Gamma Technologies and GT-SUITE: Pioneering the Future of Simulation

Unveiling the Power of GT-SUITE

This year, Gamma Technologies celebrated a significant milestone: its 30th anniversary. Since its inception in 1994, Gamma Technologies has been at the forefront of engineering simulation, revolutionizing how industries approach design and innovation. At the heart of this transformation is GT-SUITE, the company’s flagship systems simulation software that has become a cornerstone in various fields, from automotive to aerospace, HVACR, energy, and beyond. 

Gamma Technologies grew its prowess in the automotive industry with GT-POWER, the industry standard engine performance simulation tool used by most engine manufacturers and vehicle original equipment manufacturers (OEMs). GT has continuously expanded its simulation capabilities to meet consumer demands with extensive developments in batteries, electric motors, and more with products such as GT-AutoLion, GT-PowerForge, GT-FEMAG, and others. GT continues to accelerate in agnostic powertrain and systems development worldwide. 

GT-SUITE is more than just a simulation tool. It’s a comprehensive, multi-domain platform that empowers engineers to model, simulate, and analyze complex systems. With capabilities spanning mechanical, electrical, fluid, and thermal domains, GT-SUITE offers a holistic approach to understanding how different systems interact. This versatility is essential in today’s engineering landscape, where the integration of various technologies and systems is more crucial than ever. 

In the transportation industries (automotive, on-and-off highway vehicles) GT-SUITE has made a substantial impact. The software allows for the creation of detailed simulations of vehicle systems, from powertrains to suspension systems.  

Almost every vehicle on the road has components simulated and designed with one of Gamma Technologies’ simulations. Most major automotive original equipment manufacturers (OEMs) have used GT-SUITE for engine and vehicle development. 

By providing a virtual environment to simulate and optimize designs, GT-SUITE helps manufacturers improve performance, reduce costs, and shorten turnaround times. To accelerate development time, GT’s XiL (X-in-the-Loop) modeling capabilities (method that combines virtual testing with real-world elements to validate components of an Electronic Control Unit or ECU) integrate seamlessly with industry tools, ensuring a streamlined and efficient product design cycle. 

The ability to simulate real-world scenarios and interactions is particularly valuable for developing advanced technologies such as electric and hybrid vehicles, where precise predictions and optimization are critical. 

Expanding Horizons: Aerospace, HVACR, Marine, Energy, and Beyond

The influence of GT-SUITE extends beyond automotive engineering. 

In the HVACR (heating, ventilation, air conditioning, and refrigeration) industry, Gamma Technologies’ comprehensive set of validated 0D/1D/3D multi-physics component libraries have enabled HVACR engineers to tackle challenges in development such as sustainability and efficiency, decarbonization, new refrigerants, and system complexity and controls. GT-SUITE’s combined with GT-TAITherm can model human comfort which allows the user to have an additional target besides traditional temperature and humidity. The human comfort model has localized comfort zones that can be used to determine if cabin insulation or HVAC settings need to be modified. Well-known brands such as Carrier, Copeland, Daikin, Sanden, Trane, Tecumseh, Rheem, and others have found tremendous benefits utilizing GT-SUITE. Learn more about these case studies here.  

In aerospace, the software supports the design and analysis of complex systems like propulsion and avionics. Engineers from organizations such as NASA, Roush, SAFRAN, and others have used GT-SUITE to ensure that aircraft systems are both efficient and reliable, contributing to advancements in performance and safety. Some of the applications that Gamma Technologies’ simulation solutions have assisted in include cryogenic systems, propulsion system modeling, environmental controls systems (ECS), fuel cell simulation, thermal management, e-propulsion batteries, flight dynamics and controls, multi-body dynamics, landing gear development, and fuel tank modeling.  

GT is proud to say that our solutions have already been used to support the future of urban air mobility by providing simulations for electric aircraft and electric vertical take-off and landing (eVTOL) vehicles (including air taxis) development. 

In the energy and oil & gas sectors, GT-SUITE aids in the development of innovative solutions for power generation and renewable energy. Our customers are already choosing GT for upstream, midstream, and downstream applications to optimize production. The ability to simulate energy systems helps companies enhance efficiency and sustainability, addressing some of the most pressing challenges in energy production and consumption. 

It might be surprising that the marine industry is aggressively moving towards a sustainable future as well. GT is proud to have partnered and work with organizations such as the Maritime Battery Forum, WIN GD, Yanmar R&D, and Toshiba. These firms have leveraged GT-SUITE’s solutions to simulate engine and drivetrain development for ship modeling and create digital twins for electrified motors.  

