Sustainable Cooperation Between Science and Industry to Develop a High-Performance Simulation Model for Electrothermal Layout of Lithium-ion Batteries

Stuttgart. October 06, 2011

For the past three years, the Automotive Simulation Center Stuttgart e.V., asc(s, has managed to successfully bring together automotive manufacturers, suppliers, software and hardware vendors, and science in the precompetitive stage. The Adam Opel AG, Daimler AG, Dr. Ing. h.c. F. Porsche AG, and the software companies CD-adapco and Battery Design LLC are associated with, and cooperate in, the international asc(s project, "Development and Validation of a Thermal Simulation Model for Li-Ion Batteries in Hybrid and Pure Electric Vehicles (HEV/PEV)". The partners are working towards a consistent development plan of a simulation environment for the electrothermal layout of a lithium-ion battery module which at present is being consistently implemented. Dr. Kremser from the asc(s is in charge of the entire project coordination. The asc(s is the ideal platform to promote the exemplary cooperation between practice, theory, software development, model parameterization on an experimental basis, and the validation of an electrochemical system. It is this combination of expertise from all participating partners which is likely to achieve the best possible results.

Our new simulation model couples a thermal fluid-mechanical 3D model of the complete lithium-ion battery module including its cooling system (based on the CAD data from Behr GmbH and Co. KG) with an electrothermal circuit model. The latter describes the local current/voltage characteristics as well as the locally released heat loss of the individual accumulators (battery cells) built into the module. The overall model can be used to investigate heat and energy management and to optimize the layout of the battery cooling system. Knowledge about the temperature and charge distribution between cells within the battery module is crucial, since potential inhomogeneities can have a negative impact on battery life.

In the first instance the simulation model is limited to the analysis of the battery module. Subsequent overall vehicle integration will be implemented under appropriate conditions. Simulation results will be verified and validated on the basis of realistic experiments during the course of the project. For this purpose we already have available results from experiments conducted by Behr, where the battery module was exposed to typical operating conditions existing during regular vehicle operation. Currently accompanying simulations are carried out to compare the results from both worlds. The asc(s can make use of the supercomputers in the High Performance Computing Center HLRS at the University of Stuttgart for this.

The developed simulation environment can be applied during the early phase of the virtual vehicle development process to verify the narrow electrothermal requirements on the battery module in coordination with vehicle development. This is an important preliminary requirement for the development of optimized design concepts for electrified vehicles to fulfill increasing demands on energy consumption, driving range, and durability.

About CD-adapco

CD-adapco (www.cd-adapco.com) is the world's largest independent CFD focused CAE provider. Our core products are the technology-leading simulation packages, STAR-CCM+ and STAR-CD. The scope of our activities, however, extends well beyond CFD software development to encompass a wide range of CAE engineering services in fluid dynamics, heat transfer and structural engineering. Our ongoing mission is to "inspire innovation and reduce costs through the application of engineering simulation software and services."

A privately owned company, CD-adapco has maintained 17% organic year-on-year growth over the last 5 years. CD-adapco employs over 550 talented individuals, working at 21 different offices across the globe.

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