Master's Thesis

Active flow control device implementation on serial car

Author of thesis: Edgar Kozubovski

Acad. year: 2025/2026

Supervisor: Ing. Štěpán Kaspar

Reviewer: Ing. Robert Popela, Ph.D.

Abstract:

Aerodynamic drag is the dominant energy consumer for electric vehicles at highway speeds and is typically mitigated on SUVs by geometric add‑ons such as rear spoilers, which compromise styling. This thesis investigates the transfer of an Active Flow Control (AFC) concept, previously demonstrated on a Škoda Fabia hatchback, to a production‑feasible passive Flow Control System (FCS) integrated into a Škoda Enyaq Coupé battery‑electric SUV. The goal is to recover a significant portion of the spoiler’s drag benefit while preserving the clean fastback silhouette and respecting hard constraints from the existing body‑in‑white, rear door kinematics and water‑management requirements.

An industrial CFD pipeline based on Detached Eddy Simulation is used together with detailed internal‑flow simulations. First, idealized engine‑boundary‑condition studies define the most promising outlet topology and jet momentum distribution at the rear deck. Twin trailing‑edge outlets are selected for their ability to reduce drag and rear lift with limited impact on front‑axle lift. Four side‑mounted intake variants (front/rear NACA ducts and scoop inlets) and multiple duct routings are then designed within the available cavities. A rear NACA inlet feeding a compact twin‑outlet duct with a circular‑to‑rectangular transition and internal guide vanes is identified as the best compromise between attainable mass flow, external drag and packaging. The complete FCS, including realistic pressure losses, elastomeric connectors across the rear door gap and passive drainage paths, is subsequently assessed on the full vehicle.

The optimised passive FCS achieves a 2.1% reduction in drag coefficient relative to the spoiler‑less baseline, corresponding to about 53% of the production spoiler’s aerodynamic effect and a projected 5-10 km increase in highway driving range, without affecting rear door functionality or luggage volume. The results demonstrate that production‑viable passive flow control can partially substitute geometric add‑on devices on electric SUVs and provide a foundation for future actively blown systems.

Keywords:

Active Flow Control (AFC), Flow Control System (FCS), Computational Fluid Dynamics (CFD), Drag Reduction, Lift Reduction, NACA Inlet, Scoop Inlet, Road Car Aerodynamics.

Date of defence

11.06.2026

Date of publish

10.06.2029

Result of the defence

Defended (thesis was successfully defended)

znamkaAznamka

Grading

A

Process of defence

Student presented the outcomes, which he achieved in his thesis. Then, the committee heard the supervisor´s and reviewer´s report of master´s thesis. There were no direct questions from the reviewer in the report. Therefore, the committee asked several questions about improvements and the selected efficient solution, evaluated parameters, benefits for replacement of current spoilers to a new type, energy consumption, spoiler interface connection, comparison with the use of NACA inlet, air feeding, selected velocity case, boundary conditions and a sensitivity for debris contamination. The student answered all of them fully without support for the committee’s satisfaction. After this, the committee decided to evaluate the master´s thesis defense with the grade Excellent A.

Language of thesis

English

Faculty

Department

Study programme

Aerospace Technology (N-AST-A)

Composition of Committee

doc. Ing. Jaroslav Juračka, Ph.D. (předseda)
doc. Ing. Ivo Jebáček, Ph.D. (místopředseda)
doc. Ing. Jiří Hlinka, Ph.D. (člen)
doc. Ing. Pavel Zikmund, Ph.D. (člen)
Ing. Miroslav Šplíchal, Ph.D. (člen)

Supervisor’s report
Ing. Štěpán Kaspar

The submitted master's thesis deals with the implementation of passive flow control on the Škoda Enyaq Coupé to effectively replace the conventional spoiler. The author first analyzed various configurations of the exhaust slot to improve the vehicle's aerodynamic properties. Based on the optimal variant, he subsequently designed and verified several options for the complete implementation of the device, including the design of the air intake and the internal geometry of the duct.

