This report presents a comprehensive process flow for the Voltage Drop and Thermal Analysis of Busbars within a battery pack, crucial for the design phase at the component level in electric vehicles. The analysis includes steady-state voltage drop and current density, thermal analysis, and the coupled effects of voltage drop and temperature variations.

The study utilizes Ansys Maxwell for electromagnetic simulations and Ansys Icepak for thermal management, providing detailed insights into the behavior of busbars under various conditions. The findings aim to enhance the efficiency and reliability of busbars in high-voltage applications, addressing the unique challenges posed by the automotive environment.The methodology involves the use of finite element analysis (FEA) to simulate the electrical and thermal performance of busbars made from copper and aluminum.

The report outlines the steps for setting up simulations, assigning materials, and analyzing results, including voltage drop, current density, and thermal effects. Key limitations include the lack of comprehensive thermal datasets and the inability to perform system-level simulations within the given timeframe.

The conclusions emphasize the need for further research and validation to optimize busbar design for electric vehicle applications.