Gamma Technologies has been on the forefront of implementing AI (artificial intelligence) & ML (machine learning) technologies. These tools elevate simulation capabilities by allowing thousands of variables to be considered and help designers best engineer superior products. AI and ML enhance simulations by creating accurate and dynamic metamodels (mathematical models) that can adapt to complex, real-world scenarios in real-time. These technologies also streamline the analysis of vast data sets, leading to more precise predictions and informed decision-making. 

To learn more about our machine learning capabilities, read this two-part blog series on enhancing model accuracy by replacing GT’s lookup maps and optimizing neural networks.  

A Legacy of Innovation

As Gamma Technologies celebrated its 30-year milestone, it’s clear that its impact on the engineering world is profound. GT-SUITE’s ability to provide detailed, multi-domain simulations has empowered engineers across industries to tackle complex problems and push the boundaries of what’s possible. This dedication has kept GT-SUITE at the cutting edge of simulation technology, ensuring that it meets the ever-changing demands of its diverse user base. 

Looking Ahead

As we look to the future, Gamma Technologies is well-positioned to continue its legacy of pioneering simulation technology. With GT-SUITE leading the way, the company is set to drive further advancements in engineering and design, helping industries navigate the complexities of modern technology and innovate for a better tomorrow. 

Learn More About Gamma Technologies’ Simulation Solutions

To learn more about our simulation capabilities, visit our website. Learn more about GT-SUITE here. Contact us here to speak to a GT expert! 

How Will Electric and Hybrid Vehicle Development Be Impacted by the Softening of US Rules

Governmental Regulations Impacting Automotive OEMs

In recent news, new vehicle tailpipe governmental regulations in the United States have softened for original equipment manufacturers (OEMs) development of electric vehicles (EVs) and hybrids (HEVs). 

The Department of Energy has significantly slowed the phase-out of existing rules that give automakers extra fuel-economy credit for electric and hybrid vehicles they currently sell. The real-world impact of the complex regulations has helped U.S. automakers meet new federal standards for fleetwide fuel efficiency continuing to sell traditional, internal combustion engine (ICE) vehicles. 

The Role Simulation Plays in New Vehicle Development

With these changes, it’s now imperative for the engineering community to leverage simulation platforms such as GT-SUITE in today’s automotive development for several reasons: 

1. Cost Reduction: Developing new automotive technologies, especially in the context of EVs and hybrids, can be expensive. Simulation allows OEMs to test various designs and configurations virtually, reducing the need for physical prototypes and costly trial-and-error processes.
2. Time Efficiency: With simulation, OEMs can accelerate the development process. They can quickly assess the performance of different components and systems, identify potential issues, and iterate on designs much faster than with traditional methods. This agility is crucial in a competitive market where time-to-market can make a significant difference.
3. Regulatory Compliance: Although regulations may slow down, they are unlikely to disappear. OEMs still need to meet stringent emissions standards and fuel efficiency requirements. Simulation enables them to explore different powertrain configurations, optimize efficiency, and ensure compliance with current and future regulations.
4. Technology Exploration: Even as regulations ease, the demand for cleaner and more efficient vehicles continues to grow due to environmental concerns and consumer preferences. Simulation allows OEMs to experiment with emerging technologies, such as advanced battery chemistries or fuel cell systems, and stay ahead of the curve in the evolving automotive landscape.
5. Risk Mitigation: Investing in new technologies carries inherent risks. Simulation helps OEMs mitigate these risks by providing insights into potential challenges and performance limitations before committing to large-scale production. This allows them to make informed decisions and allocate resources more effectively.
6. Optimization and Innovation: Simulation enables OEMs to optimize the performance of electric powertrains, hybrid systems, and fuel cell technologies. By fine-tuning parameters such as energy efficiency, range, and power output, they can deliver vehicles that meet or exceed customer expectations while staying competitive in the market.

Learn More About Our Simulation Solutions

While phased-in regulations may temporarily ease the pressure on OEMs, simulation remains a crucial tool for innovation, efficiency, and competitiveness in the automotive industry. Especially in the context of evolving technologies such as electric powertrains and fuel cells. 

To learn more about GT-SUITE, visit our website here. Speak to GT expert today as well here and see how to incorporate simulation for your vehicle development needs.  

Top 10 Gamma Technologies Blogs of 2023!

From calculating EV range to heat pump design, there is a blog for every simulation! 

