auto industry with cae value


We work side-by-side with our clients to shorten development time using the following deliverables:

  • High-fidelity modeling of chassis and powertrain dynamics
  • Multi-objective Design Optimization (MDO) - using Design Exploration to generate balanced solutions meeting desired performance for attributes such as noise, vibration, harshness (NVH), handling, ride, driveability, durability, and more.  
  • Automation of simulation processes to increase efficiency
  • Tire measurement for Durability, Handling and Ride applications
  • Driving Simulator hardware, software and services
  • Mechatronics simulation with connected mechanical and ADAS models
  • Process assessments to identify bottlenecks, define roadmaps, and maximize return on Computer Aided Engineering activities.


6 Use Cases for CAE Simulation in
Electric Vehicle Drivetrains

As electric vehicles take over a larger share of the automotive market, OEMs and suppliers alike need to make use of every tool at their disposal to improve the performance of their vehicles. At present, no tool is more essential than CAE simulation when it comes to helping manufacturers test the design of EM components and how they contribute to the structure, efficiency, and performance of a vehicle.

While a lot of attention is often focused on battery performance in EVs, the electric drivetrain also presents completely new engineering challenges that require extensive simulation in order to understand how interconnecting systems affect each other. From our experience working in the automotive industry, we have identified six key areas where simulation helps EV engineers improve drivetrain performance. Let’s take a closer look.


1. NVH

In automotive engineering, reducing NVH (noise, vibration, and harshness) is essential to providing a comfortable passenger experience. Combustion engines are significantly more noisy than electric motors, which might lead some to believe that NVH reduction doesn’t require the same level of care and attention. However, the noise of the combustion engine masks a lot of NVH issues that would otherwise be problematic. With the engine noise gone, passengers are more likely to notice outside noises, as well as sounds from the gearbox or coolant systems.The issues are similar for vibration. A vehicle that moves and shakes is disquieting to passengers, and gives an impression of low quality. While passengers expect vibration from a combustion engine, electric vehicles will still experience vibration conditions when they are on the road. These can be more noticeable to passengers, leading them to feel less satisfied with the vehicle.

These factors are what make NVH simulation in electric vehicles so important. CAE simulations can show how disparate parts work together to contribute to passenger experiences of NVH. These can then be remedied in the design.

2. Electric Motor Performance

Electric vehicles have typically lagged behind those with internal combustion engines (ICEs) in terms of power and performance. This has been a barrier to wider adoption, as improvements in motor and transmission performance have come at a tradeoff to battery longevity. However, newer EV technologies have increased the efficiency of electric powertrains, allowing them to compete with and even outperform their ICE counterparts.

Multiphysics simulations have been integral to these improvements, and can help automotive manufacturers develop even better designs. This can be particularly important in optimizing motor efficiencies with gear ratios, to improve performance on highways or during uphill driving.

3. Thermal Management

Proper thermal management keeps components operating at optimal efficiency, which results in less drain on the battery and greater range for the vehicle. Thermal management systems in electric vehicles are more complex than their ICE counterparts, as batteries must be either cooled or heated depending on operating conditions, and because EMs don’t generate any waste heat that might be used to warm the cabin.Analyzing the way motors, inverters, generators, and batteries work together to consume energy is an important part of thermal management. Simulations can be used to model the entire vehicle to better integrate these systems for more efficient use.

4. Lubrication

Electric vehicles require different lubricants than ICEs. Without fossil fuels and with fewer moving parts, these systems run cleaner, meaning the engine oils will collect fewer contaminants over time from burning fuel. However, EV motors operate at very high speeds, and still require both oil and coolant. And, while EV transmissions are different from ICEs, they do still require lubrication for the gear reducer.

Thus far, there is no one solution to which lubricants should be used for different EV transmissions. While some manufacturers use traditional transmission fluid, others are relying on grease bearings with oil lubricants. CFD simulation can help engineers understand which lubricants work best based on their design choices.

5. New Materials

A key strategy for improving fuel efficiency in electric vehicles is to reduce the weight of the vehicle itself. Increased strength and stiffness can also improve the responsiveness and speed of electric motors, leading to better operating conditions. However, for a manufacturer to move from traditional metals to new, lightweight alloys, they must be able to ensure that these new materials can withstand the strains of use within an electric vehicle.CAE simulation can show how these new materials behave when used in EV driveline components, from the motor to the gearbox to the structural housing, so that manufacturers can continue to find new and more effective materials for their vehicle designs.

