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Our Engineering Projects

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High Power LED Thermal

LED Heat Sink Design

Thermal management and natural convection optimization for a 21W high-power LED array.

Hybrid Wind/PV Turbine

Savonius & PV Integration

Aerodynamic performance and active cooling investigation of a vertical axis Savonius wind turbine integrated with solar panels.

Structural FEA Beams

Lithium-ion BTMS Design

A multi-stage optimization process combining 3D CFD modeling, Response Surface methodology, and Six-Sigma probabilistic analysis to design an efficient air-cooled battery pack.

Porous Media Flow

Deterministic Porous Media CFD

ANSYS Fluent analysis of flow, velocity fields and pressure drop through a porous medium with deterministic distributions.

LED Thermal Management

Numerical modelling and thermal analysis of a 21W high-power LED array to ensure junction temperatures remain below critical thresholds. Utilizing ANSYS SpaceClaim and Fluent for conjugate heat transfer evaluation.

Step 01

3D CAD Model for Heat Sink

A detailed geometric model of a 7-piece LED array integrated with a specialized heat sink was created using ANSYS SpaceClaim. The design maximizes the surface area to enhance heat dissipation.

Step 02

Thermal Distribution Contour

Steady-state thermal simulations were conducted to map the temperature gradient. The analysis verified that the maximum heat sink temperature effectively prevents the LED junction from exceeding the 60°C failure limit.

Step 03

Natural Convection Velocity Flow

CFD analysis of the air velocity distribution around the LED. The results demonstrate the natural convection currents successfully carrying heat away from the fins into the ambient environment.

Hybrid Wind/PV
Aerodynamics

A comprehensive numerical modeling project combining a Savonius vertical axis wind turbine with photovoltaic panels. Designed to evaluate aerodynamic performance and the active cooling effect on PV efficiency.

Step 01

Hybrid Turbine & PV Geometry

The system geometry was constructed in Design Modeler, featuring helical Savonius blades integrated beneath thin, transparent photovoltaic panels to capture both wind and solar energy simultaneously.

Step 02

Aerodynamic Velocity Contour

CFD simulations were executed to analyze the wake regions and velocity profiles. The contours highlight the air acceleration around the maximized PV panel dimensions and its interaction with the rotor.

Step 03

Active Cooling Temperature Contour

Thermal contours revealing the cooling effect generated by the rotating turbine blades on the rear side of the PV panels, which significantly enhances the solar conversion efficiency.

CFD & Thermal Management
Optimization

Advanced computational fluid dynamics (CFD) and thermal analysis using ANSYS Fluent. We optimize complex systems such as Battery Thermal Management Systems (BTMS) utilizing parametric response surfaces and Six-Sigma reliability methodologies.

Step 01

Geometry Creation & Meshing

A detailed 3D CAD model of a 12-cell 21700 lithium-ion battery pack integrated with aluminum fins was developed. A highly refined computational mesh was generated around the cylindrical cells and cooling channels to precisely resolve the fluid-solid interfaces and conjugate heat transfer.

Step 02

CFD Setup & Turbulence Modeling

Using ANSYS Fluent, boundary conditions for forced air convection were defined, specifying inlet velocity and ambient temperature. The k-epsilon turbulence model was applied to accurately capture the aerodynamic separation and wake regions behind the cylindrical cells.

Step 03

Thermal & Fluid Flow Analysis

Steady-state simulations were executed to extract temperature and pressure contours. The analysis pinpointed potential hot spots and evaluated the pressure drop across the fins. Ensuring the maximum temperature stays below critical limits is vital to prevent thermal runaway.

Step 03

Response Surface Optimisation

Utilizing ANSYS DesignXplorer, a parametric study was conducted to establish a predictive Response Surface. Critical geometric parameters, specifically cell spacing and fin thickness, were computationally optimized to maximize cooling uniformity while minimizing fan power consumption.

Step 03

Six-Sigma Reliability Analysis

To guarantee the BTMS design's robustness against manufacturing tolerances and operational uncertainties, a Six-Sigma probabilistic analysis was performed. The results confirmed a highly stable thermal profile, ensuring the temperature difference across the pack remains safely below 5K under varying conditions.

ANSYS Fluent CFD

Porous Media
Flow Analysis

A CFD investigation of flow through porous media with deterministic distributions. The study uses ANSYS Fluent contours to evaluate velocity development, pressure drop, and field uniformity across a porous cylindrical section.

Step 01

Deterministic Porous Domain Setup

The model represents a pipe-like flow domain containing a porous section. Deterministic distributions are used to define the porous region and study how the flow field changes as it passes through the medium.

Step 02

Velocity Contour Evaluation

Velocity contours highlight acceleration, wake behaviour and local non-uniformity inside and downstream of the porous section. This helps compare how the deterministic arrangement affects flow development.

Step 03

Pressure Drop Across the Porous Medium

The pressure field shows the loss generated as the flow crosses the porous zone. The contour is useful for identifying the resistance introduced by the medium and the recovery behaviour toward the outlet.

Step 04

Field Distribution Along the Cylinder

The axial colour-gradient view provides a clean overview of how the selected scalar field develops from inlet to outlet, making it easier to observe the transition through the porous segment.

Step 05

Outlet Flow Uniformity Check

Additional velocity contours are used to verify whether the downstream flow becomes more uniform after passing through the porous medium and to compare local recirculation against the main flow direction.

Our Engineering Projects

LED Heat Sink Design

Savonius & PV Integration

Lithium-ion BTMS Design

Deterministic Porous Media CFD

LED Thermal Management

3D CAD Model for Heat Sink

Thermal Distribution Contour

Natural Convection Velocity Flow

Hybrid Wind/PV Aerodynamics

Hybrid Turbine & PV Geometry

Aerodynamic Velocity Contour

Active Cooling Temperature Contour

CFD & Thermal Management Optimization

Geometry Creation & Meshing

CFD Setup & Turbulence Modeling

Thermal & Fluid Flow Analysis

Response Surface Optimisation

Six-Sigma Reliability Analysis

Porous Media Flow Analysis

Deterministic Porous Domain Setup

Velocity Contour Evaluation

Pressure Drop Across the Porous Medium

Field Distribution Along the Cylinder

Outlet Flow Uniformity Check

Hybrid Wind/PV
Aerodynamics

CFD & Thermal Management
Optimization

Porous Media
Flow Analysis