Generative Design: The Ultimate Solution to EV Cooling Systems | Diabatix

November 16, 2023
Sarah da Silva Andrade

The latest report from the IEA [1] highlights the exponential growth of electric car markets. In 2022, electric car sales exceeded 10 million, with a share of 14% in total sales. This represents more than a three-fold increase in just three years, from around 4% in 2020. The report also predicts that EV sales will continue to grow strongly in 2023.

This growth can be attributed to several factors, including global efforts to reduce carbon emissions. Accounting for nearly 60% of the electric cars registered globally [2], China has provided sustained policy support for early adopters of electric cars for over a decade. This support includes purchase incentives [3], rapid establishment of charging infrastructure, and strict registration policies for non-electric cars. In Europe, regulations are in place to control CO2 emissions [4,5]. These regulations cover the period from 2020 to 2024 and provide targets for upcoming years. Lastly, the United States has released a blueprint [6] detailing its policies for decarbonizing transportation.

The demand for electric vehicles (EVs) has risen significantly, leading to an increase in the number of electric cars available in the market. However, this growth has brought new challenges for the industry. The most significant challenge is to ensure the efficiency and performance of EVs, which depend heavily on their cooling systems.

Designing battery cold plates for electric vehicles can be a challenging task. The traditional process of designing cold plates can be error-prone, manual, and expensive. This can lead to a disconnect from the need for effective battery thermal management, which is crucial for achieving a longer lifespan for the batteries. Furthermore, the design process has become increasingly complex, making it difficult to optimize for multiple objectives and constraints.

The Need for Advanced Cooling in Electric Vehicles

This is where Diabatix, a leading thermal generative design software provider, comes in. ColdStream, its software, uses Artificial Intelligence (AI) and advanced algorithms to design highly efficient cooling systems for electric vehicles. By utilizing the power of generative design, ColdStream is able to create complex geometries that are optimized for efficient heat transfer.

Advanced cooling systems are crucial for the performance, safety, and longevity of EVs. These systems maintain optimal battery temperatures, which directly impact the battery's lifespan. Excessive heat can degrade the battery faster, shortening its effective lifespan.

Advanced cooling systems: Ensuring battery longevity and preventing heat damage

Cooling systems also mitigate the risk of thermal runaway, a dangerous condition where excessive heat can lead to fires or explosions. This is particularly critical for EV batteries, which are susceptible to heat-related damage.

Efficient cooling is also essential for fast charging capabilities, as the heat generated during this process needs to be effectively managed to prevent battery damage.

Diabatix: Pioneering in Generative Design

Diabatix stands out with its state-of-the-art generative design software, ColdStream, which automates and streamlines the design process of cooling systems. The software significantly reduces design cycle time, enabling rapid iterations and optimizations that are crucial in the fast-paced EV market. The user-friendly workflow involves key steps:

Discover Steps 1-5 in Action
  1. Uploading CAD Geometry: Users start by uploading the basic design files into the system.
  2. Setting Materials and Conditions: Defining the materials (both solids and fluids) and their properties, along with boundary conditions, is crucial for accurate simulation and design.
  3. Specifying Design Domains: Users can specify the areas within the design where optimization is needed, allowing for targeted improvements.
  4. Setting Targets & Constraints: Users provide design goals and limitations, such as temperature minimization, pressure loss, or material restrictions. ColdStream generates designs that align with these needs and project specifications for optimal results.
  5. Algorithm-Driven Optimization: ColdStream’s algorithms then analyze these inputs to generate the most efficient and effective cooling designs, considering all specified constraints and requirements.

Case Study: Enhancing Battery Cold Plate Design

A practical demonstration of Diabatix’s capabilities can be seen in their recent project focused on optimizing a battery cold plate.

The cooling system should regulate the temperature of 15 distributed cells, each one generating a heating power of Q = 31.25 W. The fluid is water-glycol.

ColdStream considers manufacturing a constraint that should be selected before the optimization. The cooling plate was specifically designed to be manufactured using sheet metal forming technology. Once the design area and optimization targets for temperature minimization, temperature variance minimization, and manufacturing are set up, ColdStream autonomously handles the optimization of the cooling component.

Overview of the setup for the battery cold plate case. On the left, you can see the 15 heat cells distributed throughout, along with the temperature targets set for the batteries and the flow rate in the inlet. On the right, you can see the highlighted design region in yellow, along with the pressure loss target and the manufacturing constraint.

Go to the 3D results tab to discover the sheet metal forming cold plate design ready for manufacturing.

Generative-designed sheet metal forming cold plate: Ready for manufacturing
Discover the Details of this Case Study Now

ColdStream platform allows users to visualize the results in 3D, tables, and charts. Additionally, the results can be downloaded and integrated into existing workflows for improved performance.

ColdStream integrates with your current systems, saving time and reducing errors when transferring data between different platforms.

Impact on the EV Market

The contribution of Diabatix in the EV sector highlights the importance of software-driven solutions in modern automotive engineering. By using generative design, Diabatix is boosting the performance and safety of EVs and facilitating the faster development of eco-friendly transportation options.

With the continuous expansion and evolution of the EV market, the role of software, such as ColdStream, in addressing intricate engineering challenges is becoming increasingly significant.

ColdStream: Pioneering the Future of EV Cooling

In the field of cooling systems for electric vehicles, Diabatix's generative design software is setting new standards. ColdStream not only meets the current requirements of the automotive industry but also opens doors to future advancements.

In today's world, where efficiency and sustainability are crucial, Diabatix's contributions are significant in driving the automotive sector into a new era of innovation and environmental responsibility.








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