e-Mobility

e-Mobility

Delivering e-Mobility to the masses is not only a huge investment, but a significant operational undertaking. As OEMs, suppliers and emerging vehicle manufacturers invest billions to develop innovative electric vehicles, and optimize development and production processes, they are looking for a strategic partner to help realize their vision. Altair technologies are changing the way electric passenger, off-highway and autonomous vehicles are designed, enabling them to accelerate product development, enhance energy efficiency, and optimize integrated system performance.

VEHICLE DEVELOPERS' GUIDE

e-Mobility Accelerated

Learn how to build a comprehensive technology stack, develop a sustainable design process, and deploy manufacturing operations that scale to meet growing electric vehicle demand.

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Sustainable design solutions to meet next-gen vehicle demands.

Sustainable design solutions to meet next-gen vehicle demands.

Integrated system-level, multi-disciplinary and multiphysics solutions offer designers the ability to understand and optimize the complex, connected architectures of today’s battery-electric vehicles (BEVs).

Scaling e-Mobility from niche to mass-market.

Scaling e-Mobility from niche to mass-market.

As OEMs begin to create battery-electric vehicles (BEV) for their mainstream customers to address issues like range, drivetrain efficiency and charging times, design becomes an even more vital component of the development process. This requires fast exploration of higher system voltages, innovative cooling implementations and the ongoing race to reduce vehicle weight.

Bringing the power of cloud bursting to boost vehicle development programs.

Bringing the power of cloud bursting to boost vehicle development programs.

On-demand, high-performance computing (HPC) presents the opportunity to securely scale simulation capabilities during peak demand, satisfying the need for detailed multi-disciplinary optimization studies on multiple programs to reduce development costs and risk.

Using data analytics to shape early vehicle decisions.

Using data analytics to shape early vehicle decisions.

Early design exploration can be accelerated to identify the most promising concepts and a subset of critical performance criteria by applying statistical methods for dimensionality reduction of the huge number of design variables considered during a vehicle program.

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Accelerate Product Development

BEV product development: Aligning BEV development cycles with traditional powertrain vehicle program timelines requires changes to engineering team structures and toolsets. To address unique challenges, simulation-driven design processes help advance concepts to the design stage with fewer redesigns and physical prototypes.

Lightweighting during pre-program for balanced design: Mass reduction is a key contributor to the battery range and e-propulsion performance. The Altair Concept 1-2-3 design process enables designers to confidently create and assess innovative next generation architectures by using simulation to inform vehicle architecture, manufacturing processes, material selection, and platform strategies.

Design exploration for informed e-motor selection: Use rapid design exploration and feasibility ranking during concept phase to inform optimal downstream e-propulsion decisions. Altair FluxMotor™ can be used to make performance comparisons to select the best e-motor topologies, considering constraints like efficiency, temperature, weight, compactness, and cost.

Enhance Energy Efficiency

Enhance Energy Efficiency

Wide-ranging vehicle range: Lighter cars require less battery power for accelerating and maintaining speed, allowing a single charge to go further. Generative design enables engineers to remove material, while maintaining strength and stiffness properties required for safety and comfort. With less power required, the battery pack size and weight is reduced, one of the biggest contributors to an electric car’s weight.

Detailed design for efficiency, cooling and noise: To balance performance, cost and weight requirements, designers can utilize multiphysics simulation to enhance the e-Mobility driving experience. Detailed e-motor electromagnetics with Altair Flux™ and magneto-thermal simulation with Altair AcuSolve™ evaluates the convection and radiation contributing to efficiency losses. Altair OptiStruct™ offers insight into sound quality and passenger experience influenced by e-propulsion systems, as well as wind and road noise with Altair ultraFluidX™.

e-Mobility challenges in crash and safety: The battery pack is critical in e-Mobility safety, and insights from the simulation of vehicle crash events, road debris impact and shocks need to align with the speed of your vehicle program. Altair’s investment in vehicle safety, in collaboration with leaders in vehicle battery research, now enables efficient and accurate analysis of mechanical failures that could lead to battery fires because of a short circuit.

