BEV Controller Thermal Design

I have a power-board inverter destined for a modern battery-electric vehicle and I need a complete thermal solution developed around it. The work starts with accurate 3-D modelling of the board, then moves into designing an aluminium heatsink that houses an internal liquid-coolant channel. Every design decision must be validated in ANSYS, as that is the simulation environment we use in-house.

The study has three inseparable goals: maximise heat-dissipation efficiency, keep every critical component within its target temperature window, and optimise the coolant flow path so pressure drop stays reasonable. You are free to choose the most suitable ANSYS modules—Icepak, Fluent, Mechanical, or Workbench—as long as the final package covers both conjugate heat transfer and CFD.

Deliverables
• Parametric CAD model of the aluminium heatsink with embedded coolant channel
• ANSYS project files, meshes and boundary-condition setups ready for peer review
• A concise report (PDF) detailing assumptions, material data, simulation results, thermal maps, flow visualisations, and design recommendations

Acceptance will be based on meeting the temperature limits I provide after kickoff, achieving a verified pressure drop below our target, and supplying files that reproduce all results without errors on our workstation.