Thermal Simulation and Heatsink Design for Light EV Motor Controllers
Pain Points (Public)
Designing compact 15–25 kW motor controllers operating across 72 V to 108 V creates concentrated heat dissipation across the inverter power stage. Engineering teams struggle to accurately quantify semiconductor conduction and switching losses under dynamic peak loads, causing junction overheating and thermal throttling without oversized, costly aluminum heat sinks.
Suggested Approach (Public)
Perform multi-physics semiconductor loss modeling and iterative conjugate heat transfer (CFD) simulations to optimize heatsink fin topology, airflow routing, and thermal interface material (TIM) selection, maintaining safe silicon junction temperatures under continuous 15 kW and peak 25 kW operating profiles.
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Opportunity assessment PRO
Development brief PRO
- Position as a specialized thermal CAE consulting service for light EV powertrain controllers (72 V–108 V, 15–25 kW), delivering custom ANSYS Icepak and FloTHERM simulation reports rather than attempting to launch an untested standalone SaaS tool.
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- Build an internal Python/PLECS loss estimation script to calculate MOSFET/IGBT conduction and switching losses under 72 V–108 V and 15 kW/25 kW peak load profiles.
Competitor evidence PRO
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