THERMAL SIMULATION

In live wires, heat is generated due to electrical resistance – a physical effect that requires utmost attention when designing power and high voltage vehicle electrical systems. The goal is to comply with the temperature class of the wires and avoid overheating even under maximum load, while at the same time minimizing weight, space, and costs. Our engineering teams rely on high-precision thermal simulations that realistically calculate temperature development in wire bundles, busbars, and contact components – without any physical tests. Our analyses take into account not only static and transient effects but also complex environmental factors, such as air cooling, ensuring precise and reliable design.It is due to these virtual risk analyses that we can define suitable materials right from the concept phase, utilize installation space efficiently, and optimize the system weight – regardless of whether it’s for stranded conductors, flat cables, busbars, or actively cooled wires.