Optimizing Battery Cooling for Modern Mobility: Hinduja Tech’s Simulation-Driven Thermal Solution

Electrification is revolutionizing mobility, and batteries play a central role in this transformation. Yet, as the adoption of electric and hybrid vehicles rises, so does the demand for reliable and efficient battery thermal management. Ensuring batteries remain within optimal temperature ranges, regardless of real-world driving scenarios, is crucial for safety, service life, and vehicle performance.

At Hinduja Tech, we partner with leading OEMs and Tier 1 suppliers to address these evolving engineering challenges with innovation and speed. Our recent project for a prominent automotive client exemplifies our commitment to leveraging advanced simulation for pragmatic and cost-effective results.

Understanding the Challenge: Real-World Complexity

Thermal management systems for batteries must handle a broad spectrum of operating conditions from energy-intensive acceleration in dense city traffic to steady-state cruising on highways. In this program, our client needed to ensure that battery surface temperatures would remain within design limits under two critical operating modes: traffic jam conditions and cruise scenarios.

The stakes were high. Overheating can accelerate battery degradation, shorten usable life, and threaten safety, while under-cooling can compromise power delivery. The challenge? Deliver a validated solution that not only achieves thermal targets but also balances cost, weight, and packaging constraints, essential in today’s competitive automotive landscape.

Our Approach: Simulation-Led, Data-Driven

Hinduja Tech deployed industry-standard tools, ANSYS Fluent and ICEMCFD, for a rigorous Computational Fluid Dynamics (CFD) simulation study. The project’s primary objectives included:

• Estimating blower flow rates required to maintain optimal cooling, using detailed pressure drop analysis
• Assessing airflow distribution and cooling performance both in stop-and-go (traffic jam) and continuous (cruise) conditions
• Modelling complex real-world scenarios such as flow impingement on the battery box and interactions with the vehicle’s underbody and cooling components

The first round of simulation revealed a challenge: temperatures in some regions surpassed the specified maximum under certain conditions. Rather than returning to the drawing board, our engineering teams proposed a series of targeted design enhancements, including the addition and refined positioning of air guides, to direct cooling air more effectively to critical battery surfaces.

From Model to Reality: Results You Can Trust

The power of our approach lies in its iterative nature and its rigorous validation methodology. We worked hand-in-hand with the client to incorporate proposed changes in the virtual model, rapidly testing multiple design iterations in the digital domain, long before committing to costly physical prototypes.

The result? The updated simulation achieved battery surface temperatures well within the defined targets for both urban and highway use cases. When the final, optimized model was subjected to physical testing, the measured results closely matched simulation predictions, a testament to the accuracy of our CFD process and real-world engineering experience.

Key benefits realized by the customer:

• Significant reduction in costly real-world testing, since multiple concepts were virtually validated before a single prototype was produced
• Accelerated program timelines, thanks to rapid digital iterations and data-driven decision-making
• Enhanced confidence in thermal system performance, directly supporting overall battery safety, warranty, and customer satisfaction

Why Hinduja Tech?

This project exemplifies Hinduja Tech’s commitment to delivering transformative engineering services, achieving actionable results through deep domain expertise, advanced tools, and a collaborative client approach. Our teams combine simulation expertise with practical automotive experience to reach targets more quickly, mitigate risks, and optimize investment in new technology programs.

Whether designing next-generation EV architectures, developing robust thermal systems, or enabling digital transformation, Hinduja Tech stands ready to partner with organizations worldwide.

Ready to Future-Proof Your Battery Technology?

Don’t let thermal challenges slow your electrification journey. Hinduja Tech helps OEMs, suppliers, and mobility innovators accelerate product launches and exceed customer expectations. If your organization is evaluating ways to optimize battery, power electronics, or vehicle cooling systems, let’s talk.

Reach out to us at info@hindujatech.com to discuss how simulation-led engineering, proven process, and automotive domain depth can create a step-change in your next vehicle program.