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  • SolidWorks 2013

    SolidWorks Flow Simulation:

    Electronics Module

    2012 Dassault Systmes SolidWorks Corporation.Not for resale.

    Dassault Systmes SolidWorks Corporation

    175 Wyman StreetWaltham, Massachusetts 02451 USA

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  • SolidWorks 2013

    i

    Contents

    Lesson 1:Introduction to Electronics Module

    Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

    Electronic Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

    Case Study: Computer Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

    Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

    Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    Default Outer Wall Thermal Condition . . . . . . . . . . . . . . . . . . . . . 4

    Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

    Perforated Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

    Two-Resistor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

    Heat Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

    Mesh Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

    Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

  • SolidWorks 2013

    ii

  • 1Lesson 1

    Introduction to Electronics

    Module

    Objectives Upon successful completion of this lesson, you will be able to:

    Utilize the Electronic Module to design efficient cooling systems

    for electronics.

    Properly define two-resistor and heat pipe components.

    Properly specify the PCB composite laminate.

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    2

    Electronic Module

    The Electronics module features new capabilities for the simulation of

    heat pipes, two-resistor components and Joule heating by electric

    current in solids. Additionally, the engineering database is enhanced

    with multiple materials, two-resistor components, heat pipes and other

    entries specific to the design and simulation of electronics products.

    Case Study: Computer Box

    In this lesson, we will introduce some of the features of the Electronic

    module in Flow Simulation and learn how to post-process the results

    and make judgments on the design of the computer box. It is expected

    that the student is familiar with the Flow Simulation software. The

    lesson will not teach the basic aspects of the Flow Simulation project

    definition and postprocessing.

    It is recommended to refer to the Flow Simulation documentation for

    further details on the theory behind the solver.

    Project Description

    A computer box

    containing CPU,

    chipset

    (northbridge and

    southbridge), heat

    sink, two heat

    pipes and some

    peripheral

    connectors is

    placed in a room

    with ambient

    temperature of

    20C. The air at room temperature enters the box through the vents

    located on the sides, on the top and on the bottom of the box. The air is

    forced out of the box by the internal fan located on the back side of the

    box next to the heat sink.

    The objective of this lesson is to ensure that the temperature of the

    critical electronics components, namely CPU and the chipset remains

    below the maximum operating temperatures listed in the table below.

    Component Maximum operating temperature

    CPU 80C

    Northbridge 85C

    Southbridge 95C

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    3

    Stages in the Process

    Create the project.

    The project will be created using the Wizard.

    Define PCB.

    PCB composite will be defined in the engineering database and

    specified.

    Apply boundary conditions.

    Proper boundary conditions will be applied to simulate the air inlets

    and outlets. Additionally, a wall condition will be used to simulate

    the heat loss due to convection to the outside.

    Specify perforated plates.

    Custom perforated plates will be defined in the engineering

    database and applied to the model.

    Apply two-resistor components.

    Two-resistor components will be applied to accurately model CPU

    and the chipset (northbridge and southbridge).

    Define heat pipes.

    Heat pipe features of the Electronic module will be specified.

    Define contact resistances.

    Material contact resistances will be specified for the interface

    between the heat pipes and the electronic components.

    Furthermore, infinite contact resistances will be applied to the

    exposed external faces of the heat pipes.

    Define simulation goals and initial mesh.

    Run the analysis.

    Post-process the results.

    Maximum temperatures on the critical components will be

    determined.

    1 Open an assembly file.

    Open Electronics Assembly from the Case Study\Computer box folder.

    2 Activate configuration.

    Activate configuration Simulation.

    This simplified configuration was prepared specifically for the flow

    simulation. Notice that all peripheral components are modeled as boxes

    and shapes of some of the electronic components are simplified.

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    4

    3 Create a project.

    Create a new study using the Wizard with the following settings:

    Default Outer Wall Thermal Condition

    In this lesson, we specified a Default Outer Wall Thermal Condition

    as a convection coefficient and ambient temperature. This defines the

    thermal condition outside of the computer box. We assume that the

    external air has a temperature of 20.05C and moves slowly due to the

    gravity effects only (convective coefficient of 10 W/m^2/K).

