Client Overview

A global leader in manufacturing off-road construction and agricultural vehicles sought a trusted engineering partner to enhance HVAC system efficiency and optimize in-cabin comfort under extreme operating conditions.

Challenge

The client faced multiple performance and development challenges:

  • ❌ Non-uniform airflow distribution within the cabin interior
  • ❌ Insufficient cooling performance under high ambient and heavy-load conditions
  • ❌ Increased development costs due to multiple design and prototype iterations
  • ❌ Procurement delays caused by fragmented component sourcing

APA Engineering’s End-to-End Solution

With over 25 years of experience and a 500+ strong engineering team, APA Engineering delivered a turnkey HVAC solution—from initial concept design to final sourcing—leveraging deep domain expertise and advanced simulation tools.

🔧 Scope of Work

1. HVAC System Design

Developed a complete HVAC architecture customized for off-highway vehicle cabins — covering concept layouts, packaging studies, duct routing, and final manufacturing drawings.

2. Heat Exchanger Design & Simulation

  • ● Designed and optimized evaporator and condenser coils using CoilDesigner for heat exchanger sizing and positioning.
  • ● Performed system-level performance simulation using VapCyc to evaluate refrigerant flow, cooling capacity, and COP across various operating conditions.

3. CFD Simulation

Conducted Computational Fluid Dynamics (CFD) analysis to ensure uniform airflow distribution, defogging performance, and in-cabin thermal comfort optimization.

4. FEA & Moldflow Simulation

Validated structural integrity, vibration resistance, and moldability of plastic HVAC housings using Finite Element Analysis (FEA) and Moldflow simulation.

5. HVAC Component Sourcing

Executed end-to-end sourcing of critical HVAC components — including blowers, heat exchangers, ducts, and control modules — through APA’s global supplier network, ensuring cost efficiency and on-time delivery.

Performance Results

  • 🚜 20% improvement in cabin cooling efficiency
  • 🌬️ 30% better airflow distribution across the cabin
  • 💡 40% reduction in design iterations through simulation-led optimization
  • 📦 100% on-time component delivery via APA’s global sourcing network

Why Choose APA Engineering?

  • ✔ 25+ years of proven engineering excellence
  • ✔ Dedicated expert teams for HVAC Design, CFD, FEA, and Sourcing
  • ✔ Integrated development workflow — from Design → Simulation → Validation → Sourcing
  • ✔ Trusted partner to global leaders in Automotive & Off-Highway sectors

Let’s Build Smarter HVAC Systems Together

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