Electrification Challenges Demand Advanced Multiphysics Modeling

Efforts to electrify transportation and power systems are facing significant challenges that require advanced multiphysics modeling. Traditional lab prototypes often fail to translate into workable solutions in real-world scenarios. As Bjorn Sjodin, senior vice president of product management at the software company COMSOL, points out, the intricacies of electrification involve a blend of electromagnetic effects, heat transfer, and structural mechanics.

The rising demand for comprehensive engineering simulations was a key topic at COMSOL’s annual Boston conference, held from October 8 to 10, 2023, in Burlington, Massachusetts. Here, engineers and developers explored the importance of multiphysics modeling in tackling the complex requirements of electrification research and development.

Multiphysics Modeling: A Necessity in Modern Engineering

Niloofar Kamyab, a chemical engineer and applications manager at COMSOL, emphasized that while traditional experiments remain essential, simulation technologies can optimize and enhance these processes. “Some see simulation as a fancy R&D thing,” she said, “but it is crucial for understanding complex interactions in technologies like batteries.”

Multiphysics modeling allows for a deeper understanding of battery systems across various scales. Batteries exhibit complex behaviors at both the cell and pack levels, which can lead to issues like thermal runaway. Kamyab noted that engineers utilize simulations to predict and mitigate these risks, enhancing safety and performance.

For example, thermal management is a primary concern for engineers working on battery packs. Kamyab explained that by simulating malfunctioning cells, engineers can identify potential failures before they occur. This proactive approach is vital in ensuring the reliability of energy storage systems.

Another area of focus is wireless charging systems. Nirmal Paudel, a lead engineer at Veryst Engineering, highlighted the thermal challenges that arise at higher power levels. “Localized heating of the coil changes its conductivity,” he explained, impacting the overall circuit design and performance.

Innovative Solutions Through Simulation

The surge in electrification across various sectors is prompting a shift in how electric motors and power converters are developed. According to Vignesh Gurusamy, a senior application engineer at COMSOL, older design methods are becoming obsolete. “The recent surge in electrification demands a more holistic approach,” he stated, noting that this enables the creation of optimal designs for new technologies.

In freight transportation, discussions are ongoing about whether to utilize batteries or fuel cells. Sjodin highlighted the multiphysics nature of fuel cells, which involve fluid flow, heat transfer, and chemical reactions, making them an ideal candidate for advanced simulation techniques.

The challenges posed by intermittent power sources, such as wind and solar, are also reshaping the electric grid. “The grid is designed for a continuous supply of power,” Sjodin said, “but fluctuations from renewable sources create new complexities.”

Kamyab pointed out a significant trend in automotive engineering, exemplified by Berlin-based IAV, which is developing powertrain systems that integrate multiple battery formats. The combination of sodium-ion and lithium solid-state batteries creates a versatile energy solution. By using multiphysics simulations, IAV was able to optimize the thermal management for these different chemistries.

Jakob Hilgert, a technical consultant at IAV, shared insights from a COMSOL industry case study. He explained how the team designed a dual-chemistry battery pack that effectively managed the heat generated by cells operating at varying temperatures. This innovative approach demonstrates the potential of multiphysics modeling to enhance energy efficiency.

As technology continues to evolve, Sjodin believes that improvements in algorithms and hardware will further advance multiphysics simulation capabilities. “The future of multiphysics simulation will allow for the simulation of larger and more realistic systems,” he noted.

Gurusamy added that developments in GPU accelerators and surrogate models are enabling major strides in electric motor design. These advancements help optimize components such as copper wire windings, which are critical for enhancing power density and efficiency.

The landscape of wireless charging is also changing, with multiphysics simulations paving the way for new architectures. Paudel mentioned that traditional design cycles focused on tweaking coil geometry, but integrated multiphysics platforms now allow for the exploration of innovative solutions, including flexible charging textiles.

As battery technology advances towards higher power densities and lower costs, it is driving innovation beyond traditional applications. Kamyab observed that new industries, such as electric vertical take-off and landing aircraft (eVTOLs), are emerging as a result of these advancements. “The reason many ideas from 30 years ago are becoming a reality is due to the progress in battery technologies,” she said.

The ongoing electrification movement is reshaping industries and driving new possibilities, thanks to the integration of advanced multiphysics modeling. As engineers continue to tackle complex challenges, the collaborative efforts between simulation and experimentation will play a crucial role in the future of electrification.