Optimising EV Performance Through Simulation

Electrification is transforming the automotive landscape, but electric vehicles bring engineering challenges unlike any seen in combustion platforms. Battery temperature, power management, range optimisation and weight distribution all play a significant role in vehicle performance. Simulation has become one of the most effective ways to address these challenges early and efficiently.

Understanding the Complexities of EV Systems

EVs are not simply combustion vehicles with different powertrains. They are complex electro-thermal systems with tightly integrated components, including:

• Battery packs
• Cooling systems
• Inverters and motors
• Thermal management circuits
• Regenerative braking systems
• High-voltage electronics

Optimising these systems requires a deep understanding of how they interact under real-world conditions.

Accelerating Development Through Virtual Exploration

Simulation allows engineers to test thousands of EV design variations without building a single physical prototype. Teams can quickly evaluate:

• Cooling strategies
• Battery degradation behaviour
• Thermal runaway conditions
• Charging profiles
• Motor and inverter efficiency
• Vehicle aerodynamics

This rapid exploration reduces risk and helps engineers converge on the best design faster.

“The key to EV performance is understanding its behaviour before it ever hits the road.”

Improving Range and Energy Efficiency

EV range is influenced by dozens of variables, from aerodynamics to battery temperature. Simulation tools allow engineers to model how these variables interact and identify the most effective optimisation strategies.

This includes:

• Minimising thermal losses
• Reducing drag
• Optimising motor efficiency maps
• Improving regenerative braking control
• Fine-tuning battery preconditioning

A more efficient system delivers greater range without increasing battery size — significantly improving vehicle competitiveness.

Ensuring Safety and Durability

Battery packs are among the most critical safety components in an EV. Simulation helps engineers evaluate cell behaviour under extreme conditions, including:

• High load
• Rapid charging
• Mechanical impact
• Thermal runaway

This early analysis ensures EVs meet stringent safety standards without relying solely on physical testing.

Reducing the Need for Physical Prototypes

Because EV components are expensive and complex to manufacture, simulation becomes even more valuable than in combustion platforms. By validating designs virtually, teams reduce the number of prototypes required and shorten development timelines.

Supporting Continuous Improvement

With the rise of connected vehicles, real-world data can feed back into simulation models, creating a digital twin that evolves with the vehicle. This enables ongoing optimisation long after the car has entered production.

Simulation isn’t just a development tool — it’s a lifecycle tool.