    4 Apply solid materials.

    Under Input Data, right-click Solid Materials and select Insert Solid Material.

    Select Copper under Metals and apply it to the heatsink component.

    Click OK.

    Configuration

    nameUse current:

    Simulation

    Project name Cooling

    Unit system SI (m-kg-s)

    Change the units for Temperature to C.

    Analysis Type

    Physical Features

    Internal

    Select Exclude cavities without flow conditions.

    Select the Heat conduction in Solids check box.

    Select the Gravity box.

    The Y component of -9.81 m/s^2 is the correct direction and value for

    this analysis.

    Database of

    FluidsIn the Fluids list, under Gases, double-click Air to add it to the Project Fluids.

    Solids Default solid should be set to Aluminum.

    Wall conditions Select Heat transfer coefficient as the Default outer wall thermal

    condition. Enter 10 W/m^2/K and 20.05C as the Heat transfer

    coefficient and Temperature of external fluid, respectively.

    The default Roughness value of 0 micro meter is acceptable for this

    analysis.

    Initial conditions Default conditions.

    Results &

    Geometry

    Resolution

    Set the Result resolution to 3.

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    5

    Note The rest of the components are modeled using the special features of

    the Electronics module, (two-resistor components for CPU and the

    chipset parts, for example). Solid materials are not assigned to these

    components.

    Printed Circuit

    Boards

    PCB composite laminates exhibits anisotropic material behavior. The

    electronics module allows users to enter the detailed layup of various

    PCB composites and store it in the Engineering database. Flow

    Simulation then automatically calculates the effective material

    properties (conductivities in all directions, for example).

    5 Define PCB composite.

    Under Flow Simulation, Tools open Engineering Database.

    Under Database tree, expand Printed Circuit Boards and select the User Defined folder.

    Click New Item and enter the following properties for conducting and

    dielectric layers.

    Effective composite

    Material constants forconducting anddielectric layers

    constants

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    6

    When finished, click the

    Tables and Curves tab

    and input the composite

    layup, as shown in the

    figure.

    Note The Layer Thickness implies the thickness of the conducting layer

    defined by the thickness of the conductive material in each lamina. The

    Percentage Cover parameters indicate the volume fraction of the

    conducting material in the body of each conducting layer.

    Click Save and close the Engineering Database window.

    The effective properties of the PCB composite are automatically

    computed and shown in the table (see the Engineering Database

    figure).

    6 Assign PCB material.

    Under Input Data, right-click Printed Circuit Boards and select Insert Printed Circuit Board.

    From the User Defined folder, select 6S2P

    composite created in the previous step.

    Select the PCB assembly part.

    Click OK.

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    7

    7 Specify pressure boundary conditions.

    Define Environment Pressure boundary condition on four lids of the

    Base. Use the internal faces of the lids.

    Note The inlet is defined by the opening in the side walls of the Base rather than the perforated area of the Cover.

    Define Static Pressure boundary condition on the bridge opening.

    Use the internal face of the lid.

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    8

    Specify Environmental Pressure boundary condition on the lid

    covering the main four slits on the top of the Cover.

    Note Flow Simulation will automatically detect four slits and correctly apply

    the boundary condition.

    Specify Environmental Pressure boundary

    condition on the inside face of the fan outlet

    lid.

    8 Define internal fan.

    Under Input Data, right-click Fans and select Insert Fan.

    Under Type select Internal Fan.

    Under Faces Fluid Exits Fan and

    Faces Fluid Enters Fan select the two

    faces as shown in the figure. Note that

    the air is forced out of the enclosure.

    Under Fan select Axial, Papst, Papst

    405 from the Pre-Defined folder. Keep the rest of the parameters at their default

    values.

    Click OK.

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    9

    Note The air is forced out of the enclosures.