Designing the Future of e-Mobility

Designing the Future of e-Mobility

EV performance optimization: EV subsystems have considerable influence on surrounding systems, providing opportunities to optimize vehicle performance. Using a multi-disciplinary approach, designers can analyze and optimize key performance attributes across complex systems to find a balanced final design.

Drive and control integration: Altair’s model-based development solutions leverage simulation models to accelerate design delivery, while supporting different levels of mechatronic system complexity. Varying levels of model fidelity (from 0D to 3D) can be deployed in electric machine, power converter and control strategy design to match the vehicle development phase. 1D and 3D simulation studies can be coupled, sequentially or simultaneously to evaluate product performance through representative system models, all built to enhance design efficiency.

V2X, ADAS and autonomous vehicles: e-Mobility solutions must connect and interact with their surroundings without interfering with in-vehicle electrical systems (EMC/EMI). Altair Feko™ high-frequency electromagnetics software and wave propagation tools help vehicle designers perform virtual drive testing, and consider a full array of environmental obstacles using either Dedicated Short Range Communications (DSRC) or 5G wireless signals.

Featured Resources

Guide to Accelerating e-Mobility to Realization

The electric mobility revolution is ready to go mainstream. OEMs, suppliers, and emerging vehicle manufacturers are investing billions to develop innovative electric vehicles and optimize development and production processes to deliver e-mobility to the masses. For companies to realize their goals of achieving mass adoption and profitability, we see simulation technology as the cornerstone of any e-mobility strategy. Whether updating existing vehicle design processes to go electric or developing a new program from the ground up, it can be challenging to identify the technology required and ensure these tools work harmoniously to model the complexities of the vehicle’s interconnected systems. In this guide, we set out to help electric vehicles manufacturers build a comprehensive technology stack, develop a sustainable design process, and deploy manufacturing operations that scale to meet growing demand.

Brochures

E-motor Design using Multiphysics Optimization

Today, an e-motor cannot be developed just by looking at the motor as an isolated unit; tight requirements concerning the integration into both the complete electric or hybrid drivetrain system and perceived quality must be met. Multi-disciplinary and multiphysics optimization methodologies make it possible to design an e-motor for multiple, completely different design requirements simultaneously, thus avoiding a serial development strategy, where a larger number of design iterations are necessary to fulfill all requirements and unfavorable design compromises need to be accepted.

The project described in this paper is focused on multiphysics design of an e-motor for Porsche AG. Altair’s simulation-driven approach supports the development of e-motors using a series of optimization intensive phases building on each other. This technical paper offers insights on how the advanced drivetrain development team at Porsche AG, together with Altair, has approached the challenge of improving the total design balance in e-motor development.

Customer Stories, Technical Papers

Using Multiphysics to Predict and Prevent EV Battery Fire

Electric vehicles (EV) offer the exciting possibility to meet the world’s transportation demands in an environmentally sustainable way. Mass adoption could help reduce our reliance on fossil fuels, but the lithium-ion (Li-on) batteries that power them still present unique challenges to designers and engineers, primary among them to ensuring safety against battery fire. To achieve vehicle manufacturer’s ambitious adoption goals, it is necessary to improve the safety of Li-on batteries by better understanding all of the complex, interconnected aspects of their behavior across both normal and extreme duty cycles. Altair is focused on developing a comprehensive understanding of automotive battery safety issues which it has named the Altair Battery Designer project. It combines innovative design methods and tools to model and predict mechanical damage phenomena as well as thermal and electro-chemical runaway. Altair has developed an efficient way to calculate mechanical and short-term thermal response to mechanical abuses, providing accurate computational models and engineer-friendly methods to design a better battery.

White Papers

e-Mobility Development Webinar Series

The electric mobility revolution is ready to go mainstream. OEMs, suppliers, and emerging vehicle manufacturers are investing billions to develop innovative electric vehicles and optimize development and production processes to deliver e-mobility to the masses. In these presentations, learn how Altair works with the world’s leading manufacturers and suppliers to accelerate product development, enhance energy efficiency, and optimize integrated system performance.

Webinars
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