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Digital Multiphysics Simulation Platform for Thermal Management Improvement in Electric Vehicles

The crucial effort to reduce CO2 emissions is changing drastically the automotive industry, where a strong competition among well-known OEMs and new actors in the market is quite intense with respect to electrification, demanding a severe reduction in development times. Development of battery thermal management systems for electric vehicles (EVs) is one of Valeo’s R&D teams main challenges. Customers ask for shorter and more accurate simulations as product lines are evolving quickly. The solution proposed by the FEA and CFD simulation teams is an automated process that encapsulates the standards and the know-how, in order to assess the performances and the resistance of the battery coolers. This process should be very robust to deal with a technology that has no standard configuration yet: the product size can vary a lot within a wide range of designs. The target users are the design teams, in order to take into account the simulation at an early stage of the product development. By providing a CAD prepared according to the simulation’s standards, the project designers can directly access both CFD and FEA simulations and obtain results for pressure drop evaluation, thermal performances and fatigue durability. Those simulations require specific scripts for meshing, model setup, job submission and post-process that are fully integrated on a digital platform which can be accessed through a web interface. Such a tool relies heavily on the reliability of the individual scripts in use but also on the training and documentation available to users, a strong and robust workframe must be created. With this automated tool, response time on battery coolers simulation requests can be cut from weeks to day or even hours allowing the designers to evaluate more design iterations and explore more possibilities. In the future, both types of simulations could be run simultaneously to perform multiphysics optimization from an unique parametrized CAD file.

Document Details

ReferenceNWC23-0168-extendedabstract
AuthorsMabire. A Oropeza. J Cavagna. P Francois. N-Y Luneau. F
LanguageEnglish
TypeExtended Abstract
Date 16th May 2023
OrganisationVALEO
RegionGlobal

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