Simulation-driven design approach for high power-density electric vehicle power electronics

A power electronics pack for refrigerated transport was redesigned to overcome limitations in power density, efficiency, and compactness. An iterative approach combining CAD modeling with thermal and mechanical simulations guided geometry, material selection, and cooling design. Applying Design-for-Excellence principles, multiple submodules were consolidated into a single enclosure with three functional zones. Structural and thermal validations confirmed compliance under extreme conditions. The optimized pack achieved 31 kg (57% reduction) and 671 W/L power density (338% improvement).