Thermal-Fluids CFD Engineer

The Thermal/CFD Support Engineer - eMotors will be responsible for the thermal and fluid flow analysis of high-performance automotive electric motor (eMotor) systems. This role supports the design and optimization of active and passive cooling systems to ensure high power and torque density while maintaining thermal reliability.

Working under the guidance of the Head of eMotor Design, the engineer will develop and own CFD and thermal FEA models, collaborate with electromagnetic and mechanical design teams, and contribute to the delivery of robust, thermally optimized eMotor systems. The role may also extend to inverter cooling analysis as part of the broader work package.

 

Structural CAE Support Engineer - eMotors, will be responsible for the following activities:

Planning:

Understand thermal and fluid flow challenges in high-performance eMotors and define simulation strategies accordingly.
Collaborate with E-Mag and Mechanical Design teams to define accurate boundary conditions and drive cycle profiles.
Develop a thermal simulation roadmap aligned with eMotor design and release milestones.
Identify thermal risks and propose mitigation strategies early in the design phase.
Forecast simulation workload and adapt plans based on evolving design requirements or test feedback.

Execution:

Design and optimize active and passive cooling systems for eMotors to meet performance and durability targets.

Develop and maintain CFD models to analyze coolant flow within the eMotor/EDU and calculate heat transfer coefficients on critical components such as:
Wound Stator Assemblies
Rotors
Bearings
Create and own thermal FEA models to evaluate temperature distribution across components under various drive cycles.
Work closely with E-Mag engineers to ensure accurate thermal boundary conditions and load inputs.
Identify areas for thermal performance improvement and collaborate with design teams to implement solutions.
Present multiple design options for evaluation, enabling trade-offs between thermal performance, packaging, and cost.
Support potential inverter cooling analysis as part of the extended work package.
Use simulation tools (software open for discussion) to execute and validate results.

Key Deliverables:

You will be responsible for ensuring robust thermal design and validation of eMotor systems with the following outcomes:

CFD and thermal FEA models for all critical eMotor components.
Detailed thermal analysis reports including:
Flow visualization
Heat transfer coefficients
Temperature distribution
Design recommendations
Optimized cooling system designs that meet thermal performance targets.
Validation of simulation results with physical test data where applicable.
Support for engineering gateway reviews with thermal insights and documentation.
Contribution to DFMEAs and resolution of thermal concerns via eCMS.
Support for redesign activities based on test feedback and program evolution.
Bearings.
Create and own thermal FEA models to evaluate temperature distribution across components under various drive cycles.
Work closely with E-Mag engineers to ensure accurate thermal boundary conditions and load inputs.
Identify areas for thermal performance improvement and collaborate with design teams to implement solutions.
Present multiple design options for evaluation, enabling trade-offs between thermal performance, packaging, and cost.
Support potential inverter cooling analysis as part of the extended work package.
Use simulation tools (software open for discussion) to execute and validate results.