Multiphysics simulation: Scaling Electrification Beyond the Lab
As the world rapidly electrifies, a critical challenge is emerging: designs that perform flawlessly in the lab often falter in real-world applications. advanced multiphysics modeling is becoming essential to bridge this gap,offering engineers the ability to simulate the complex interplay of forces governing everything from electric vehicle batteries to the power grid.
The push to electrify everything – cars,trucks,planes,and even entire cities – is running into a essential hurdle. What works as a lab-bench mockup breaks down when faced with the complexities of real-world operation. Harnessing and safely storing energy at scale demands a deeper understanding of the interconnected physical phenomena at play. “In electrification,at its core,you have this combination of electromagnetic effects,heat transfer,and structural mechanics in a complicated interplay,” explained a senior industry official.
The Rise of Multiphysics Modeling
traditionally, engineering simulations focused on individual physics domains. Though, modern electrification demands a more holistic approach. Multiphysics modeling,the simultaneous simulation of multiple physical phenomena,is rapidly becoming indispensable. Engineers and developers gathered in Burlington, Massachusetts, from October 8-10 for COMSOL‘s annual Boston conference to discuss the latest advancements in this emerging field.
COMSOL, an engineering R&D software company, specializes in simulating these complex interactions. Unlike software that focuses on a single physics domain,COMSOL allows engineers to model the combined effects of electricity,heat,fluid flow,and structural stress. This capability is proving crucial for optimizing designs across a wide range of electrification applications.
The benefits of multiphysics extend beyond batteries. Traditional progress methods for electric motors and power converters are proving inadequate for the demands of widespread electrification. “The recent surge in electrification across diverse applications demands a more holistic approach as it enables the development of new optimal designs,” said an electrical engineer.
Even the electric grid itself requires a new level of simulation sophistication. The integration of intermittent renewable energy sources like wind and solar power introduces new challenges to a grid designed for continuous, predictable power supply.
Innovative applications and Future Trends
Companies are already leveraging multiphysics to push the boundaries of electrification. Berlin-based IAV, such as, is developing power-train systems that combine different battery chemistries – sodium-ion and lithium-ion – to maximize performance. “Sodium ion cannot give you the energy that lithium ion can give,” explained an IAV technical consultant in a recent case study. “So they came up with a blend of chemistries, to get the benefits of each, and then designed a thermal management that matches all the chemistries.”
This involved creating a cooling system that intelligently redistributes heat between cells operating at different temperatures, optimizing overall efficiency and safety. according to industry observers, this approach exemplifies a broader trend: the convergence of algorithmic and hardware improvements. “Algorithmic improvements and hardware improvements multiply together,” a senior official stated. “That’s the future of multiphysics simulation. It will allow you to simulate larger and larger, more realistic systems.”
Advances in GPU accelerators and surrogate models are further accelerating progress, enabling engineers to optimize electric motor capabilities and efficiencies with unprecedented precision. Even seemingly minor components, like the windings of copper wire in a motor core, can be optimized using multiphysics simulations.
Furthermore, simulation is driving innovation in wireless charging, enabling the exploration of new architectures, including flexible charging textiles and smart surfaces. And as battery technology continues to advance – pushing toward higher power densities and lower prices – it’s unlocking new possibilities, such as electric vertical take-off and landing aircraft (eVTOLs).
“The reason that many ideas that we had 30 years ago are becoming a reality is now we have the batteries to power them,” one expert concluded. “That was the bottleneck for many years. And as we continue to push battery technology forward, who knows what new technologies and applications we’re making possible next.”
