What’s it about

Embracing electrification has introduced its fair share of challenges in all industries, for example battery temperature control, novel noise emissions, electric motor design and an increased focus on overall product performance. Join us as we explore the solutions connected to these challenges.

Day 1: Full day of conferencing and networking

Day 2: Simulation workshops

TIME: March 14th -15th, 2024

LOCATION: Scandic Mölndal & Siemens Mölndal Office

CONTACT: Ola Dahlin,

ola.dahlin@siemens.com

Evaluating Thermal Performance using Simcenter ​STAR-CCM+ Batteries

Amir Movaghar

Rajukiran Antham

CFD Engineer

Volvo Group

08h30​

Re​gistration

09h00

Welcome

09h15

Roadmap to a comprehensive digital twin

11h30

EDU Development Using Virtual Methods​

12h00

90 minute lunch

Fluids and Thermal ​workshops

System simulat​ion worksh​ops

Design exploration and ​optimization workshops

Road noise w​orkshops

08h45

Fluids & Thermal roadmap ​update

09h45

Efficient workflows in Simcenter STAR-CCM+

08h45

System simulation ​Update

09h45

Pre-sizing hybrid ​and electric ​powertrains in few ​clicks (HOT)

08h45

Design exploration and optimization update

09h45

Process Automation in Simcenter HEEDS

08h45

Simcenter Component-based TPA and ​Virtual Point Transformation (VPT) ​Introduction and Update

09h45

Tire blocked force characterization using CAD-based instrumentation and VPT

12h00

Lunch

13h00

Currents of innovation: Modeling e-powertrains

13h00

Tesla 3 battery engineering: Workflow

Identifying battery requirements

13h00

Electrifying your curve fitting

Study definition: Improving your search

13h00

How to create virtual assemblies combining test and simulation

E-drive interior noise and road noise prediction using Simcenter Virtual Prototype Assemblies

14​h00

Br​eak

14h15​

Adding dimensions with 3D-CAD

Sound of Silence:

Aeroacoustics in an electric age

Heat transfer: Keeping it cool while we charge it up

14h00

Designing a pack that answers these requirements

Designing the cooling plate

Accounting for cells aging

14h00

Speed up studies using HEEDS AI Simulation Predictor

HEEDS Post: How to ignite your insights

14h00

NOTE SEE ABSTRACTS ​BELO​W

16h15​

Closing remarks

Previous session continued

Listen to the assemblies using Simcenter NVH Simulator

Efficient workflows in Simcenter STAR-CCM+

This presentation explores advanced automation techniques in ​Simcenter STAR-CCM+ to optimize simulation workflows. Participants ​will learn about filters, dynamic queries, simulation operations, ​template files and stages. A demonstration will showcase an existing ​simulation template incorporating these concepts. Additionally, ​integration of Java macros to extend automation possibilities beyond ​built-in features will be covered. Join us to unlock the full potential of ​Simcenter STAR-CCM+ for efficient and automated simulation ​workflows.

Currents of innovation, modelling E-powertrain

Battery cell technology plays a crucial role in the development of ​propulsion systems, with a strong emphasis on achieving maximum ​range at an affordable price, all while ensuring safety and minimizing ​the risk of power failure or fire. This session highlights the capabilities ​of Simcenter STAR-CCM+ in efficiently setting up and modeling battery ​pack cooling throughout its operating cycle. Additionally, it ​demonstrates how the software can simulate thermal runway and the ​venting of explosive gases, offering varying levels of complexity. The ​session concludes by showcasing examples of thermal runway with ​melting and arcing detection using the Paschen model.

Adding dimensions with 3D-CAD

Immerse yourself in the world of 3D-CAD in Simcenter STAR-CCM+ and ​unlock new possibilities for your designs. This session centers around ​how you can parametrize your model to automate design changes and ​optimize models effortlessly. We will also show how 3D-CAD ​streamlines the modification and preparation of imported geometries, ​boosting efficiency and productivity.

Sound of Silence, aeroacoustics in an electric age

With more products being powered by silent electrical systems, other ​sources of noise are becoming more prominent. In this workshop, we ​will look at how to simulate flow-induced noise from HVAC ducts, fans, ​and external wind noise using Simcenter STAR-CCM+ using recently ​developed state-of-the-art methods to achieve excellent correlation ​with test data. The methods we will discuss include Wall-Modeled LES ​for the flow as well as the new Lighthill Wave and Perturbed ​Convective Wave models for the acoustics. We will also have a quick ​look on how to take installation effects into account by coupling ​Simcenter STAR-CCM+ to Simcenter 3D.

Heat transfer: Keeping it cool while we charge it up

Heat transfer plays a crucial role in computational fluid dynamics (CFD) ​applications. With electrification being on everyone's lips, new ​applications are emerging that require additional understanding of ​new physics, setup, and approaches. In this workshop, we will address ​new important considerations such as coupling electromagnetism with ​fluid dynamics and heat transfer, as well as oil cooling all within ​Simcenter STAR-CCM+. Attendees will gain insights into the best ​practices for approaching and integrating these disciplines to tackle ​the challenges posed by this new age of electrification.

