Simulation expertise for e-mobility
Two projects. Two challenges. One goal: maximum safety and performance for high-current connectors.
Mechanically robust, thermally efficient – these were the requirements for two liquid-cooled high-current connectors from Amphenol Tuchel Industrial. The d.u.h.Group supported the development with two targeted simulation projects:
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Project 1: FEM analysis of an MCS connector in a roll-over scenario
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Project 2: CFD optimisation of a CCS2 connector under operating conditions
Different tasks – one common goal: to ensure reliability at an early stage through simulation.
Simcenter 3D and Simcenter FLOEFD were used – to deliver robust results on which the development team could rely.
CUSTOMER
A strong partner for a strong product.
Amphenol is one of the world’s leading suppliers of electrical connectors – with over 100,000 employees worldwide and customers in sectors such as IT, the automotive industry, industrial electronics and aviation. We are therefore all the more delighted to have supported Amphenol in the development of a high-performance CCS2 charging connector for electric mobility.
Project 1
FEM analysis of an MCS connector: rollover simulation under real-world conditions
Initial situation and objectives
An MCS connector with a liquid-cooled interior is required to withstand extreme mechanical stresses. The aim was to validate its structural integrity in a realistic rollover scenario – in three mounting positions and whilst meeting all sealing requirements.
Challenges and solutions
The FEM analysis placed high demands on modelling, contact definition and numerical stability. The d.u.h.Group developed a targeted simulation strategy:
- Development of a precise simulation model in Simcenter 3D
- Time-dependent loading from an idealised tyre model
- Realistic representation of complex contact conditions within the connector housing
- Model adjustments to ensure numerical stability
- Identification and assessment of critical stress zones
Results & Achievements
- In all three scenarios: No structural damage
- The cooling area remained completely watertight
- The target protection class was achieved
- Critical zones were identified and validated
Project 2
Simcenter FLOEFD: a boost to development.
Initial situation and objectives
The aim was to analyse the thermal and fluid dynamics properties of a liquid-cooled CCS2 connector. The focus was on the effect of current flow on the temperature distribution, as well as identifying potential for optimising cooling performance.
Challenges and solutions
The d.u.h.Group developed a CFD model based on Simcenter FLOEFD to identify thermal hotspots and optimise them in a targeted manner:
- Development of a simulation-capable geometric model with parametric variants
- Simulation of real-world operating conditions, including electromagnetism effects
- Investigation of the flow distribution and local temperature maxima
- Comparison and evaluation of several design options
- Identifying specific measures to improve efficiency
Results & Achievements
- Reduction in the maximum component temperature by 14 %
- Compliance with all thermal limits through targeted CFD-based design optimisation
- Efficient design cycles thanks to parametric modelling
- Rapid and successful implementation through close collaboration with Amphenol
Consultancy
Simulation
Both projects were carried out on behalf of Amphenol Tuchel Industrial – part of the internationally active Amphenol Group and a leading manufacturer of electrical connectors. This close collaboration enabled efficient implementation and targeted product optimisation in the field of e-mobility. Would you like to underpin your product development with precise simulation? The d.u.h.Group can support you with its in-depth FEM and CFD expertise. Please get in touch!
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Success stories
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