Senior CAE Engineer (Thermal Simulation) - Detroit Engineered Products (DEP)

Thermal Management Engineer

Job Summary:

Responsible for designing and optimizing thermal management systems for vehicle components, this role focuses on ensuring the reliability and longevity of critical components such as batteries, power electronics, and electric motors. The Thermal Management Engineer leverages advanced simulation tools to analyze and improve thermal performance under various operating conditions.

Key Responsibilities:

• Develop and implement thermal management strategies for high-power components, including batteries, inverters, electric motors, and power electronics, using tools such as ANSYS, GT-SUITE, and STAR-CCM+.
• Conduct thermal simulations to evaluate and enhance the performance of cooling and heating systems under different operating conditions, such as high-speed driving, rapid acceleration, and charging.
• Collaborate with powertrain, electrical, and control teams to integrate thermal management solutions into overall vehicle design, ensuring compatibility and efficiency.
• Analyze heat transfer and cooling requirements, assessing the effectiveness of components like radiators, heat exchangers, and HVAC systems to maintain optimal operating temperatures.
• Optimize battery thermal management to ensure consistent performance, prolong battery life, and enhance vehicle range under various environmental conditions.
• Validate thermal models against real-world data by conducting physical tests under different load and environmental conditions, adjusting simulation parameters as needed to improve accuracy.
• Document thermal analysis results, preparing detailed reports with recommendations for design improvements to enhance cooling efficiency and component reliability.
• Research and implement advanced cooling technologies, such as phase change materials, liquid cooling systems, and thermal insulation, to improve overall vehicle thermal performance.

Additional Requirements:

• Proficiency in thermal simulation tools like ANSYS, GT-SUITE, and STAR-CCM+.
• Strong knowledge of electric vehicle thermal management principles, particularly for high-power components like batteries and inverters.
• Familiarity with HVAC system design and the role of heat transfer in electric and hybrid vehicle applications.