08h45

09h45

Fluids & Thermal ​roadmap update

Efficient workflows in ​Simcenter STAR-CCM+

13h00

Currents of ​innovation: Modeling ​e-powertrains

Adding dimensions ​with 3D-CAD

Sound of Silence:

Aeroacoustics in an ​electric age

Heat transfer: Keeping ​it cool while we charge ​it up

Process Automation in ​Simcenter HEEDS

To capitalize on the value of integrating multiple simulations tools in Simcenter HEEDS, a large number of portals are included to assist the users in performing process automation efficiently and to help ensure the quality and consistency of your virtual prototype models.. During this session, we will showcase how to use portals and other useful functions that will support you in setting up the simulation infrastructure. It helps unlock the full power of your computer-aided engineering (CAE) tools so you can move beyond troubleshooting and verifying designs and use simulation to drive innovation and performance.

Electrifying your curve fitting

In complex products like electric vehicles, it’s often necessary to include complete curves in your design studies. It could be to match a required target curve, but also when correlating your simulation models to physical measurements. In this session, we will show how to handle this in Simcenter HEEDS. The built-in functionality makes it easy to define and include in your design study, and with the powerful postprocessor you can gain great advantages by including these curves.

Study definition: Improving your ​search

Whether it’s optimizing the range, reducing aerodynamic drag, and/or ​fine tuning the weight, Simcenter HEEDS can help the engineers to ​convert fresh ideas into the next generation products that maximize ​performance. During this session we will demonstrate the tools ​available and discuss various alternatives in defining your study, and ​the importance of spending the extra time during this step. Even with ​the best simulation models, the possible performance gain can be left ​out if the studies aren’t defined correctly.

Speed up studies using HEEDS AI ​Simulation Predictor

When companies strive to improve overall design performance, the challenge is often how to discover better designs, faster. Companies tend to spend most of their virtual prototyping efforts on building and testing simulation models to validate designs, and comparatively little time on exploring how to improve design performance. We will here show the latest function in the already powerful search engine in Simcenter HEEDS to accelerate the study even more.

HEEDS Post: How to ignite your ​insights

Are you drowning ​in data, but starving for insight? Then, you will learn in this session h​ow Simcenter HEEDS can help you navigate through the massive amoun​t of data that our simulation models are generating. The c​hallenge is to extract useful information that can guide you to a be​tter products, in addition to provide insights into relationships of ​product behavior that will accelerate building experience. We wi​ll demonstrate some of the tools and plots that are available for the​ user to make the necessary investigations of the studies to make n​ew innovations.

09h45

Process Automation in Simcenter HEEDS

13h00

Electrifying your curve fitting

Study definition: Improving your search

Speed up studies using HEEDS AI Simulation Predictor

HEEDS Post: How to ignite your insights

Pre-sizing hybrid ​and electric ​powertrains in few ​clicks (HOT)

The Hybrid optimization tool (HOT) is a Python tool available in ​Simcenter Amesim. It is an interactive interface dedicated to get the ​energetic potential

for different powertrain architectures on a given driving cycle. This ​session will walk the attendees through the workflow covering ​different powertrains (hybrid, electric, fuel cell) for different types of ​vehicles (car, wheel loader, …)

Tesla 3 battery engineering: Workflow

This session introduces the workflow of sizing the battery of an electric ​vehicle, considering the Tesla Model 3 as an example. This explains ​how system simulation can cover the full V cycle of a product ​development process and ensure a digital continuity between the ​different steps.

Identifying battery requirements

This sessions details the pre-sizing stage of a battery electric vehicle. It ​ranges from benchmarking competitor’s vehicles, through application ​engineering to battery pack power and energy requirements

Designing a pack that answers these requirements

Once performance, safety and durability requirements are defined, ​system simulation can be used to properly size the battery pack ​arrangement as well as cooling system requirements for worst case ​scenario. This session will demonstrate the benefits of system ​simulation for electro-thermal simulations of electric powertrains.

Designing the cooling plate

The battery thermal management is a key function that impacts the range, the safety and even the cabin comfort of a battery electric vehicle. This session demonstrate how a Tesla 3 cooling plate is modeled and how alternative design can be simulated to find a good trade-off between max cell temperature and gradient and energy consumption.

Accounting for cells aging

Battery pack durability is a key attribute as well and is mostly ​influenced by battery cells aging. This session shows how system ​simulation users can leverage test data to identify an aging model that ​can be fitted in the previously built battery pack model and how the ​charging strategy and thermal management impact the cells aging

08h45

09h45

13h00

14h00

System simulation ​Update

Pre-sizing hybrid ​and electric ​powertrains in few ​clicks (HOT)

Tesla 3 battery engineering: Workflow

Identifying battery requirements

Designing a pack that answers these requirements

Designing the cooling plate

Accounting for cells aging