ElectroFlo®<br />Complex Electronics Cooling Analysis<br />
Why do I care that Electronics are Getting Hot?<br />Electronics fail due to excess heat.<br />For every 10 °C temperature...
Introduction to ElectroFlo®<br />Liquid Cooled Motor Controller<br />Component Definition<br />Joulean/Trace Heating<br />...
Why do Electronics Get Hot?<br />Complexity<br />Compactness<br />CostFactors<br />
Benefits of Thermal Analysis<br /><ul><li>Low Cost
Much lower cost than experimental investigation
Speed
Study many different scenarios and optimize your design
Completeness of Results
Results available for entire system; not just at sensor locations
No inaccessible locations
No inaccuracies as a result of probe interference
Modeling Difficult Conditions
Study worst case and other scenarios</li></ul>A Stitch in Time Saves Nine<br />
ElectroFlo® Finds Solutions for Complex Electronics Cooling Problems<br />Utilizes many years of aerospace experience<br /...
Patented Automated Radiation Network
Automatically  calculates heat from voltage calculation
Used globally with customers in US, South America, Europe and Asia
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Thermal Analysis webinar

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Thermal Analysis webinar

  1. 1. ElectroFlo®<br />Complex Electronics Cooling Analysis<br />
  2. 2. Why do I care that Electronics are Getting Hot?<br />Electronics fail due to excess heat.<br />For every 10 °C temperature increase there is a 50% reduction of operating life<br />Overheating on the Xbox cost Microsoft an estimated $1.15 Billion<br />
  3. 3. Introduction to ElectroFlo®<br />Liquid Cooled Motor Controller<br />Component Definition<br />Joulean/Trace Heating<br />Coldplate Modeling (Liquid Cooling)<br />Results<br />Contents<br />
  4. 4. Why do Electronics Get Hot?<br />Complexity<br />Compactness<br />CostFactors<br />
  5. 5. Benefits of Thermal Analysis<br /><ul><li>Low Cost
  6. 6. Much lower cost than experimental investigation
  7. 7. Speed
  8. 8. Study many different scenarios and optimize your design
  9. 9. Completeness of Results
  10. 10. Results available for entire system; not just at sensor locations
  11. 11. No inaccessible locations
  12. 12. No inaccuracies as a result of probe interference
  13. 13. Modeling Difficult Conditions
  14. 14. Study worst case and other scenarios</li></ul>A Stitch in Time Saves Nine<br />
  15. 15. ElectroFlo® Finds Solutions for Complex Electronics Cooling Problems<br />Utilizes many years of aerospace experience<br /><ul><li>Very fast and stable solver
  16. 16. Patented Automated Radiation Network
  17. 17. Automatically calculates heat from voltage calculation
  18. 18. Used globally with customers in US, South America, Europe and Asia
  19. 19. Easy to use and full-featured </li></li></ul><li>Example: Thermal Analysis of a Liquid Cooled Motor Controller<br />Geometry<br />Coldplate, components, traces and other conductors from sources in various formats.<br />Heat Generation<br />Two main contributors:<br /><ul><li>Switching Devices and other Component losses
  20. 20. Current flow in traces and connectors</li></ul>Internal Heat Transfer<br /><ul><li>Conduction
  21. 21. Internal natural convection (using CFD)
  22. 22. Internal thermal radiation</li></ul>Cooling to Ambient<br /><ul><li>Ambient natural convection, conduction and radiation
  23. 23. Cooling through Liquid Channels of Coldplate</li></ul>Sample model of Motor Controller<br />
  24. 24. Defining IGBTs and other Complex Components<br />Geometry Definition<br />Geometry can be created within ElectroFlo or read in from CAD<br />Boundary Conditions (BCs)<br />Thermal Resistance Planes are created to isolate different sections of component<br />Using manufacture data (i.e. junction to case resistance), thermal links are created with a given resistance<br />Functions and Tables can be used to accurately depict the power dissipation of the devices.<br />Saving to Component Library<br />Once the component has been created, the it can be saved to a database and then added to any model.<br />BCs and Geometry will be automatically read in and linked to the component, but changes can be made like anything else in ElectroFlo<br />
