0 UL := 20 CONTR_OUT THRES1 := -2.5 VAL1 := -1 THRES2 := 2.5 VAL2 := 1 CONST N_REF 1000 M DCM J := 4m LA := 9.5m RA := 1.2 KE := 0.544 A + AM1 D7 TR CONST CLOCK .1m 3 Bridge1 TLoad
  • 52.
    Drive System Control L_R 0.3m L_S L_T ET1 ET2 ET3 R_R 10m R_S R_T M DCM J:= 4m LA := 9.5m RA := 1.2 KE := 0.544 D7 TR 3 Bridge1 TLoad SiM2SiMSIMPLORER Link Interface  SiM2SiM 50 SIM2SIM1 SIM2SIM1.CS
  • 53.
  • 54.
  • 55.
  • 56.
    SIMPLORER – AdvisorLink SIMPLORER Single Voltage Electrical Automobile System Template voltage regulator curve Regulator Generator p mGeneratorPower p m BatteryPower RearDefrost FrontHVAC Engine BrakeLightsMisc ExternalLights HeatedSeats FrontWipers RearWipers Radio TurnSignalRadiatorFan RearHVAC generic generator generator Battery Loads Starter p m ® Simulation properties: Step width max 100m Step width min 100u Simulation end time 1369 GAIN Battery -+ pm LoadPower + V VM1 A + AM1 generic generator generator1 SiM2SiMSIMPLORER Link Interface  SiM2SiM 50
  • 57.
    Results Generator Current AM1.I t 100.00 -50.00 0 0 793.91500.00 Speedin RPM Speed t 4.00k -2.00k 0 2.50k 0 793.91500.00 Bus Voltage VM1.V t 13.00 11.50 12.00 0 793.91500.00 Load Power LoadPower t 500.00 -1.50k 0 -1.00k 0 793.91500.00
  • 58.
    Complete Set ofAnalyses DC Analysis NINV INV OUT + - NSC_LM_7411 NINV INV OUT + - NSC_LM_7412 NINV INV OUT + - NSC_LM_7413 R1 10k R2 10k R3 10k R4 10k Rp 15916 R1p 10k C1 100p C2 1n E1 + V VM Rfp 30k R9 30k R 15916 OP: -0.00100994 V OP: -0.00405477 V OP: -7.9752e-006 V OP: 0.999992 V OP: 0.998936 V OP: 3.99573 V OP: 0.000980576 V OP: -3.98873 V OP: 1 V
  • 59.
    E1 1 R1 500m L1 R2 16 L2 C1132.6u 31.83m 3.18m OP: 0 V OP: 0.969697 V OP: 0.969697 V OP: 1 V Complete Set of Analyses Bode C1.VGain Phase 100 100 1k 1k 200 200 300 300 400 400 500 500 600 600 700 700 800 800 900 900 100 100 1k 1k 200 200 300 300 400 400 500 500 600 600 700 700 800 800 900 900 -28.01 -20.00 0.00 20.00 -28.01 -20.00 0.00 20.00 0.00 0.79 1.57 2.36 3.14 0.00 0.79 1.57 2.36 3.14 f [Hz] f [Hz] [dB] [rad] AC Analysis
  • 60.
    Experiments 1D, 2D &3D Parameter Sweep Monte Carlo Sensitivity Worst Case Optimization Simplex Algorithm Successive Approximation Genetic Algorithms
  • 61.
  • 62.
  • 63.