Muhammad Khizr Sheikh, an automotive engineering student at the Arnhem and Nijmegen University of Applied Sciences, has won the Student Award organized by the Automotive Center of Expertise (ACE Mobility) on July 2, 2024. The award ceremony took place at the Automotive Campus in Helmond. Khizr did his graduation project at Sensata Technologies focused on improving the existing end-of-line testing procedure for one of their products.

Innovative Testing Approach for Electrification of Heavy-Duty Vehicles

To support the electrification of heavy-duty vehicles for long-distance transport, Sensata Technologies has developed a new Power Distribution Unit (PDU) that can handle 2200A and 850V. Each product undergoes a stringent end-of-line testing process to ensure quality. Due to the high currents and associated safety risks, Sensata Technologies recognized the need to research the best testing approach for this PDU.

PDUs use busbars attached to the housing and thermally conductive silicones to transfer heat to the cooling plate and dissipate it via coolant. During his research, Sheikh used a mix of methods and tests to define the best protocol for testing the power distribution units. "The research shows that the PDU can be safely tested at 2200A for up to 60 seconds without cooling. Air cooling did not provide sufficient temperature reduction. The conclusions from this study need to be validated with further tests once the newest generation of PDUs is available," said Sheikh. Reducing the production lead time for power distribution units for vehicle electrification is of great importance to Sensata Technologies. This enables Sensata Technologies to deliver more PDUs to their customers more quickly, thus stimulating the electrification of vehicles in Europe.

Future Plans

Sheikh is a highly motivated student who was even offered a job at Sensata Technologies after completing his research. "During my studies, I learned a lot. I am very happy that I can now apply this knowledge in my job as a Technical Support Engineer at Sensata Technologies." Next year, Sheikh will redeem his prize, which consists of an unforgettable experience at a Formula 1 Grand Prix in Belgium or the Netherlands. "For me, the ACE Mobility Student Award was the icing on the cake for the work I did in the recent months. It was an ultimate opportunity to communicate directly with people in the automotive industry and gain a better understanding of what potential employers value in students. My advice to current and future students is: take every opportunity to network with the industry! Not only to boost your career but also to broaden your perspective on the automotive industry."

ACE Mobility Student Award 2024

ACE Mobility established the Student Award to highlight knowledge and innovation in the automotive industry. Four nominated students from Fontys University of Applied Sciences and the Arnhem and Nijmegen University of Applied Sciences presented their research on July 2 at the Automotive Campus in Helmond to a three-member jury consisting of Monika Hoekstra, Director at NXTGEN Hightech, Jean Pierre Heijster, Program Manager Manufacturing & Materials at RAI Automotive Industry NL, Wim Vossebelt, CEO at V-Tron, and representatives from the automotive industry and education sector.