4c were engaged to investigate the thermal design of two of MEP‘s automotive battery packs which they had in development. The first was a large battery pack containing several hundred cells, and required forced cooling within very tight packaging constraints. After preparing the CAD model (e.g. stripping out extraneous detail), 4c used SolidWorks Flow Simulation CFD package to investigate the air flow through the pack using a variety of different fan configurations. Transient thermal studies enabled temperatures throughout the pack to be monitored over time, peaks to be measured, warm areas to be identified, and suggestions for improvements to the cooling system to be made.

A second CFD study looked at a smaller battery pack, and involved an A/B comparison to determine whether natural convection would be sufficient to cool the pack under load via its heatsink, or whether forced circulation would be required.