What is the Virtual Twin Experience in electric vehicle simulation projects?

A digital replica of an EV that simulates real-world behavior, allowing for extensive virtual testing and reducing the need for physical prototypes.

Why do electric vehicle motors need to be simulated?

Electric motors convert electrical energy into mechanical energy, providing high torque and efficiency for smooth vehicle acceleration. Optimizing the performance of the electric motor finds the best trade-off between these factors for high performance and efficiency. This improves range while providing the experience drivers expect.

Why do EV power electronics need to be simulated?

Electronics manage the flow of electrical energy to motors, enabling features like regenerative braking for enhanced efficiency. These high-voltage electronic systems need to be carefully designed for reliability, taking into account factors such as heating, electromagnetic interference (EMI) and power integrity (PI).

Why do EV gear drives need to be simulated?

Gear drives transmit power from motors to wheels, simplifying design with single-speed transmissions that reduce weight and maintenance. Simulation can improve the efficiency of these systems and reduce noise vibration and harshness (NVH) by optimizing transmission and lubrication.

What are the benefits of using electrical vehicle simulation tools and services?

Simulation tools are instrumental for engineers to optimize vehicle performance, reduce costs, and expedite market readiness. Virtual prototyping allows extensive testing of electric vehicle components, powertrain systems, and thermal management solutions before physical prototypes are developed. Neural Concept has noted that these tools significantly enhance vehicle aerodynamics by analyzing air flow dynamics to reduce drag, thus improving fuel efficiency and extending driving range. Moreover, Lotus Engineering's 2012 report underscores the pivotal role of advanced computer simulations in maintaining automotive safety standards like crashworthiness and structural integrity, demonstrating that significant mass reductions are achievable without sacrificing performance, safety, or manufacturability for 2020 productions and onwards.

Electric Vehicle Engineering

Steering the Digital Future of Electric Vehicles

Electric vehicles (EVs) are propelling us into an era of efficient, affordable, and clean transportation. They are set to revolutionize travel and become a cornerstone of the mobility landscape in smart cities.

To integrate this new generation of vehicles, innovators, OEMs, and suppliers must rethink vehicle engineering. The compressed development cycles demand unprecedented collaboration among all stakeholders. As multiple systems within the vehicle are impacted, integrating new technologies presents a complex engineering challenge. Electrification requires innovative solutions that unify disciplines and offer a clearer view of vehicle performance.

Key Benefits of Simulation for Electric Vehicle Engineering

Enhanced performance

Electrification improves torque and acceleration, boosting EV acceptance.

Increased battery efficiency

R&D and simulation extend the driving range and reduce charging times.

Reduced cost

Affordable EVs lower costs and increase accessibility.

Virtual Twin Experience for Vehicle Electrical System Simulation

Developing an electric vehicle is a lengthy process involving multiple iterations from concept to final design, along with extensive prototyping and testing. Simulation creates a virtual twin experience that captures all relevant design data and accurately reproduces real-world behavior. This virtual testing replaces physical tests, reducing the number of prototypes and significantly cutting development time and costs.

Engineers using SIMULIA MODSIM solution on my 3DEXPERIENCE platform > Dassault Systemes

MODSIM Facilitates Electric Vehicle Modelling

Unified modeling and simulation (MODSIM) eliminates silos between design and analysis by integrating computer-aided design (CAD) and computer-aided engineering (CAE) into a single environment. This integration allows engineers to receive immediate feedback on the impact of design changes, ensuring optimal performance. All stakeholders in EV design can actively participate and democratize simulation, and team members work with the same, up-to-date data, maintaining a single source of truth.

Explore MODSIM - Unified Modeling and Simulation

Fundamentals of Electric Vehicle Engineering Processes

Component Level
System Level
Full Vehicle Level

Electric Motors for Traction Applications

Electric motors are crucial components in electric and hybrid vehicles, trains, and industrial machinery. They convert electrical energy into mechanical energy, enabling motion. Traction motors are engineered for high torque and efficiency, providing powerful acceleration and smooth operation across various speeds. These motors are typically robust, lightweight, and designed to withstand harsh operating conditions. Key features include precise speed control, low maintenance, and high energy efficiency, making them ideal for sustainable transportation solutions. Ongoing advancements in motor technology continue to improve their performance, reliability, and integration with modern power electronics systems.