As we kick off 2024, let’s look back at the best blogs of 2023! Since the inception of Gamma Technologies, GT-SUITE has optimized system simulation solutions for manufacturers! In no order, these are the top 10 blogs written in 2023 that highlight the vast application use cases and technical capabilities GT-SUITE can deliver!   

1. Decreasing Battery System Simulation Runtime using Distributed Computing
2. Calculating Electric Vehicle Range with Simulation
3. Engine Manufacturers Leverage Simulation to Engineer Ahead of Increasing Regulations
4. Enhancing Model Accuracy by Replacing Lookup Maps with Machine Learning Models (Machine Learning Blog Part 1)
5. Optimizing Neural Networks for Modeling and Simulation (Machine Learning Blog Part 2)
6. Mitigating the Domino Effect of Battery Thermal Runaway with Simulation
7. Designing Thermally Secured Electric Motors with Simulation
8. Understanding Fuel Cell Systems Simulation for Vehicle Integration
9. Addressing Heat Pump Challenges, from Home to Industry with Simulation
10. Simulating Predictive Cruise Control for a Heavy-Duty Truck: Quickly and Easily

Shout-outs to our colleagues for their contributions! 

Learn more about our simulation solutions!  

If you’d like to learn more about how Gamma Technologies can be used to solve your engineering challenges, contact us here! 

Wishing you a healthy & prosperous 2024!   

Top 10 Gamma Technologies Blogs of 2022!

From battery thermal runaway to fleet route optimization, there is a blog for every simulation! 

Since the inception of GT-SUITE, Gamma Technologies has offered state-of-the-art simulation solutions for manufacturers. Our simulation solutions help guide customers and partners toward highly optimized products.  

In no order, these are the top 10 blogs of 2022!  

1. Simulating Your Way to HVACR Innovation 
2. How a Catastrophic Ship Fire Reminded us Why Battery Thermal Runaway Simulation is Important 
3. Reducing Costs & Increasing Efficiency in Power Converter Design  
4. Using Simulation to Model Closed-Cycle Argon Hydrogen Engines 
5. Sensitivity Analysis: How to Rank the Importance of Battery Model Parameters Using Simulation 
6. Accelerate Electric Aircraft Design Certification with Systems Simulation 
7. Vehicle Modeling and Simulation: ICEV & BEV Correlation Procedure 
8. How to Automate Real World Vehicle Route Generation Using Simulation 
9. A Look Inside Large-Scale Electrochemical Storage Systems Simulation 
10. Simulating a NASA Hydrogen Powered Rocket 

Other Gamma Technologies Blogs to check out in 2022! 

1. Using Simulation for Battery Engineering: 12 Technical Blogs to Enjoy 
2. Machine Learning Simulation: HVACR Industry 
3. Fast, Accurate Full Vehicle Thermal Management Simulation with GT-SUITE and TAITherm 
4. Using Simulation To Predict Battery Aging for Real World Applications 
5. How Simulation Can Increase Productivity in Electric Vehicle Thermal Management Design 
6. Using Simulation to Optimize Driving Routes and Vehicle Emissions 
7. How Simulation Is Used To Design ICE vs. Battery Electric Vehicle Thermal Management Systems  
8. Are Your Vehicle Passengers Comfortable? How to Validate An Accurate, Thermal Cabin Management Simulation Solution  

Shout-outs to our colleagues for their contributions! 

Learn more about our simulation solutions!  

If you’d like to learn more about how Gamma Technologies can be used to solve your engineering challenges, contact us here! 

Have a great holiday season and wishing you a healthy & prosperous 2023!   

Reducing Costs & Increasing Efficiency in Power Converter Design

Optimizing Power Converter Design through Simulation 

Optimal power converter design requires a fine balance between design efficiency and physical testing costs. Finding the right efficiency point can be expensive for companies — simply jumping from 98% to 99% efficiency could double the converter cost. In this blog, we’re going to explore the technical approaches power converter design engineers may take to optimize their product designs as well as highlight simulation solutions such as GT-PowerForge.

Reducing Switching Losses 

In power electronic conversion, losses are created by power semiconductor devices in conduction and switching. Conduction losses can be reduced by using a larger semiconductor section, but costs will increase as a bigger die or module needs to be used. Moreover, this solution negatively impacts the switching losses as the parasitic elements are increased.  

