Project Overview

We are seeking an experienced Multiphysics Simulation Engineer or Simulation Services Team with strong expertise in the ANSYS ecosystem to support the development and validation of a liquid-cooled high-current cable and connector assembly for megawatt-class electric vehicle charging applications.

The project involves thermal, electrical, and potentially mechanical simulation of a next-generation cooled cable and connector system. Initial technical discussions will be conducted under a Non-Disclosure Agreement (NDA), after which detailed design data, calculations, and CAD models will be shared.

Scope of Work1.

Thermal

Simulation

Develop detailed thermal models of the cable and connector assembly to evaluate steady-state operating performance.

Responsibilities include

Review existing engineering calculations, including:

Heat generation estimates

Thermal resistance network

Fluid properties

Mass flow rates

Fluid velocities

Reynolds and Nusselt number calculations

Develop

Full 3D thermal model of the connector assembly

2D thermal model of the cable (where appropriate)

Perform steady-state thermal analysis.

Evaluate

Temperature rise for specified current levels

Metal conductor temperatures

Effect of varying coolant inlet temperatures

Effect of varying ambient temperatures

Surface (touch) temperatures of exposed plastic components, including connector hood and cable outer jacket.

Recommend design improvements to optimize thermal performance where applicable.

2.

Electrical

Simulation

Develop electrical models of the cable and connector assembly suitable for circuit-level simulation.

Responsibilities include

Perform electromagnetic model extraction using ANSYS Q3D Extractor or equivalent.

Generate equivalent circuit models compatible with SPICE/LTspice.

Calculate

DC resistance (DCR)

Series inductance

Overall impedance

Produce aggregated electrical parameters including:

Equivalent Series Resistance (ESR)

Equivalent Series Inductance (ESL)





Frequency-dependent impedance |Z(f)|

Support analysis across operating frequency ranges as defined during the project.

3.

Mechanical

Simulation (Optional)

If required, perform mechanical analyses to assess connector usability and robustness.

Potential analyses include

Connector insertion force during normal mating.

Misalignment and incorrect insertion scenarios.

Forced engagement analysis.

Mechanical stress and deformation evaluation.

Deliverables

Thermal simulation models and reports.

Temperature contour plots and steady-state results.

Electrical equivalent circuit models.

SPICE/LTspice-compatible extracted models.

Electrical parameter summary (DCR, ESR, ESL, impedance).

Mechanical simulation report (if included).

Design recommendations based on simulation findings.

Presentation of key findings and engineering assumptions.

Required Skills

Solid proficiency with ANSYS simulation tools, including:

ANSYS Mechanical

ANSYS Fluent or Icepak

ANSYS Q3D Extractor

Experience with conjugate heat transfer and liquid cooling.

Electromagnetic simulation and equivalent circuit extraction.

Thermal management of high-current electrical systems.

SPICE/LTspice model generation.

Experience with cable assemblies, connectors, busbars, or EV charging systems is highly desirable.

Ability to interpret engineering calculations and integrate them into simulation models.

Strong technical reporting and communication skills.

Project Timeline

Project commencement: As soon as NDA is executed.

Priority: High (urgent project).

Collaboration: Regular technical review meetings with the client engineering team.

Design details, CAD files, and existing engineering calculations will be provided under NDA.

Preferred Experience

Experience in one or more of the following is highly desirable:

Megawatt Charging Systems (MCS)

High-power EV charging infrastructure

Liquid-cooled cable assemblies

High-current electrical connectors

Power electronics interconnects

Multiphysics simulation involving thermal, electrical, and mechanical domains

📌 Multiphysics Simulation Engineer (Short Term / Freelance) (Noida)
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📍 Noida