Asian Modelica and FMI Conference 2026

Yang Qi


Session

09-22
13:50
25min
Calibration workflow development using FMI-based reduced-order models for NEVs thermal management
Rui Gao, Yuhao Xu, Junjie Chen, Junyang Hou, Weilin Li, Da Li, Yang Qi, Yue Tang

New Energy Vehicles (NEVs) drive China's automotive market. However, calibrating thermal management for the battery, motor, and inverter is a major bottleneck, especially as development cycles shrink to 24 months. High-fidelity thermal-fluid models are too slow for repeated calibration and fixed-step real-time execution. This paper presents an end-to-end industrial workflow: 1) Build high-fidelity models using 3D data; 2) Train reduced-order models (ROMs), implemented here as nonintrusive data-driven surrogate models, from simulation data; 3) Export the trained surrogates as FMI-compliant co-simulation FMUs for NI VeriStand real-time testing. The ROM tool proves efficient for repeated calibration runs; in this paper, ROM refers to a non-intrusive datadriven surrogate model exported as an FMI-compliant cosimulation FMU, rather than a projection-based or equation-level model-order-reduction method. The reported speedup is interpreted as repeated-simulation acceleration, with data generation and training treated as one-time amortized costs. For the reported battery validation cases, temperature RMSE was evaluated against experimental or CAE reference data and normalized by the initial temperature of the battery heat-generation operating condition. The calculation results show that the single-cell RMSE is within 5%, the battery-pack RMSE is within 10%, and the absolute temperature error is within 3 K. For a representative 10-module battery-pack cooling case, the 250 s closed-loop simulation time was reduced from 2200 s to 44 s after surrogate-FMU replacement, and the calibrated PI response met the control targets.

Thermal Management
(Electric) Mobility & Buildings (R2003)