When switching losses are reduced, here’s how this impacts costs: 

• Lowering the switching frequency: will increase the filtering needs as it needs more inductance and capacitance to keep the same ripple level. In this case, the inductors and capacitors are going to be more expensive.
• Using wide bandgap (WBG) semiconductor devices: increasing switching speed becomes more expensive (up to 5 to 10 times the cost of silicon devices).
• Using multi-level topologies: the voltage switched by the semiconductor is lower with a lower voltage rating. From a cost standpoint, more semiconductor devices can be used but with a lower voltage rating. The device cost is non-linear to the voltage rating, therefore the semiconductor cost will depend on the applications. The filtering multilevel needs are usually more important in terms of input filters (Flying Capacitance, NPC, T-type topologies) but with smaller output filters. The complexity cost is also to be considered. 
• Reconsider cooling device size: by proactively analyzing and optimizing the power converters to reduce the losses, the cooling demands are also reduced resulting in a lower cost device. 

Electric Vehicle Power Converter Simulation Case Study
To illustrate these previous assertions, let’s explore these solutions on an electric vehicle’s (EV) 3-phase inverter with a sine filter using power converter design software such as GT-PowerForge. (NOTE: for this example, the inverter nominal operating point will be at 200kW with a DC bus of 800V, 400V between phases, a frequency of 50Hz, cos(φ)=0.8 and Space vector modulation)

How using simulation can find the best trade-off between COST and EFFICIENCY  
Si IGBT vs SiC MOSFET  

The figure of merit between Si IGBT and SiC MOSFET in the efficiency vs cost plan allows us to separate the plan in two: 

• The solutions with efficiency below 98.3% equipped with Si IGBT device have the lowest cost 

• The solutions above this efficiency equipped with SiC MOSFET have the lowest cost. To explain this result, while SiC MOSFET are indeed more expensive, increasing the switching frequency has a small impact on the loss, while reducing greatly the sine filter cost. At high switching frequency however, the gain on filter will be compensated by an additional heatsink price and additional losses. 

Si IGBT vs SiC MOSFET

The figure of merit between Si IGBT and SiC MOSFET in the efficiency vs cost plan allows to separate the plan in two :

• The solutions with efficiency below 98.3% equipped with Si IGBT device have the lowest cost
• The solutions above this efficiency equipped with SiC MOSFET have the lowest cost. To explain this result, SiC MOSFET is more expensive but increasing the switching frequency has a small impact on the loss while reducing greatly the sine filter cost. At high switching frequency, the gain on filter will be reduced by an additional heatsink price and additional losses.

2 Level topologies vs Multilevel topologies

The result from this comparison are not intuitive at a first glance. Below 98.7% efficiency, 4L Flying capacitor with Si IGBT are less expensive. Indeed, while being more expensive in terms of semiconductor devices and capacitor, the AC filter is greatly reduced by the apparent output switching frequency. At low frequency, the Si IGBT is more performant in terms of efficiency and cost. In this application T-Type and NPC are not competitive because they need a large amount of capacitor in the DC bus to keep the imposed 1% DC bus voltage ripple between the middle point and the bus voltage, which greatly impacts the cost.

2 Level topologies vs Multilevel topologies vs Si IGBT vs SiC MOSFET

The combination of the topologies and the semiconductor device technology has been tested as shown in Fig. 3. In term of efficiency vs cost, Flying Capacitor with Si and 2 Levels with SiC are forming best solutions.

The solutions presented do not exclude the existence of a better solution. In particular, loosen the ripple constraints on NPC and T-Type middle point, evaluate the modulation strategy influence or other semiconductor device as well as refine the optimal switching frequencies for this converter. Finally, the best presented conclusion only have a meaning for this specific converter specifications and cannot be generalized.

Figure 3: (eff vs cost) 2L vs ML and Si vs SiC

Now that all dimensions have been explored and pareto fronts identified, it is easier to identify a preferred solution for our converter efficiency vs. cost trade-off. But while efficiency and cost are key, we also need to dive deeper into estimating the concrete impacts of this solution into our vehicle system. 

Power Converter Design and Vehicle Systems Simulation  

GT-PowerForge offers the ability to export a loss map destined to be integrated into GT-SUITE’s GT-ISE model. This loss map will evaluate the power converter when its operating condition varies, effectively allowing a simulation in GT-ISE to take more dimensions into account, such as input power or temperature fluctuations. This therefore allows for a more precise and detailed evaluation of the vehicle capabilities such as: the estimation of range capabilities, focus on battery sizing and powertrain optimization. 

Interested in power converter design software? 

If you find this piece insightful, see how GT-PowerForge‘s simulation capabilities can assist with your power converter design needs.