  25. 25. Component Definitions<br />Switching Stack<br />Due to complexity of components, simplified models of the IGBTs and Diodes are created using variable Power Dissipation values<br />Define components in your terms<br />
  26. 26. Electrical Calculation to Determine Power Dissipation within Traces and Leads<br />Circuit Definition<br />Geometry is defined like any other package, but materials have electrical properties as well as thermal properties<br />Electrical Links can be added (with optional Heat Generation)<br />Electrical Connection Regions are automatically determined<br />Fixed/Variable Electrical Resistance planes can be added<br />Voltage Calculation<br />Voltage Field is incrementally determined as electrical resistance varies with temperature<br />Voltage inputs (Current and Voltage) can vary with time<br />Power Dissipation (Thermal Losses)<br />From the voltage field, ElectroFlo calculates the power dissipation for the electrical circuit<br />Determines local hot spots, within both traces and simple components<br />
  27. 27. Electrical Calculation to Determine Power Dissipation within Traces and Leads<br />Fuse Model<br />All heat comes from Voltage Field calculation<br />Fuse will “blow” if it reaches a set temperature<br />User can look at transient case of what will happen in the time immediately following the blown fuse.<br />Fuse Case<br />Electrical Resistance Planes<br />Temperature Results<br />Aluminum Standoffs<br />
  28. 28. Electrical Calculation to determine Power Dissipation within Traces and Leads<br />Trace Heating<br />All heat comes from Voltage Field calculation<br />Shows local “Hot Spots” within layer<br />Accurately capture transient effect<br />Use Links to model vias without overloading your model<br />Temperature Plot<br />Power Dissipation Plot<br />Don’t miss the Hot Spots<br />
  29. 29. Heat Exchanger Model for Determining Cooling through Coldplate Channels<br />Define Geometry<br />Define the size and shape of the channel<br />Create coolant path by either reading in file, or clicking on screen<br />Pressure Calculation<br />User can set fixed/variable flowrate<br />Solver will calculate the flowrate based on the pump and pressure loss through the model<br />Coolant through ElectroFlo model can be part of larger system<br />Heat Transfer<br />Heat is removed by the coolant path and the fluid temperature increases as it travels through the Coldplate<br />Optimizing your Design<br />User can quick change the coolant path, or channel properties with having to modify the rest of the model<br />
  30. 30. Heat Exchanger Model for determining cooling through Coldplate Channels<br />Coldplate Model<br />Solved assuming fixed volumetric flowrate through channels<br />By creating full system model, you can get very accurate transients and solve for thermal soak back issues<br />The right tool for the job<br />
  31. 31. Model Results<br /><ul><li>Postprocessing
  32. 32. Animation and Color plots for all variables
  33. 33. Watch streamlines developing
  34. 34. Over 100 post processing tools</li></li></ul><li>Model Results<br />Create Automated Reports<br />Transient Graphs<br />Hottest Components<br />See where your heat is going<br />Report is customizable<br />Use your Company Template in PowerPoint<br />Stop spending most of your time creating reports, just automate it!<br />
  35. 35. Introduction to ElectroFlo®<br />A Stitch in Time Saves Nine<br />Liquid Cooled Motor Controller<br />Component Definition<br />Define components in your terms<br />Joulean/Trace Heating<br />Don’t miss the Hot Spots<br />Coldplate Modeling (Liquid Cooling)<br />The right tool for the job<br />Results<br />Stop spending most of your time creating reports, automate it!<br />Contents Revisited<br />
  36. 36. Questions/Comments<br />Join us next time when we see how this model fits into a rack system with three other liquid cooled electronics boxes<br />Thank you<br />Hamish Lewis<br />hlewis@tesint.com<br />
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