ECS have a wealth of experience in the design and implementation of thermal management solutions for electrical drives.

Our simulation capabilities allow us to preditct temperatures of machines and power converters with high fidelity and speed. This allows an analysis lead design approach to implementing effective and innovative cooling solutions to meet and exceed performance specifications.

We are able to implement different approaches depending on the need and development stage of each project. These range from first principle sizing calculations and speedy analytical models to detailed fully conjugate heat transfer Computational Fluid Dynamics (CFD).

Key services:

Thermal Design & Engineering
  • Strong application-based knowledge of motors and power electronics
  • Full thermal analysis from CAD to verified thermal map
  • Templated analysis methods offering increased speed, accuracy and functionality
  • Tailored to specific problem definitions ensure ensuring high confidence, conclusive outcomes
  • In-house HPC hardware, increasing simulation capacity and reducing project cost

Click here for a Case Study on Thermal Design

Process Review / Peer Review
  • Expert review & critique of existing thermal simulation, modelling and test procedures
  • Increase value of thermal analysis through verification and confidence assessment
  • Development of internal processes for thermal analysis
  • Training of your internal team

Click here for an overview of Thermal Design Process & Training

Bespoke Tool Development – for use by your engineers
  • Creation of parametrised thermal models, customised for specific customer hardware
  • Model transferred to your engineering team for on-going cost-free analysis
  • Model updates from ECS to track your product evolution

Click here for a case study of a Bespoke Tool project

Design, Prototype and Test of Thermal Devices
  • Design, prototype and test thermal management hardware, such as cold plates and converter casings
  • Tailored to reflect electronics and duty load profiles
  • Apply state-of-the-art cooling methods
  • Mechanical analysis  – structural & manufacturability

 Click here for an Case Study on Thermal Device Development & Prototyping

Simulate Early, Simulate Often

A study by the Aberdeen Group has shown that the ‘best in class’ performers across multiple engineering sectors put a strategic emphasis on using simulation to gain better insight into product behaviour from the very beginning of the design process. This is a key differentiator of their success.

Using simulations systematically and at regular intervals leads to higher performance in terms of the product meeting its quality and cost targets and launching the product on time.

In contrast, poor industry performers turn to simulations at advanced development stages, when performance issues are uncovered in prototypes or in rereleased products.

We encourage customers to employ thermal simulations early in the design process to ehlp ensure their project delivers to the best possible standard.

CFD in Reduced Time

CFD is often underused in product development due to the perception that it cannot generate results quickly enough to impact decisions without slowing the entire design process. This need not be true!

ECS have developed highly automated CFD procedure saves significant time compared to traditional packages.

Our experience has shown that CFD simulation of an electrical machine can be created and solved in just one third of the time that it would in traditional commerical CFD packages.

Running variants of a machine design is incredibly quick as well due to the automation. We predict we can run 7 design variations of the same machine in the time that a single variant can be produced in alternative packages. This allows for insightful comparison between design options, and the ability to assess benefits and trade-offs.

CFD at Reduced Cost

The cost of performing CFD is also a common put-off. With outlays that can reach £100,000s before generating a single result, this is not surprising. Unreasonably high licensing costs, expensive hardware to compute large simulations and the need to employ experienced CFD engineers all add up.

ECS can offer a drastically different outlook on this landscape. Our processes are created with time and cost savings in mind.

Compared to adopting traditional CFD approaches, our approach can save considerable money.

  • License costs of traditional packages can easily be over £100,000. We use trusted and reliable open-source solvers, so our license costs and nil.
  • A standard HPC computer costs over £30,000. We have our own high computing capabilities, so customers need not outlay for expensive computing power. Our computing rates are very affordable, around half the price of AWS.
  • Experienced CFD engineers are compulsory to use traditional packages. A simulation setup incorrectly may well provide a plausible yet incorrect result which can cause huge downstream rectification costs. All our CFD engineers are very experienced, and because our CFD is significantly quicker than traditional packages, less time is engineering needed.