Multiphysics Modeling Key to Electrifying Energy Solutions

Efforts to electrify various sectors face significant challenges, particularly in developing practical energy storage solutions. At the recent COMSOL annual conference held in Burlington, Massachusetts, from October 8 to 10, 2023, experts discussed the need for advanced modeling techniques to address the complexities involved in this transition. Traditional lab-bench prototypes often fall short when applied in real-world scenarios, highlighting the critical role of multiphysics modeling in overcoming these obstacles.

Bjorn Sjodin, the senior vice president of product management at COMSOL, emphasized the intricate interplay of electromagnetic effects, heat transfer, and structural mechanics in the electrification process. “In electrification, at its core, you have this combination of electromagnetic effects, heat transfer, and structural mechanics in a complicated interplay,” he stated, underscoring the necessity for comprehensive simulations that encompass multiple physical phenomena.

At the conference, engineers and developers explored how multiphysics modeling can enhance research and development in electrification. Niloofar Kamyab, a chemical engineer and applications manager at COMSOL, remarked that while some view simulation as merely a replacement for physical experiments, it actually serves as a tool to optimize and streamline testing processes. “Experiments still need to be done, though experiments can be done in a more optimized and effective way,” she explained.

The discussion also highlighted the challenges posed by battery technology. Kamyab noted that batteries exhibit complex behaviors at both the cell and pack levels, making traditional experimental approaches inadequate. “Thermal management is one of their primary concerns,” she stated, explaining that multiphysics simulations allow engineers to test battery designs under extreme conditions, thereby preventing potential malfunctions and safety hazards.

The conference also delved into wireless charging systems, which present their own set of thermal challenges. Nirmal Paudel, a lead engineer at Veryst Engineering, pointed out that localized heating of coils can significantly impact circuit performance. This necessitates sophisticated modeling to ensure the reliability of charging systems.

Electric motors and power converters are also undergoing significant transformations. Vignesh Gurusamy, a senior application engineer at COMSOL, highlighted that the recent surge in electrification demands a holistic approach to the development of these technologies. “The recent surge in electrification across diverse applications demands a more holistic approach as it enables the development of new optimal designs,” he explained.

The freight transportation sector is exploring various energy solutions, including batteries and fuel cells. Sjodin noted that fuel cells are particularly well-suited for multiphysics modeling due to their complex interactions involving fluid flow, heat transfer, and chemical reactions. “Fuel cells are very multiphysics friendly,” he said.

The electric grid itself faces new challenges as renewable energy sources like wind and solar become more prevalent. “The grid is designed for a continuous supply of power,” Sjodin explained, indicating that the intermittent nature of these sources creates entirely new problems for energy management.

Innovative companies are leveraging multiphysics modeling to create advanced powertrain systems. For instance, IAV, an automotive engineering firm based in Berlin, is developing a dual-chemistry battery pack that combines sodium-ion and lithium solid-state batteries. Jakob Hilgert, a technical consultant at IAV, shared insights from a COMSOL case study, explaining how the team utilized multiphysics simulations to optimize the interactions between different battery chemistries. “If we have some cells that can operate at high temperatures and some that can operate at low temperatures, it is beneficial to take the exhaust heat of the higher-running cells to heat up the lower-running cells,” he said.

The advancements in multiphysics modeling reflect a broader trend across various industries impacted by electrification. Sjodin noted that improvements in algorithms and hardware are enhancing the capabilities of simulation tools. “Algorithmic improvements and hardware improvements multiply together,” he remarked, suggesting that this evolution will enable simulations of increasingly complex systems.

According to Gurusamy, innovations such as GPU accelerators and surrogate models are facilitating significant advancements in electric motor technologies. “A primary frontier in electric motor development is pushing power density and efficiency to new heights, with thermal management emerging as a key challenge,” he stated, emphasizing the importance of temperature-dependent behavior in optimizing motor components.

The wireless charging sector is also experiencing a shift due to multiphysics modeling. Paudel highlighted how traditional design methods focused on tweaking coil geometry, while modern integrated platforms allow for the exploration of new charging architectures, including flexible textiles and adaptive smart surfaces.

As battery technologies continue to evolve, Kamyab noted that the push for higher power densities and lower costs is driving innovation across multiple industries. “The reason that many ideas that we had 30 years ago are becoming a reality is now we have the batteries to power them,” she explained. The progress in battery technology not only advances existing markets like consumer electronics and electric vehicles but also opens doors to new applications, such as electric vertical take-off and landing aircraft (eVTOLs).

The discussions at the COMSOL conference underscore the critical role that multiphysics modeling will play in shaping the future of electrification. As the industry moves forward, the integration of diverse physical phenomena into simulation practices will be essential for developing effective and safe energy solutions.