Automotive

Durability

• Suspension and Chassis components stiffness evaluation and Life prediction
• Powertrain Components – Thermo-mechanical simulations & Plasticity simulations
• BIW Stiffness Evaluation

Crash Simulation

• Full-Frontal Collision as per FMVSS and European (ECE)
• Side Impact Simulation with injury level to the passenger using dummy
• Occupant Safety including Airbag deployment and Seat belt safety test

Noise, Vibration and Harshness

• Brake Squeal Simulations
• Acoustic simulations for sound pressure level inside cabin
• Powertrain NVH

Design Optimization Studies

• BIW & Chassis Topology Optimization
• Size and Shape Optimization of Suspension and Chassis components
• Optimization studies using Design Sensitivity analysis and Pareto curves for trade-off studies

Hyper Elastic problems

• Door Seal analysis to simulate effect of coating on seal.
• ANSYS CLASSICAL/WORKBENCH

CFD Simulation (Interiors and Exteriors)

• Simulation of Inlet and outlet ports for Hino Engine
• Exterior flows on car bodies
• Interior flow analysis for car AC ducts.

Automotive CAD Capabilities

• Industrial Design and styling
• Creation of digital mock-ups from styled (Class A) surfaces
• Design of Interior and Exterior parts
• Full Vehicle Integration and design of under-body parts
• Adaptation of existing design to new vehicle variants
• Plastic Mould, Stamping die, Pressure Die Casting Die, Jigs & Fixture design
• Scanning and reverse engineering
• Parametric Part modelling and CAD customization
• Legacy data conversion, 2d to 3d conversion services
• Onsite manpower deployment
• PLM implementation and customization
• Interactive part catalogs and manufacturing process simulation

Automotive FEA Capabilities

• Static, Dynamic, Non-Linear and Non-linear Dynamic, Buckling, Modal, Transient simulations
• Occupant safety, Crash, Impact as per standards like FMVSS
• Product optimization and weight reduction
• Product validation using alternate materials
• External vehicle aerodynamics and HVAC using CFD
• Thermal, Modal, Vibration analysis on components like headlamps, tail lamps, radiators, mounting brackets etc
• Durability, Vehicle stability, NVH, Rollover simulation
• Mechanism simulation and multi-body dynamics
• Moldflow and Sheet metal forming simulation for tool design validation

NVH Analysis

• Extensive modernization resulted in negative impact of sound and vibration on environment and all of us. Increased awareness towards noise and extensive knowledge about noise related health issues like hearing impairment, discomfort, stress and possibly trauma is driving the demand on keeping a safety valve over the sound source of all industry products. So product development is now having a new road block called noise and vibration analysis.
• AES’s widespread knowledge and the proficient NVH testing team looks at the entire vehicle and reflects the numerical facts and figures on noise generated in terms of both air-borne and structure-borne grounds. With shorter lead times, DEP enables the manufacturers to gain a competitive advantage over other players.

Battery Thermal Analysis

• The performance and utility of clean energy mobility models like Hybrid Electric Vehicles (HEVs), Battery Electric Vehicles (BEVs) and Plug-In Hybrid Electric Vehicles (PHEVs) primarily dependent on the performance and efficiency of the battery package which acts as the powerhouse for the above means of transport.
• AES’s analysis specifically covers:
  – Thermal abuses (over current)
  – Pressure drop and Full CHT
  – Sensing circuit analysis
  – 1D AMESIM model for system simulation

Durability and Fatigue Analysis

• Fatigue and durability analysis is the test of time for structural parts that operates over and over, day after day. Mainly this analysis aims to explain how mechanical material behavior relates to the design of structural machine components.
• AES’s capabilities for lifetime assessment ranges from basic tools with simplified loading assumptions to advanced applications that target specialized engineering-analysis tasks. The basic fatigue and durability analysis done by DEP design engineers can provide an elaborate stress analysis to avoid under- or over-designing of products by simulating actual loading conditions and useful when comparing designs or design options. Eventually the test result states the service life until damage is sustained.

Motor Thermal Analysis

Motor thermal analysis are done as follows:

• 3D Induction motors analysis for mild hybrids
• 3D PM motor for full hybrid/ EV’s
• 1D AMESIM model for system simulation

Inverter Thermal Analysis

Our Inverter services includes:

• Power module steady state thermal Analysis
• Transient thermal analysis of power module for Thermal impedance and Time constants for the damage life estimation
• DC/AC bus bars coupled electric thermal analysis
• Component level thermal performance and Full inverters

Coupled Control/Circuit Simulations

• Building hardware is a great art that requires time and lot of procedures & guidelines. But evaluating the machine model by connecting them to circuit model is the new extraordinary experience that AES can provide
• The analyses are performed by linking to power electronic simulators such as Simplorer and MATLAB/Simulink. The coupled simulation technique is developed based on the finite element method. The circuit simulation is mainly devised for improving design capability and efficiency.

EV/HEV Traction Motor Simulation

• AES’s traction motor simulation capability is a perfect solution for today’s automotive engineers whose optimization needs include Performance, efficiency, size & cost along with NVH, Reliability & Durability
• With our accumulated knowledge and experience in motor design, the various mechanical, fluid dynamics, thermal, electrical and electromagnetic requirements are fulfilled up to the expectations