Case Study: Delphi achieves faster, more accurate force‑deflection predictions for ECM silicone spacers with ANSYS Structural

Analyzing Silicone Rubber Spacers for Automotive Engine Control Modules

Delphi, a global leader in mobile electronics and transportation systems, faced a critical design challenge with silicone rubber spacers used in engine control modules (ECMs): the spacers must exert just the right force to ensure ICs are cooled and secured without exceeding housing and PCB constraints. To address this, Delphi partnered with ANSYS and used ANSYS Structural to analyze the truncated-cone spacers and determine accurate force‑deflection behavior.

ANSYS implemented FEA models using experimentally derived Mooney‑Rivlin material constants, validated the simulations against measured compression tests, and leveraged ANSYS contact elements to capture spacer-to‑PCB interaction. ANSYS also delivered APDL scripts and a C++ GUI to automate runs for product engineers, enabling faster, more accurate force‑deflection predictions than prior linear estimates, supporting optimal spacer designs, and extending ECM life in harsh automotive environments.

Delphi

Fereydoon Dadkhah

Sr. Mechanical Engineer Mechanical Analysis and Simulation