Developing and integrating an electric drive requires an entire ecosystem to collaborate efficiently. This ecosystem contains engineers with various scientific fields of expertise, working on conflicting attributes, specialized in the development of different high-end components, sometimes working in different companies. This presentation focuses on developing a new electric drive for a two-seat electric vehicle known as the Simrod. The vehicle is 600kg with a maximum speed of 120kph and a range of 180km that serves as Siemens’ demonstration platform for electric vehicle virtual development and integration. The project covers the entire V-Cycle of the electric drive development, from its preliminary, architectural sizing, to the detailed engineering of its components, and the in-vehicle verification and validation of its prototype. The electric drive must power the Simrod through a complete ‘Worldwide Harmonized Light Vehicles Test Cycle’ (WLTC) while keeping an acceptable temperature for the motor and the inverter, a low noise level and the expected range. It must accelerate from 0 to 40kph in 2.5s and from 0 to 60kph in 4.0sec. It must be able to start with a 30% slope. Our project begins with a full-vehicle system model, that runs through all those use cases. Target is to identify the most critical driving operating conditions and define requirements for the electric drive and for each of its components: the motor, the transmission, and the inverter. While virtual models of each component or system gain accuracy, they are re-introduced into the system model to constantly check that the vehicle requirements are fulfilled. The motor, the inverter and the transmission are developed using vertical and scalable Multiphysics simulation of electromagnetics, electrical, thermal, and mechanical performance. They are eventually assembled into one single three-dimensional, CAD-based model representing the complete electric drive. This ‘digital twin’ of the electric drive is used to design and validate the cooling system and the mechanical integration strategy, against NVH, structural and thermal performance, before the first prototype exists. Once a prototype becomes available, the fidelity of the digital twin is increased using correlation with results of physical testing. XiL technology is introduced to test the electric drive prototype, to develop and validate its controls algorithms while the rest of the vehicle does not exist yet. Finally, when the entire vehicle is produced, physical campaigns measurements on real roads start and a multi-physical data acquisition system is used to understand the full state of the vehicle.
Reference | NWC23-0276-presentation |
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Authors | Magneville. B Brunel. J |
Language | English |
Type | Presentation |
Date | 16th May 2023 |
Organisation | Siemens Digital Industries Software |
Region | Global |
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