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.
1. 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.
1. 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