Innovating EV Charger Design: UNO MINDA’s Simulation Success

About the Customer: UNO MINDA, a pioneer in automobile component manufacturing since 1958, provides innovative automotive solutions to OEMs and Tier 1 manufacturers globally.

Their Challenge: Amidst the transition to electric vehicles (EVs), UNO MINDA faced the intricate task of designing efficient onboard chargers. Compact size and high power density added complexity to achieving optimal thermal management and mechanical performance.

The Role of Digital Simulation: Leveraging Altair® SimLab®, UNO MINDA conducted diverse design experiments and sensitivity analyses to streamline product development. Digital simulation accelerated design iterations, fostering innovation while minimizing time and costs.

Main Product Development Challenges: Designing compact yet high-performance onboard chargers required meticulous attention to thermal management, power integrity, and structural rigidity. Altair’s SimLab and PollEx™ proved instrumental in optimizing electromechanical performance and PCB-level simulation.

Results: UNO MINDA’s thermal analysis using SimLab revealed critical heat transfer paths and PCB hotspots, leading to design improvements. By comparing simulation results with physical tests, they achieved a 10% deviation, paving the way to further enhance designs and aim for a deviation of less than 5%.

Original source Engineering Review