Power Electronics Engineering

Power electronics for traction applications play a crucial role in controlling and converting electrical energy to drive electric motors in vehicles and trains. These systems manage power flow between the energy source (like batteries or power grids) and the traction motor, ensuring optimal performance. Key components include inverters, converters, and controllers that regulate voltage, current, and frequency to achieve efficient and precise motor operation. Power electronics enable regenerative braking, which recovers energy during deceleration, enhancing overall efficiency. Their compact design, reliability, and efficiency are critical for advancing electric and hybrid traction systems, supporting the shift towards greener transportation.

Learn how to design & simulate an Inverter Power Module for EVs

Mechanical Gear Drive Simulation

Gear drives in electric vehicles (EVs) are vital components that transmit power from the electric motor to the wheels, optimizing performance and efficiency. Unlike traditional internal combustion engine vehicles, EVs often use single-speed transmissions due to the broad torque range of electric motors. This simplicity reduces mechanical complexity, weight, and maintenance needs. Gear drives ensure smooth torque delivery, enhancing acceleration and energy efficiency. Some advanced EVs incorporate multi-speed gearboxes for improved performance at high speeds. The design focuses on minimizing noise, vibration, and harshness (NVH), contributing to the overall quiet and smooth driving experience that electric vehicles are known for.

Electric Drive Engineering

Electric drive engineering is a multidisciplinary field focused on designing, developing, and applying systems that convert electrical energy into mechanical energy. These systems, known as electric drives, are integral to electric vehicles. Although electric machines have been around for a while, using electric propulsion systems for traction systems widely opens up new engineering challenges.

The electric motor is at the core of electric drive systems, and it is controlled by an electronic controller that regulates speed, torque, and position. The engineering involved in these systems includes several key areas: electrical engineering, control theory, power electronics, and mechanical engineering.

Automotive Battery Pack Design

Battery packs are the heart of electric vehicles (EVs), providing the energy needed to power the electric motor. They must store as much energy as possible to minimize range anxiety and maintain safety in unexpected events.

Battery packs consist of numerous lithium-ion cells arranged in modules, optimized for energy density, longevity, and safety. The design focuses on maximizing range, minimizing charging time, and ensuring thermal management to prevent overheating. Advanced battery management systems (BMS) monitor the health and performance of each cell, balancing the charge and discharge cycles. Innovations in battery technology, such as solid-state batteries and fast-charging capabilities, are driving the evolution of EVs, making them more efficient, reliable, and accessible for widespread adoption. Batteries are highly complex systems, requiring advanced engineering methods at all levels: from chemistry to cell engineering, to module and pack engineering, and finally integration into full vehicles.

Automotive Battery Pack Design > Dassault Systemes

Thermal Behavior Analysis

Electric vehicle thermodynamics focuses on managing heat within the vehicle to ensure optimal performance and efficiency. Unlike internal combustion engines, EVs generate less heat, but efficient thermal management is still crucial, particularly for the battery, power electronics, and electric motor. Systems like liquid cooling, heat pumps, and phase change materials are used to maintain optimal temperatures, preventing overheating or cold-related efficiency losses. Proper thermodynamic management enhances battery life, charging speed, and overall vehicle performance. As EVs evolve, advanced thermal systems become increasingly important for maximizing range and reliability across different climates and driving conditions.

Electromagnetic Compatibility

Electric vehicle electromagnetics plays a critical role in the operation and efficiency of EVs, particularly in the design of electric motors and charging systems. In motors, electromagnetic fields convert electrical energy into mechanical motion, with precise design needed to maximize torque, efficiency, and power density. Electromagnetic principles are also applied in wireless charging systems, where energy is transferred through inductive coupling between coils. Effective electromagnetic design minimizes energy losses, reduces heat generation, and limits electromagnetic interference (EMI) that could disrupt vehicle electronics. As EV technology advances, optimizing electromagnetics is key to enhancing performance, improving range, and ensuring reliable and safe operation.