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SIMULATION & ENGINEERING VALIDATION

From digital models to real operating conditions,
make design conclusions withstand system validation

Through multiphysics simulation, engineering prototype tests, real-data correlation analysis, and system-level HIL validation, keep design assumptions, model parameters, and actual operating conditions continuously linked—so every engineering conclusion has quantifiable, reproducible, and traceable evidence.

Tmax
56.2°C Simulate maximum temperature
ΔT
6.7°C Maximum temperature difference
Err
2.15% System integration error

One closed loop across design through delivery

Yes Definition of needs Requirements
Performance indicators / safety boundaries / environmental conditions
Mod System Model System Model
Electrical / Thermal / Control / Structure
Simulate multiphysics simulation Multiphysics
Thermal/ electric/ current/ structure
Sample Pilot development Prototype
Project Pilot
Measure Physical tests Instrumented Test
Total sites and measured data
Fire! Project release Engineering Release
Design Freeze/ Release
Number Data Relevance Data Correlation
Simulation vs reality
School Model calibration Model Calibration
Parameter fixes
Yu Design optimization Design Optimization
Parameters and structure optimization
Check Revalidate Revalidation
Fix Model Retest

Multiphysical field synergetic modelling Hot / Stream / Electricity / Structure / Security Integration Simulation

Hot Thermal Model CFCD
  • The cooling field.
  • Temperature Distribution
  • Hotspot Identification
Electricity Electrical model E/E
  • Main-line voltage
  • Power current
  • Electrical Quality
Structure Structure Model
  • Still / Model
  • Vibration and impact
  • Transforming and stress.
Safe Security Model
  • Thermal runaway propagation
  • Frozen gas diffusion
  • Fire policy
Link
Model Integration By harmonizing parameters, interfaces and boundary conditions, thermal, electrical, structural and safety models are inter-domain-linked to ensure that different models use the same set of engineering baselines.

Typical relevance Examples of typical work situations: simulation / factual / error

Temperature distribution & critical temperature

R² 0.96
RMSE 1.42°C
MAPE 2.51%

Bus & Power

R² 0.97
RMSE 3.28 V
MAPE 0.42%

Structural adaptation Critical

R² 0.94
RMSE 7.8με
MAPE 3.18%
Engineering Model 128 Group
Sensory Channel 1,248 roads
Number of data points 36.7M+
Average relevance of models R² = 0.96
General temperature error RMSE 1.56°C

Sample and Point Layout

Experimental validation Real situation: covering operations, limits, safety and environmental verification

Run Task Test FAT Charge, power, control and protection
Maximum Work Test High temperature, high load and abnormal boundary
Security test Thermal runaway, fire protection, interlocking, and isolation
Mechanical and vibrating tests Impact, vibration and transport validation
Environmental protection certification IP, dust, water and salt fog

Environment and reliability verification

High -40°C ~ 85°C High-temperature cycle
Wet 10% ~ 95% RH Wet thermal cycle
Temp -40°C ~ 65°C Temperature impact
Salt 5% NaCl Salt fog corrosion
IP IP54 / IP65 Ingress protection
Jin! IEC 60068 Mechanical vibration
Life Up to 10,000 h Long run

System-level HIL integration validation BMS - PCS - EMS - Grid

BMS Battery management system
PCS Resilient transformer
EMS Energy Management System
Network / Load Grid / Load
HIL real-time simulation platform | grid control | network network switching | failure through | black start | steady and dynamic verification

Example: Unusual conditions: model and how to correct deviations

Before amendment

R² 0.71
RMSE 4.92°C
MAPE 8.34%

After model correction

R² 0.96
RMSE 1.38°C
MAPE 2.28%

Design decision-making and evidence systems

General Conceptual programme Concept
  • Needs definition completed
  • Clear border conditions
  • Preliminary feasibility verification
Evidence status: Completed
Commentary Programme evaluation Evaluation
  • Multi-programme comparison
  • Assessment of key parameters
  • Risk identification
Evidence status: Completed
Detail Detailed design Detailed Design
  • Simulation Model Fixed
  • DFMEA finished
  • Sample mechanism freeze
State of evidence: ongoing
Check Design Verification Design Verification
  • Test data complete
  • Relevance to target
  • Security clearance passed.
Evidence status: Completed
Fire! Project release Release
  • Design Freeze
  • Configuration baseline completed
  • Controlled release
Evidence status: Completed

Delivery and traceability

Mod Digital model pack CFD / E-E / Structural
Simulate Simulation Report Models, parameters, boundaries and results
Measure Test report Test / FAT / HIL
Risk Risk assessment report FMEA / Safety Assessment
Change Change records Change Request / Baseline
Rectangular Authentication Matrix Requirements → Evidence