    Make sure that the faces for Faces Fluid

    Exits Fan and Faces Fluid Enters Fan

    are selected correctly and the direction of

    the feature arrows points as shown in the

    figure.

    Note A reasonable simplification would be the outlet fan type defined

    directly on the enclosure face. The current solution represents more

    accurate position of the fan with respect to the heatsink.

    Perforated Plates The perforated plates feature is used to model inlet and outlet flows

    through thin perforated walls where a typical 3D mesh would result in

    an excessive number of cells. The perforated plate condition must be

    applied in conjunction with the environmental pressure boundary

    conditions.

    9 Define perforated places.

    Similar to step 5, open the Engineering Database.

    Expand the Perforated Plates folder. Under the User Defined folder define the following two perforated plate features.

    Note The parameters of the Plate 1 and Plate 2 features correspond to the

    perforated plates at the fan outlet and the four side air inlets,

    correspondingly.

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    10

    10 Assign perforated plates.

    Under Input Data, right-click Perforated Plates and select Insert

    Perforated Plate.

    From the User Defined folder,

    select Plate 1.

    Select the inside face of the fan

    outlet lid.

    Click OK.

    Note The perforated plate feature requires existing environmental pressure or

    fan boundary condition. The selected face must therefore be the same

    as the one used in the definition of the pressure condition in step 7.

    Note To automatically select the correct face you may choose to click the

    corresponding environmental pressure boundary condition in the Flow

    Simulation analysis tree.

    Similarly, assign

    Plate 2 perforated

    plate feature to the

    four lids of the Base.

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    11

    Two-Resistor Components

    Two-resistor components are used to model thermal behavior of the

    small electronic components such as CPU, chipsets, memories etc.

    Rather than using a single body, two-resistor component simplifies the

    complex shape with two parallelepiped parts. The Junction is the lower

    part directly in contact with the PCB. The upper part is then referred to

    as the Case.

    Both parts are isolated at their sides forcing the heat to travel in the

    direction normal to the plane of the parallelepiped. The thermal

    properties are expressed using Junction-to-Case (JC) and Junction-to-

    Board (JB) thermal resistances of the infinitely thin plates at the

    respective interfaces.

    Package

    Junction

    Adiabatic wallsAdiabatic walls Case

    PCB board

    JC

    JB

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    12

    Electronic module has an extensive library

    of two-resistor components. The figure

    shows parameters for

    PBGAFC_40x40mm_2R consisting of the parallelepiped dimensions (thickness

    and two planar dimensions), and two

    thermal resistances.

    Caution must be paid to the geometry of the parallelepiped components

    in the SolidWorks model. Their physical dimensions must agree with

    the dimensions in the engineering database.

    11 Specify two-resistor

    components.

    Right-click the Two Resistor

    Components icon and select Insert Two-Resistor

    Component.

    Select cpu 2r case as the Case Body and cpu 2r junction as the Junction Body.

    Under Component select

    PBGAFC_40x40mm_2R.

    Under Source enter 14W for

    the Heat Generation Rate.

    Click OK.

    Following the same procedure, specify the remaining two-resistor

    components for the chipset (northbridge and southbridge).

    Northbridge Southbridge

    Case northbridge 2r case southbridge 2r case

    Junction northbridge 2r junction southbridge 2r junction

    Component PBGAFC_37_5x37_5mm_2R LQFP_256_28x28mm_2R

    Heat Rate 4.3 W 2.5 W

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    13

    Heat Pipes A heat pipe is an efficient heat transfer mechanism between two solid interfaces. It combines the principles of both thermal conductivity and

    phase transition.

    To define a heat pipe component, a solid body and two faces (one for

    cold, one for hot interfaces) are required.

    12 Specify heat pipes.

    Right-click the Heat Pipes

    icon and select Insert Heat

    Pipe.

    Select cpu heat pipe as the Components to Apply Heat

    Pipe.

    Select the face of the cpu heat pipe in contact with the CPU as Heat In Faces.

