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Thermal Analysis webinar
 

Thermal Analysis webinar

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This is a presentation showing the thermal analysis of a complex electronics cooling device. The

This is a presentation showing the thermal analysis of a complex electronics cooling device. The

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    Thermal Analysis webinar Thermal Analysis webinar Presentation Transcript

    • ElectroFlo®
      Complex Electronics Cooling Analysis
    • Why do I care that Electronics are Getting Hot?
      Electronics fail due to excess heat.
      For every 10 °C temperature increase there is a 50% reduction of operating life
      Overheating on the Xbox cost Microsoft an estimated $1.15 Billion
    • Introduction to ElectroFlo®
      Liquid Cooled Motor Controller
      Component Definition
      Joulean/Trace Heating
      Coldplate Modeling (Liquid Cooling)
      Results
      Contents
    • Why do Electronics Get Hot?
      Complexity
      Compactness
      CostFactors
    • Benefits of Thermal Analysis
      • 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
      A Stitch in Time Saves Nine
    • ElectroFlo® Finds Solutions for Complex Electronics Cooling Problems
      Utilizes many years of aerospace experience
      • Very fast and stable solver
      • Patented Automated Radiation Network
      • Automatically calculates heat from voltage calculation
      • Used globally with customers in US, South America, Europe and Asia
      • Easy to use and full-featured
    • Example: Thermal Analysis of a Liquid Cooled Motor Controller
      Geometry
      Coldplate, components, traces and other conductors from sources in various formats.
      Heat Generation
      Two main contributors:
      • Switching Devices and other Component losses
      • Current flow in traces and connectors
      Internal Heat Transfer
      • Conduction
      • Internal natural convection (using CFD)
      • Internal thermal radiation
      Cooling to Ambient
      • Ambient natural convection, conduction and radiation
      • Cooling through Liquid Channels of Coldplate
      Sample model of Motor Controller
    • Defining IGBTs and other Complex Components
      Geometry Definition
      Geometry can be created within ElectroFlo or read in from CAD
      Boundary Conditions (BCs)
      Thermal Resistance Planes are created to isolate different sections of component
      Using manufacture data (i.e. junction to case resistance), thermal links are created with a given resistance
      Functions and Tables can be used to accurately depict the power dissipation of the devices.
      Saving to Component Library
      Once the component has been created, the it can be saved to a database and then added to any model.
      BCs and Geometry will be automatically read in and linked to the component, but changes can be made like anything else in ElectroFlo
    • Component Definitions
      Switching Stack
      Due to complexity of components, simplified models of the IGBTs and Diodes are created using variable Power Dissipation values
      Define components in your terms
    • Electrical Calculation to Determine Power Dissipation within Traces and Leads
      Circuit Definition
      Geometry is defined like any other package, but materials have electrical properties as well as thermal properties
      Electrical Links can be added (with optional Heat Generation)
      Electrical Connection Regions are automatically determined
      Fixed/Variable Electrical Resistance planes can be added
      Voltage Calculation
      Voltage Field is incrementally determined as electrical resistance varies with temperature
      Voltage inputs (Current and Voltage) can vary with time
      Power Dissipation (Thermal Losses)
      From the voltage field, ElectroFlo calculates the power dissipation for the electrical circuit
      Determines local hot spots, within both traces and simple components
    • Electrical Calculation to Determine Power Dissipation within Traces and Leads
      Fuse Model
      All heat comes from Voltage Field calculation
      Fuse will “blow” if it reaches a set temperature
      User can look at transient case of what will happen in the time immediately following the blown fuse.
      Fuse Case
      Electrical Resistance Planes
      Temperature Results
      Aluminum Standoffs
    • Electrical Calculation to determine Power Dissipation within Traces and Leads
      Trace Heating
      All heat comes from Voltage Field calculation
      Shows local “Hot Spots” within layer
      Accurately capture transient effect
      Use Links to model vias without overloading your model
      Temperature Plot
      Power Dissipation Plot
      Don’t miss the Hot Spots
    • Heat Exchanger Model for Determining Cooling through Coldplate Channels
      Define Geometry
      Define the size and shape of the channel
      Create coolant path by either reading in file, or clicking on screen
      Pressure Calculation
      User can set fixed/variable flowrate
      Solver will calculate the flowrate based on the pump and pressure loss through the model
      Coolant through ElectroFlo model can be part of larger system
      Heat Transfer
      Heat is removed by the coolant path and the fluid temperature increases as it travels through the Coldplate
      Optimizing your Design
      User can quick change the coolant path, or channel properties with having to modify the rest of the model
    • Heat Exchanger Model for determining cooling through Coldplate Channels
      Coldplate Model
      Solved assuming fixed volumetric flowrate through channels
      By creating full system model, you can get very accurate transients and solve for thermal soak back issues
      The right tool for the job
    • Model Results
      • Postprocessing
      • Animation and Color plots for all variables
      • Watch streamlines developing
      • Over 100 post processing tools
    • Model Results
      Create Automated Reports
      Transient Graphs
      Hottest Components
      See where your heat is going
      Report is customizable
      Use your Company Template in PowerPoint
      Stop spending most of your time creating reports, just automate it!
    • Introduction to ElectroFlo®
      A Stitch in Time Saves Nine
      Liquid Cooled Motor Controller
      Component Definition
      Define components in your terms
      Joulean/Trace Heating
      Don’t miss the Hot Spots
      Coldplate Modeling (Liquid Cooling)
      The right tool for the job
      Results
      Stop spending most of your time creating reports, automate it!
      Contents Revisited
    • Questions/Comments
      Join us next time when we see how this model fits into a rack system with three other liquid cooled electronics boxes
      Thank you
      Hamish Lewis
      hlewis@tesint.com