I highly appreciate the overall conceptual design for real-world vehicle integration. The student demonstrated excellent engineering thinking; beyond aerodynamics, he also considered practical structural aspects – particularly reliable water and dirt drainage, as well as the joint connection to the car body. To verify the proposed variants, he utilized advanced CFD tools provided by Škoda Auto. Although the thesis does not address the actual calibration of the computational model, the application of a validated corporate methodology ensures a high level of credibility for the simulations.

Throughout the project, the student worked proactively and entirely independently. He excellently interpreted the obtained data, drew logical conclusions, and proposed his own design solutions. Given the achieved results and the student's outstanding approach, I evaluate this thesis as highly commendable.
Evaluation criteria Grade
Splnění požadavků a cílů zadání A
Postup a rozsah řešení, adekvátnost použitých metod A
Vlastní přínos a originalita B
Schopnost interpretovat dosažené výsledky a vyvozovat z nich závěry A
Využitelnost výsledků v praxi nebo teorii A
Logické uspořádání práce a formální náležitosti A
Grafická, stylistická úprava a pravopis A
Práce s literaturou včetně citací A
Samostatnost studenta při zpracování tématu A

Grade proposed by supervisor: A

Reviewer’s report
Ing. Robert Popela, Ph.D.

Mr. Kozubowski, in the framework of his diploma thesis, carried out an analysis of the implementation of an active flow control device for drag reduction on a Škoda Auto production electric vehicle.

The work has a systematic and logical structure. Following a theoretical introduction that explains the nomenclature and key aspects of automotive aerodynamics, the background of both active and passive flow control approaches is presented.

In the following chapter, the state of the art is analyzed, and a patented drag-reduction device—developed in collaboration between Brno University of Technology and Škoda Auto—is introduced. The main objective of the thesis is then clearly defined as the transfer of this patented solution from a small-class hatchback (Škoda Fabia) to the Škoda Enyaq Coupé electric SUV.

In the subsequent chapters, the student presents the steps involved in the preparation of the computational model and the execution of CFD simulations. The results are discussed from the perspective of vehicle performance, particularly with respect to drag and downforce for the baseline geometry of the Škoda Enyaq.

Next, three different configurations of active flow control implemented on the rear edge of the vehicle body are analyzed, and their results are compared in terms of drag variation as a function of vehicle speed. The configuration with two separate outlets was identified as the most promising candidate.

For this selected configuration, Mr. Kozubowski performed important steps toward assessing its practical implementation. This included the design and optimization of the inlet system (both shape and placement on the vehicle body), as well as the design and optimization of the internal ducting. Based on these modifications, a complete CFD analysis of the updated vehicle configuration was carried out. The student then evaluated and compared the results against both the baseline and production configurations.

Following the selection of the optimal configuration, further analyses were performed addressing practical aspects such as mechanical integration, drainage, debris protection, freezing, and other real-world operational considerations.

The thesis is written in a consistent and clear manner, and the results are of high quality, with strong potential for practical industrial application.

Through this work, Mr. Kozubowski has demonstrated his ability to independently and creatively solve complex engineering problems, as well as his ability to critically assess results and draw meaningful conclusions. Moreover, he successfully collaborated with an industrial partner, Škoda Auto, throughout the course of the thesis.
Evaluation criteria Grade
Splnění požadavků a cílů zadání A
Postup a rozsah řešení, adekvátnost použitých metod A
Vlastní přínos a originalita A
Schopnost interpretovat dosaž. výsledky a vyvozovat z nich závěry A
Využitelnost výsledků v praxi nebo teorii A
Logické uspořádání práce a formální náležitosti A
Grafická, stylistická úprava a pravopis A
Práce s literaturou včetně citací A

Grade proposed by reviewer: A

Reasons for publication postponement

Publication of the final thesis has been postponed in compliance with the provisions of Section 47b (4) of Act No. 111/1998 Coll., on the Higher Education Institutions and on amendments and supplements to other acts, as amended.

Responsibility: Mgr. et Mgr. Hana Odstrčilová