aerospace webinar 2
TRANSCRIPT
8/8/2019 Aerospace Webinar 2
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Complex
Electronics CoolingAnalysis
ElectroFlo®
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Why do I care thatWhy do I care thatElectronics are Getting Hot?Electronics are Getting Hot?
For every 10 °C temperature increase there is a 50%reduction of operating life
Electronics fail due to excess heat.
Overheating on the Xbox cost Microsoft an estimated$1.15 Billion
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Introduction to ElectroFlo®◦
Liquid Cooled Motor Controller◦ Component Definition
◦ Joulean/Trace Heating
◦ Coldplate Modeling (Liquid Cooling)
◦ Results
◦
ContentsContents
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Why do Electronics GetWhy do Electronics GetHot?Hot?
Complexity
Compactness
Cost Factors
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Benefits of ThermalBenefits of ThermalAnalysisAnalysisLow 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
l l ®® i d l i f
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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
ElectroFloElectroFlo®® Finds Solutions forFinds Solutions forComplex Electronics CoolingComplex Electronics Cooling
ProblemsProblemsUtilizes many years of aerospace experience
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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 connectorsInternal Heat Transfer
Conduction
Internal natural convection (using CFD)
Internal thermal radiation
Cooling to AmbientAmbient natural convection, conduction and
radiation
Cooling through Liquid Channels of Coldplate
Sample model of Motor Controller
Example: Thermal Analysis of a Liquid CooledExample: Thermal Analysis of a Liquid CooledMotor Controller Motor Controller
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Geometry Definition
◦ Geometry can be created within ElectroFlo or read in from CAD
Boundary Conditions (BCs)
◦ Thermal Resistance Planes are created to isolate different sectionsof 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 powerdissipation 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 inElectroFlo
◦
Defining IGBTs and other ComplexDefining IGBTs and other ComplexComponentsComponents
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◦ Switching Stack Due to complexity of components, simplified models
of the IGBTs and Diodes are created using variablePower Dissipation values
Component DefinitionsComponent Definitions
Define components in your terms
El t i l C l l ti t D t it t t t
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Circuit Definition
◦ Geometry is defined like any other package, but materials haveelectrical 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 dissipationfor the electrical circuit
◦ Determines local hot spots, within both traces and simplecomponents
◦
Electrical Calculation to Determineectr ca a cu at on to eterm nePower Dissipation within Traces andPower Dissipation within Traces andLeadsLeads
El t i l C l l ti t D t it t t t
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Temperature Results
◦ Fuse Model
All heat comes from Voltage Field calculationFuse will “blow” if it reaches a set temperature
User can look at transient case of what will happen inthe time immediately following the blown fuse.
Electrical Calculation to Determineectr ca a cu at on to eterm nePower Dissipation within Traces andPower Dissipation within Traces andLeadsLeads
Electrical ResistancePlanes
Aluminum Standoffs
Fuse Case
El t i l C l l ti t d t it t t t
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◦ Trace Heating
All heat comes from Voltage Field calculationShows local “Hot Spots” within layer
Accurately capture transient effect
Use Links to model vias without overloading yourmodel
Electrical Calculation to determineectr ca a cu at on to eterm nePower Dissipation within Traces andPower Dissipation within Traces andLeadsLeads
Don’t miss the Hot Spots
Temperature PlotPower Dissipation Plot
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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 andpressure 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 DeterminingHeat Exchanger Model for DeterminingCooling through Coldplate ChannelsCooling through Coldplate Channels
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◦ Coldplate Model
Solved assuming fixed volumetric flowrate throughchannels
By creating full system model, you can get veryaccurate transients and solve for thermal soak backissues
Heat Exchanger Model for determiningHeat Exchanger Model for determiningcooling through Coldplate Channelscooling through Coldplate Channels
The right tool for the job
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Model ResultsModel Results
Postprocessing
Animation and Color plots for all variablesWatch streamlines developingOver 100 post processing tools
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Create Automated Reports◦ Transient Graphs
◦ Hottest Components
◦ See where your heat is going
◦ Report is customizable
◦ Use your Company Template inPowerPoint
Model ResultsModel Results
Stop spending most of your time
creating reports, just automate it!
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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 creatingreports, automate it!
Contents RevisitedContents Revisited
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Join us next time when we see how this model fits into arack system with three other liquid cooled electronics
boxes
Thank you Hamish Lewis
Questions/CommentsQuestions/Comments