Flow simulation, thermal validation and comfort for electromobility

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  • Air Conditioning & Comfort (HVAC)

  • Electrical Machines and Drives

  • Battery Thermal Management

  • Electronics and Power Electronics Cooling

Air Conditioning & Comfort (HVAC)

Intelligent thermal management increases the range of electric vehicles. By optimally utilizing waste heat from the powertrain by means of heat pumps, coolant pumps, intelligent coolant valves and the targeted distribution of heat and cooling in the vehicle, the energy required to heat and cool the passenger compartment and accumulators can be reduced, thus increasing the range. We take care off all your specific simulation requirements in the following areas:

  • Convey, conduct, distribute and regulate air and other fluids
  • Heat recovery (heat exchangers, heat pumps etc.)
  • Window defrosting and demisting
  • Flow and temperature fields in passenger compartments and housings
  • Particle studies, particle separation in filters, air contamination, exhaust emissions
  • Humid air and condensation

We simulate with:

  • Thermal models based on finite elements
  • RANS-based CFD models based on finite volume
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Electrical Machines and Drives

In order to make the electric motor ready for mobile operation, great efforts are required in terms of size, service life, temperature insensitiveness, reliability and efficiency. For safe operation, even in case of a temporary overload occurrence, the design and development or integration must take into account both the maschines pure performance data and the heating processes during operation under real changing loads. The goal is always to protect the machine against excessive overheating in case of overload. This calls for highly qualified and experienced fluid mechanics specialists. In order to analyze and evaluate the thermal behavior of electrical machines under dynamic load requirements, we incorporate latest computational methods into your design process of your electric drive. In this context, we take into account:

  • Complex assemblies and construction space geometries
  • Heat transfer through conduction, convection and radiation
  • Transient processes
  • Turbulence
  • Fluid structure coupling (material heating and thermomechanical stress)
  • Moving and Rotating assemblies

Possible applications include:

  • Validation and development of cooling concepts or measures
  • Flow and heat transfer in rotation cavities
  • Expected heating due to dissipation of electrical energy (Joule heating)

Battery Thermal Management

In operation, various factors influence the behavior of batteries. Thus, the battery temperature has a significant impact on performance and capacity. In addition, certain temperature limits must not be exceeded. Frequently high charging and discharging rates generate anwonted heat. Inadmissibly high temperatures are the result, if not actively intervened by cooling measures. On the other hand, it is important to protect the batteries from low temperatures by heating. Consequently, thermal management is necessary for the safe and stable long-term operation of batteries. With our in-depth know-how in the field of thermal analysis and CFD, we are happy to assist you in the development of highly efficient cooling concepts and systems.

We simulate with:

  • Thermal models based on finite elements
  • RANS-based CFD models based on finite volume

The following physical phenomena are considered:

  • The complete packing geometry as well as the materials used
  • Heat transfer through conduction, convection and radiation
  • Transient, turbulent processes
  • Structure coupling
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Software text and image block

Electronics and Power Electronics Cooling

The continuing miniaturization of electronic components leads to a spatial concentration of electrical energy. At the same time, as the switching frequencies increase, the power loss due to increased current flow also increases. This has a negative effect on the operating temperature and thus raise the failure rate of the electronic components. We support you in the context of thermal management in all matters relating to the packaging, heat dissipation and thermal dimensioning of your electronic devices and systems. In this respect, we perform thermal simulations to fully explore the room of improvement for your design.

Some application examples:

  • Localization of hotspots, shadowing, air shortcuts
  • Design and dimensioning of cooling systems
  • Radiator, heat exchanger and air conditioner
  • Pressure losses (fan and system characteristic curve)
  • Fan integration and selection

The following physical properties are considered:

  • Heat conduction, convection and radiation
  • Transient Flows
  • Turbulence
  • Joule heat

If you miss your specific application, please contact us. We are sure to find a solution for your request.