Case study
Aerodynamic and thermal validation for an EV battery enclosure
CAE studies on an electric vehicle underbody enclosure covering drag contribution, thermal soak and water management, delivered as an actionable design change list.
The problem
An engineering team had a battery enclosure design close to tooling release but no simulation evidence for the thermal and drainage behaviour under real operating conditions. Releasing to tool would have locked in the geometry.
What we did
- Built the simulation model from the client's CAD and their stated operating envelope.
- Ran drag contribution analysis on the underbody geometry and its effect on overall vehicle drag.
- Ran thermal soak studies against the component temperature limits the client specified.
- Ran water management analysis to verify drainage paths and check for ingress risk at the seal lines.
Result
Three design changes were adopted before tooling was cut, avoiding a tooling revision. Each study shipped with its mesh, boundary conditions and assumptions so the client's own engineers could defend the conclusions internally.
- Sector
- Electric vehicles
- Scope
- Drag analysis, thermal management, water management
- Result
- Three design changes adopted before tooling, avoiding a tooling revision