Optimizing Cooling Systems for Electric Heavy-Duty Trucks - Refining EV Powertrain Design and Cooling System Efficiency with Altair CFD Simulation

Propel Industries is advancing sustainable transportation in India with smart electric dump trucks and tractor-trailers for heavy-duty use. Effective thermal management is crucial to maintain safe operating temperatures for batteries and powertrains under extreme conditions. Propel faced challenges in analyzing heat flow across complex cooling subsystems, including radiators, pumps, and motors. Using Altair’s advanced CFD and thermal simulation tools, they developed a precise system-level model validated with over 90% accuracy against real data. This enabled optimization of cooling performance, reducing prototype cycles and achieving a first-time-right design. The simulation-driven approach improved product reliability, efficiency, and shortened development time, showcasing how innovative simulation and AI-powered solutions can accelerate the design of next-generation electric vehicles for demanding industrial applications like mining and construction.