    Select the two faces of the

    cpu heat pipe in contact with the heatsink as Heat Out Faces.

    Under Effective Thermal Resistance, enter 0.3 C/W.

    Click OK.

    Note The Effective Thermal Resistance parameter represents the

    resistance of the heat pipe to the flow. This value is typically very small

    as heat pipes are very efficient.

    Following the same procedure, specify the remaining heat pipe

    between the northbridge and the heatsink components. Use the same Effective Thermal Resistance.

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    14

    13 Specify contact resistances for heat-in faces.

    Right-click the Contact Resistances icon and select Insert Contact

    Resistance.

    Select the heat in faces on both heat pipes (see the figure). Identical

    faces were used as Heat In Faces in the definition of the heat pipes in

    the previous step.

    Under Type select Resistance and under Interface Materials select

    the Bond-Ply 660 @ 25 psi from the Pre-Defined, Interface Materials, Bergquist, Bond-Ply folder.

    Note The Flow Simulation engineering database with the Electronics module

    license features extensive list of the available interface materials.

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    15

    14 Specify contact resistances for exposed heat pipe faces.

    Heap pipes are very efficient heat conductors with minimum thermal

    resistance. To simplify the calculation we will assume that no heat is

    flowing from the heat pipes into the surrounding air. This will be done

    by specifying infinite contact resistance.

    Right-click the Contact Resistances icon

    and select Insert Contact Resistance.

    In the FeatureManager tree, using the CTRL

    key, click both bodies of the cpu heat pipe and heat pipe short components. Flow Simulation will select all outside faces into

    the Faces to apply the contact resistance

    selection window.

    Click the Filter Faces icon to open the filter

    dialog, select Keep outer and fluid-

    contacting faces and run the filter by

    clicking the Filter button.

    Under Type select Resistance.

    Under Thermal Resistance select Infinite

    resistance (Pre-Defined folder).

    Click OK.

    15 Specify volume goals.

    Under Input Data, right-click Goals and select Insert Volume Goal.

    Under Selection select cpu 2r case and cpu 2r junction components.

    Under Parameter specify Av and Max for Temperature (Solid).

    Edit the Name Template to CPU VG

    .

    Click OK.

    Continue with the definition of the volume goals for the chipset

    components (northbridge and southbridge) and the heatsink.

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    16

    16 Specify surface goal.

    Following similar procedure, define a separate Mass Flow Rate

    surface goal for each air inlet and outlet.

    Note A definition can be conveniently done with a

    single command using the Create goal for

    each surface option.

    Mesh Considerations

    As in any simulation project, mesh plays important role in the quality

    of the solution. Proper mesh generation requires iterative approach

    while adjusting various mesh parameters until the desired optimum

    discretization is achieved.

    In the current model, it is advisable to discretize the interface between

    the PCB and the two-resistor components with cells terminating at this interface. We will achieve this by placing one control plane at the said

    interface (figure in the next step). Also, to mesh the thin features of the

    PCB and the two-resistor components, we will adjust the cell Ratio values accordingly.

    Lastly, local mesh controls for the thermally important components,

    heatsink and the two-resistor components, will be defined as well.

    17 Specify initial mesh.

    Right-click Input Data and select Initial Mesh.

    Clear the Automatic settings checkbox.

    Under Basic Mesh, Control Intervals, click the Add Plane button to

    open the Create Control Planes window.

    Select plane parallel to ZX, Reference

    Geometry, and click the vertex on the

    PCB face defining the plane of interface with the two-resistor components (see

    the figure).

    Click OK to close the Create Control

    Planes window.

    Back in the Initial Mesh window, under Basic Mesh, enter the Ratio

    values of 2 and -3 for Y1 and Y2 intervals, respectively.

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    17

    Note With Ratio values as specified, the cells adjacent to PCB will be smaller, growing in size with the distance.

    Under Number of cells, enter the basic mesh parameters as indicated

    in the figure below.

