ANALYSIS TYPE / 09

Busbar Simulation for EV Battery Systems, Switchgear & Power Electronics

Current Distribution · Joule Heating · EMI · Mechanical Stress

Ansys MaxwellAnsys Q3D ExtractorAnsys MechanicalAnsys Icepak

Overview

Busbars

Busbar simulation analyses current density distribution, Joule heating, inductance, and mechanical stress under rated and fault conditions — ensuring reliable power distribution in EV battery systems, switchgear, and power electronics. Coupled electromagnetic-thermal analysis predicts thermal hotspots and stray inductance — a critical parameter for limiting voltage overshoot during SiC MOSFET switching — while short-circuit force analysis verifies structural integrity of the busbar assembly under fault conditions.

Industries Served

AutomotiveEnergyIndustrial EquipmentAerospaceHigh TechConsumer Electronics

Deliverables

Current Density MapsStray Inductance ValueTemperature DistributionShort-Circuit Force Analysis

Key Aspects

What Busbars Involves

01

Current Density & Hot Spot Prediction

Predicting the non-uniform current distribution in complex busbar geometries and identifying thermal hotspots under normal and peak current conditions.

02

Stray Inductance Extraction

Computing the frequency-dependent loop inductance of the busbar arrangement — critical for limiting voltage overshoot during IGBT and SiC MOSFET switching.

03

Thermal Analysis (Joule Heating)

Coupling electromagnetic losses to thermal conduction to predict steady-state and transient temperature rise — verifying compliance with insulation temperature limits.

04

Fault Current & Short Circuit Stress

Simulating the extreme currents and resulting forces during short-circuit events — verifying structural integrity of the busbar assembly under fault conditions.

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