Enhancing electric vehicle battery performance and safety through simulation and testing of key electrical components

scenarios like fast charging and acceleration. The effects of these incidents are excessive heating, mechanical stress and failure of electrical connections. This study presents a prototype of a multi-physics Digital Twin that is a model of electromagnetic, thermal, and structural environments that evaluates the functionality of copper busbars operating at EV operating current levels (100–500 A). The framework will consist of a combination of cross-domain corroboration as simulations with the use of finite-elements and experimental testing. The measurements indicate steady operation up to 200 A, small voltage drops (0.009–0.047 V), contact resistances (12.4–18.7 μΩ), and magnetic emissions (8–40 mT), all within the IEC 60269-1, IEC 61439-1 and CISPR 25 limits. Localized heating (273 ◦C) and deformation (>1 mm) at 500 A transient loads are characteristic of critical conditions, leading to design changes in the form of increased cross-sectional thickness, integral cooling, and laminated structures. The paper presents an experimentally evaluated prototype of a Digital Twin which is a bridge between simulation and physical experiment and can be used as a predictive instrument in safer and more dependable busbar design in future EV battery systems.