Simulation Tools
Simulation Tools
HEXsim & EVAPSKIN
PROPRIETARY SOFTWARE
Simulation Tools
Advanced simulation is at the core of Thermal Design Solutions’ engineering approach. Our proprietary tools are validated by extensive test data and enable us to predict performance with high accuracy, shorten development cycles, and reduce prototyping costs.
HEAT EXCHANGER SIMULATION
HEXsim
HEXsim is TDS’s in-house software for sizing and rating compact heat exchangers across automotive and industrial applications. It handles both single-phase and two-phase flow with a wide variety of fluids, including synthetic and natural refrigerants (R1234yf, R134a, R744, R290).
Key Features
- Models all automotive HEX types and many compact industrial designs
- Simulates fin, tube, and plate geometries:
- Fin: Plain, Louvered, Offset Strip, Wavy
- Tube: Flat, Multiport, Inner Fin, Dimpled
- Plate: Chevron, Inner Fin
- Predicts thermal-hydraulic performance and pressure drop
- Incorporates both state-of-the-art theory and empirical correlations validated by vast test data
- Extremely user-friendly interface for rapid iteration
Advantages
- Enables design trade-off analysis (performance vs. pressure drop)
- Reduces reliance on costly prototype testing
- Optimises designs for real-world manufacturing constraints
The ultimate tool for rapid, accurate HEX sizing and rating.
A TDS PRODUCT
HEXsim
HEXsim is the dedicated product identity for TDS’s proprietary heat exchanger simulation software. Built on years of validated thermal-hydraulic research, HEXsim delivers rapid, accurate sizing and rating of compact heat exchangers for automotive and industrial applications.
From single-phase liquid-to-air radiators to complex two-phase evaporators and condensers, HEXsim supports the full range of HEX types with an extremely user-friendly interface designed for engineering professionals.
Capabilities
- Fin, tube, and plate geometry modelling across all standard HEX configurations
- Single-phase and two-phase flow simulation with natural and synthetic refrigerants
- Thermal-hydraulic performance and pressure drop prediction
- Design trade-off analysis optimised for real-world manufacturing constraints
heat exchanger simulator
EVAPORATOR SIMULATION
EVAPSKIN
EVAPSKIN specialises in evaporator performance simulation, particularly for refrigeration systems equipped with skin-type evaporators.
Key Features
- Predicts heat and mass transfer in compact evaporators
- Models refrigerant-side boiling and air-side condensation
- Accounts for condensate retention and drainage geometry effects
- Enables wet-condition thermal performance optimisation
Applications
- Household refrigerators and freezers
- Medical refrigerators and ultra-freezers
SYSTEM-LEVEL SIMULATION
Thermodynamic System Simulation
Beyond individual components, our tools support system-level thermal simulations including:
Thermodynamic Systems
Heat pump systems for automotive and stationary applications, ORC, Brayton cycles, and Carnot batteries.
Front-End Cooling Module Performance
Coupled airflow and HEX sizing simulation for Cooling & Radiator Front Modules.
Example Applications
- Sizing and performance evaluation of a Carnot battery with or without waste heat recovery
- Optimising vehicle front-end cooling modules to find an optimal trade-off between thermal performance, energy saving, and noise reduction
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