Graduation assignment: thermodynamics in Electric Truck in Eindhoven

Functiebeschrijving

The automotive industry is undergoing a radical transformation to hybrid and electric vehicles. Vehicle thermal management plays a major role in the development of these vehicles. For example, the battery temperature impacts on life, safety and performance of batteries. To prevent battery thermal damage, a battery thermal management system is essential. In addition, thermal management of the e-motor is not only important for the reliability of the e-motor, but the temperatures of the components within the e-motor affect the torque production, control and efficiency of the machine.
Nowadays, simple lumped thermal capacity Amesim-models of the e-motor and battery are available within the Technical Analysis department. There is a need for detailed thermal simulation models of the battery and e-motor. Simcenter Amesim is a simulation software for the modeling and analysis of multi-domain systems. Within Technical Analysis Amesim is used for thermal, hydraulic and pneumatic simulations.
The assignment can be distinguished into three parts:

1. Development and validation of detailed thermal simulation models of the battery pack.

• A literary review has to be done on the different approaches to thermal modelling of the battery. 
• A detailed one-dimensional Amesim-model has to be developed to examine the thermal behavior of the complete battery pack (i.e., cell temperature). The model includes the heat exchange interface between the battery cells, heat exchange interface between battery modules and cooling plate, and heat exchange between battery pack and surroundings. 
• Model parameters can be extracted from battery supplier information, literature and test data (if available). Supplier information and test data could possibly also be used for model validation.

1. Development and validation of detailed thermal simulation models of the e-motor.
   • A literary review has to be done on the different approaches to thermal modelling of the e-motor.
   • A detailed one-dimensional Amesim-model has to be developed to examine the thermal behavior of the complete e-motor (i.e., winding temperature). The model includes the heat exchange interface between the several layers within the e-motor (rotor, windings, stator, cooling system and housing), and the heat exchange between the e-motor and surroundings.
   • Model parameters can be extracted from e-motor supplier information, literature and test data (if available). Supplier information and test data could possibly also be used for model validation.
2. Integration of submodels (e-motor, battery) into available full vehicle thermal model.
   • A sensitivity analysis has to be performed to identify the assumptions whose variation have the most impact on the key outputs (cooling/heating concept) and to demonstrate the effect of changing these assumptions.
   • A sensitivity analysis has to be performed to study the impact of the component design (sizing of e-motor, sizing of battery, insulation of battery, etc.) on the vehicle thermal management concept (sizing of cooling unit, etc.) of the electric vehicle.

Jouw profiel

• Bachelor or Master student Automotive or similar;
• Knowledge of Thermodynamics;
• Knowledge of AmeSim simulation tool is a pré.

Afdeling

The Technical Analysis department consists of a team with specialists, responsible for the numerical verification and validations of new vehicle concepts and vehicle designs within the Product Development division. By means of simulations, new developments on vehicle and system level are evaluated and optimized for different vehicle performance aspects: fuel economy and CO2 emission, aerodynamics, thermodynamics, NVH, vehicle handling, crash safety, durability. These simulations support the design process from the first concept ideas to the final validation and sign-off of the truck design.

Wij bieden

• A view behind the scenes at a large international corporation;
• You will get a lot of freedom and responsibility. We are open to your initiatives and depending on the assignment you see your results back in the workplace;
• An experienced coach and supervisor who can teach you a lot and is willing to help you with your assignment;
• After your graduation, you will have the opportunity to start your career at DAF;
• An internship wage of € 375,- (HBO) or € 450,- (WO) based on 36 hours;
• A travel allowance, if you don’t have a student travel product (provided by the Dutch government);
• A housing allowance, if you temporarily rent a room near DAF.