Our Test Bench – Your Solution

Cooling Lab

Hot spots lead to decrease of lifetime, efficiency and reliability of e-powertrain components

Maximizing efficiency involves operating components safely and reliably, pushing them close to their thermal limits without leaving safety margins. VIRTUAL VEHICLE cooling lab achieves this through local operation-dependent temperature monitoring and the use of digital twin technology for precise temperature detection and prediction. By incorporating these methods into component design and operation, it’s possible to extend their lifetime while ensuring fail-safe performance.​

Typical Problems

with Power Electronics


  • Additional costs for the cooling system due to avoidable safety margins not to reach junction temperature limits​
  • Reduced lifetime because of high thermal stresses of power electronic components

with Battery


  • Difficulty to achieve local well-being temperature for all operating conditions (even for fast charging) ​
  • Lifetime decrease due to the temperature gradients

Tailored Measurement Methods

High Fidelity Models


New Cooling Concepts & Optimized Component Design

Tailored Measurement Methods

High Fidelity Models

Thermal Digital Twin


Predictive Control strat.
Lifetime assessment

Research Activities

Battery Thermal Management System​

Investigations of new battery cooling designs and their impact​

  • Di-electric coolant efficiency with coolant and cell aging ​
  • Thermal safety of immersive cooled modules​
  • Battery ccoling design and protopye construction on module level ​

SIMBAT – Combined multi-physics battery model​

  • Multi-physics simulation model to evaluate thermal safety in vehicles​
  • Extension of particle venting​
  • ROM approaches for speed up​

Tailored measurement methods​

  • Optical temperature measurements​
  • Thermal impedance spectroscopy ​

Research Activities

Power Electronics Cooling

Investigations of new cooling designs and their impact

  • Immersion cooling, di-electric coolant efficiency and two-phase cooling  
  • New heat spreading design research (e.g. pin fin optimization studies) 
  • Power electronics ccoling design and protopye cooler construction​​


Thermal digital twinning for power electronics 

  • Developing TDT based on the high fidelity thermal CFD results using new ML based ROM approaches (e.g. POD methods)
  • Using TDT for predictive control, predictive operation
  • TDT embedded into system simulation tools


Tailored measuremetn methods

  • Optical temperature measurements
  • Flexible principle power electronic cooling test bench 
  • Thermal impedance spectroscopy

Advanced Measurements​

Thermal impedance spectroscopy

Heat conductivity and capacity measurements ​

Parameter changes over lifetime ​

Local non-intrusive surface temperature measurement​

Spectroscopic temperature measurement

Inner Cell Temperature and Gradient

Heat flux + surface temperature​

Fiber Bragg​

Inverse problem cell temperatures

Coolant and Cell Aging​

Long term measurements with cooling system​

Coolant aging

Thermal Digital Twins and Fast CFD​

  • Developing TDT based on the high fidelity thermal CFD results using new ML based ROM approaches (e.g. POD methods)
  • Using TDT for predictive control, predictive operation and embedded into system simulation tools
  • Running research projects for  in the field
    • Multi zone cabin comfort 
    • Cabin and human comfort digital twin
    • Power electronics and e-motor cooling 
    • Battery thermal management​​

Reference Projects