Caliber Technologies

Why Thermal Cycling Causes Reliability Problems in EV Power Electronics EV power electronics experience repeated temperature changes during normal vehicle operation. Power-up, high-load driving, regenerative braking and shutdown create thermal cycles that cause components and circuit boards to expand and contract. Solder joints connect electronic components to printed circuit boards…

Why Onboard Charger Enclosures Face Structural Challenges An electric vehicle onboard charger (OBC) converts incoming AC power into DC power for battery charging. Its enclosure must protect internal electronics while supporting mounting loads and withstanding vibration transmitted through the vehicle structure. The challenge is particularly important in compact EV platforms,…

Why Vibration Is a Reliability Challenge for EV Power Electronics Electric vehicles expose electronic assemblies to mechanical loads generated by road inputs, vehicle structures, powertrain operation and component mounting. These loads can reach inverter control boards, onboard charger electronics and other power electronics assemblies. Although a circuit board may pass…

Why EV Inverter Busbars Overheat In an electric vehicle inverter, busbars carry high currents between the DC link, power semiconductor modules and associated electrical connections. These conductors must handle demanding electrical loads within a restricted package, often close to heat-generating components. A busbar can meet its nominal current rating and…

Electric motor designers are continuously balancing power, efficiency, size, weight, temperature, and reliability. Increasing power output within a smaller package can improve system-level performance, but higher power density often increases electromagnetic losses and thermal loading. This creates a fundamental product-development problem. A motor cannot be optimized for electromagnetic performance alone…

Electric motor performance is influenced by more than electromagnetic geometry and conductor selection. Winding and insulation design can affect the amount of copper that fits inside a slot, winding resistance, electrical losses, heat transfer, and ultimately the motor’s thermal operating margin. Insulation is essential for electrical isolation and winding reliability,…

Winding architecture has a direct influence on an electric motor’s electrical performance, thermal behaviour, manufacturability, and packaging. Hairpin and wire-wound motors use different conductor geometries and winding arrangements, which affect slot utilization, resistance, current density, copper losses, heat transfer, and manufacturing processes. Neither architecture is universally preferable. The appropriate choice…

Choosing between 2D and 3D electromagnetic analysis of electric motors is primarily an engineering modelling decision. A 3D model is not automatically better than a 2D model. The appropriate approach depends on the motor geometry, required outputs, operating conditions, and level of physical detail needed. For many motor development programs,…

Electric motor performance cannot always be evaluated from electromagnetic performance alone. Torque, efficiency, flux density, and back EMF may meet the design requirements while localized losses create excessive temperatures in windings, cores, magnets, or other components. This makes electromagnetic and thermal analysis of electric motors a connected multiphysics problem. Electromagnetic…