UNO MINDA aimed to reduce thermal deviation in compact on-board EV chargers while accelerating innovation. Physical prototyping was costly and slow, especially given complex electrothermal requirements. Using Altair SimLab and PollEx, engineers conducted extensive digital experiments, sensitivity studies, and thermal analyses across more than 100 design variants. Simulation identified critical heat paths and hotspots, enabling improved thermal management and structural performance. The company achieved weight reduction, fewer physical tests, and reduced deviation between simulation and testing toward a target below 5%. The approach strengthened product reliability and supported future system-level EV simulations.

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