    Click the Solid/Fluid Interface tab and reduce Small solid feature

    refinement level to 1. Also, make sure that the rest of the parameters

    are set as shown in the figure below.

    Click OK.

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    18

    18 Specify local initial mesh for two-resistor components.

    Under Input Data, right-click Local Initial Meshes and select Insert Local Initial Mesh.

    With the help of the CTRL key, multiple select all two-resistor

    components. A total of six bodies should be selected.

    Clear Auto settings.

    Under Refining Cells, set both the Refine partial cells and Refine

    solid cells parameters to level 2.

    Click OK.

    19 Specify local initial mesh for heatsink.Using the same procedure, create another local initial mesh for the

    heatsink.

    Use the settings from step 18 for the parameters under the Refining

    Cells tab.

    Under the Narrow Channels tab, set the Characteristic number of

    cells across a narrow channel to 5 and Narrow channels

    refinement level to 2.

    20 Generate mesh.

    Under the Flow Simulation menu, click: Solve, Run.

    Uncheck the Solve checkbox.

    Make sure that the Mesh and the Load results options are checked.

    Click Run.

    Note The above step will generate mesh only.

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    19

    21 Mesh plots.

    Show the mesh on the plane parallel to the assembly Front plane, at the position -0.0595 m.

    It can be seen that the cells terminate at the interface between the PCB and the two-resistor components, Also, cells are growing in size with

    distance from the PCB.

    Show the mesh on the plane parallel to the assembly Front plane, at the position -0.00381 m.

    At this position, the plane is passing through the heatsink. We can see that only one full cell is discretizing the narrow channel. This mesh

    deficiency is caused purposely to reduce the computational time

    required to solve this simulation. For more accurate solution in the

    heatsink region, the Narrow channel refinement level specified in step 19 needs to be increased.

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    20

    Show the mesh on the plane parallel to the assembly Right plane, at the position 0.0109 m.

    At this position, the plane is passing through one of the heatsink narrow channels. The discretization seems fine in the direction.

    However, as we found out the discretization would have to increase

    somewhat to correctly mesh the width of the narrow channels.

    22 Solve.

    Similarly to step 20, execute the Solve, Run command.

    This time, uncheck Mesh.

    Check the Solve and the Load results checkboxes.

    Click Run.

    Note The solve time should take up to thirty minutes.

  • SolidWorks 2013 Lesson 1Introduction to Electronics Module

    21

    23 Show temperature results.

    Define a Surface Plot for all thermally important components:

    heatsink and all of the two-resistor components.

    Make sure to set the plot legend limits to the plot rather than the global

    maximums.

    The temperature of the electronic components must now be compared

    against the limits stated at the beginning of the lesson. We can

    immediately see that the CPU temperature of 81.5 C exceeds the limit of 80 C. The cooling system is therefore insufficient.

    The temperature of the other components can be checked easily with

    the help of the goals or surface parameters.

    24 List temperature of the important components.

    Define a Goal Plot for all defined temperature goals and show the table

    with the extremes for all important components.

    The critical temperatures are marked in red. It is clear that the CPU overheats and the cooling must be redesigned. The chipset components

    (northbridge and southbridge) are thermally safe with sufficient margin

    of safety.

  • Lesson 1 SolidWorks 2013Introduction to Electronics Module

    22

    Conclusions In this lesson, we evaluated a design of cooling for electronic computer box. Advanced features of the electronics module, namely heat pipes,

    two-resistor components, PCB composite interface were shown and

    practiced in detail.

    Two-resistor components are special features enabling users to model

    thin electronic components such as CPUs with greater level of fidelity.

    Heat pipes are efficient heat transporting devices employing both

    principles of the heat conduction and phase transition. Lastly, the PCB

    composite interface enables users to enter the layup composition of the

    PCBs and store them in the engineering database. Flow Simulation then

    automatically computes the effective material constants required for the

    simulation.

    In this lesson we found that with the proposed cooling the CPU unit overheats. Redesign of the cooling system is therefore necessary.

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