Master’s Thesis: Thermal-Electric Simulations for Automotive Cable Dimensioning
Mastering thermal-electric simulations to optimize automotive cable design
This thesis focuses on thermal-electric simulations conducted in ANSYS for the dimensioning of automotive cables. The research addresses both steady-state and transient simulations, aimed at optimizing cable size and insulation, improving safety, and reducing material costs. By leveraging finite element analysis (FEA) in the context of automotive harness design, this study provides valuable insights into the thermal behavior of cables under various loading conditions.
Key Contributions and simulations
Theoretical Foundations
This section lays out the theoretical background of thermal-electric simulations, covering essential principles such as Joule heating, conduction, convection, and radiation. Detailed equations and material properties necessary for simulation inputs are provided to support the practical modeling aspects of the study.(Chapter 3)
Steady-State Analysis of Copper Conductors
This section explores the steady-state thermal behavior of copper wires under constant current loads. Using ANSYS, simulations were performed to determine temperature distribution and verify results against real-world measurements and commercial PSS software used in the automotive industry. The analysis focused on the influence of ambient temperature and various heat transfer modes.(Chapters 4 & 5)
Transient Thermal-Electric Simulations
Investigating time-dependent thermal responses under varying electrical loads, this section analyzed the transient behavior of copper conductors. Using random current profiles, the study explored how different conductor sizes and insulation thicknesses affected the transient heating of automotive cables.(Chapter 5)
Fill Factor and Insulation Influence
This section focused on the optimization of cable cross-sections and the influence of insulation thickness on cable performance. Various fill factors were explored to determine the optimal design that balances thermal performance, material usage, and cost. The thermal response was analyzed for both steady-state and transient conditions.(Chapter 6)
Appendices: Simulation Results and Calibrations
The thesis includes a broad appendices section featuring extensive simulation results, calibration data, and input-output comparisons. These appendices provide detailed insights into the accuracy of the simulation methods and the impact of various parameters on cable performance.(Appendices A-F)
This thesis demonstrated the effectiveness of thermal-electric simulations in optimizing automotive cable design. The proposed methodology, validated by industry-standard software and real-world measurements, provides a valuable framework for improving the safety, cost-efficiency, and reliability of automotive harnesses.