Master’s Thesis: Thermal-Electric Simulations for Automotive Cable Dimensioning
My thesis project applied the skills from the FEM program to a real-world engineering challenge in the automotive sector: the thermal-electric behavior of cable harnesses. Modern vehicles carry increasingly complex electrical loads, and correct cable dimensioning is critical for both safety and reliability
The project focused on developing a simulation-based methodology for predicting cable performance under different electrical and thermal conditions. Key aspects included:
Coupled thermal–electric analysis: modeling cables under current load to evaluate temperature rise, resistive heating, and safe operating limits.
Steady-state and transient simulations: assessing both long-term operating conditions and short-duration peak loads.
Geometry and material modeling: incorporating insulation properties, conductor cross-sections, and ambient conditions to create accurate models.
Validation and dimensioning rules: comparing simulation results against design guidelines and experimental data to propose improved methods for cable sizing.
The thesis bridged numerical simulation and practical design rules, showing how advanced FEM tools can reduce over-conservatism while ensuring safety. It provided a framework for integrating multiphysics analysis into everyday engineering workflows for harness design
This project demonstrated how FEM can directly support design decision-making in industry. By combining thermal and electrical analysis in a unified simulation approach, I developed tools and insights that improve the efficiency, safety, and reliability of automotive electrical systems