6. Durability

The reputations of automotive manufacturers are made or broken on the reliability and longevity of their products. Premature failure of components leads to lost trust among consumers, as well as extra expenses for manufacturers in case of a large recall.

Using CAE simulation, engineers can create models to run fatigue tests and predict failure conditions for every component in the EV driveline. These simulations can help manufacturers determine repair schedules and write better warrantees for their vehicles.

CAE VAlue can support your simulation needs for electric vehicle drivetrains.
CAE VAlue offers CAE simulation support for OEMs and suppliers in two key ways. First, we are value-added resellers (VARs) of VI-grade simulation apps and driving simulators, Siemens Simcenter HEEDS and Amesim, SES-Agile Tire, and our own ParaMount bushing simulation tool. For manufacturers who hope to expand their CAE departments we offer support for using this software to set up custom workflows.

As CAE consultants, we bring our multidisciplinary expertise to the table, helping our clients find solutions to complex problems. We can perform CAE simulations for our clients, increasing the capabilities for those who do not have CAE engineers on staff, and expanding the capacity for those who need extra assistance during peak production times.

If you are looking for a CAE partner to help test designs for EV components, contact us

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How to Make Your Simcenter Amesim Model Real-Time Compatible

30 June 2022


"A good model is a judicious trade-off between realism and simplicity.”

Anu Maria, Introduction to modeling and simulation

 siemens simcenter amesim real-time compatible how to


This statement perfectly highlights the challenge of choosing the right level of modeling / assumptions when starting a new simulation study. It is particularly true when you want to reach real-time capability for doing virtual sensing, IIOT on edge, model-based system testing or simply want to have your model running faster.

In this blog post, we provide you with some tips on how to make your Simcenter Amesim models run faster.

This can be done through the following best practices:

→ Avoid generating implicit variables
→ Avoid useless states variables
→ Define the best simulation run parameters
→ Avoid useless discontinuities
→ Save only useful variables
→ Condition correctly your maps


Avoid generating implicit variables

Implicit variables are generated by the solver whenever there is an algebraic loop in the system. An algebraic loop occurs when there is no order in which the submodels can be called such that all the inputs of each submodel are known when the submodel is called.

Example: ? = (?, ?)

  simcenter amesim avoid implicit loop



The solution to remove an implicit loop can be to include a time constant within the loop (inertia, first order lag, inductor …) or to remove the calculation of the variable generating the algebraic loop.



Avoid useless states variables

avoid useless state variables

The computation time is directly impacted by the number of states N. For a standard problem to solve within Simcenter Amesim, Adams’ method is used where CPU = k*N. When backward differential formulae method is used, CPU=k1*N + k2*N².

The solution to reduce the number of states variables is to group hydraulic volumes, mechanical masses or electric resistances.



Define the best run parameters

Usually, the higher the tolerance of the integrator is, the higher the simulation time is.


 simcenter amesim minimize tolerance parameter

The solution is to minimize the tolerance parameter without compromising the simulation results accuracy.



Avoid useless discontinuities

A discontinuity appears when a variable is suddenly jumping from one value to another (switch from laminar to turbulent flow, friction stick-slip, hysteresis…). This causes a restart of the solver to manage the interpolation between the two values.

 simcenter amesim avoid useless discontinuities


The solution for avoiding useless discontinuities can be to disable the discontinuity handling of tabulated submodels (when possible) or to add damping.



Save only useful variables

Simulation results are written in a data file all along the simulation and by default all submodels variables are saved (the frequency of the results saving is set by the user in Run Parameters’ Print interval).

 simcenter amesim save only required variables


The solution for reducing the number of saved data is either to save only the required variables or to increase the print interval (for the complete simulation or dynamically during the simulation).



Correctly condition your maps

Maps imported from experimental data can typically be quite noisy or contain discontinuities.


 simcenter amesim properly condition your maps


The solution to properly condition your maps is either to disable the discontinuity handling, use an appropriate data sample or filter the noisy signals.


 simcenter amesim filter noisy signals




Print out our step-by-step process 

Most of the information above are explained in the infographic below, for the particular case of reaching real-time capacity:


 simcenter amesim infographic how to make real-time compatible



Finally, a dedicated hands-on workshop can be organized on-site to walk you through the process.

Need more information? Contact our CAE Value team


Republished from Siemens blog
©Siemens - all rights retained by Siemens

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