TES Presentation

Complex Electronics Cooling AnalysisElectroFlo

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Why do I care that Electronics are Getting Hot?For every 10 C temperature increase there is a 50% reduction of operating lifeElectronics 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 ControllerComponent Definition

Joulean/Trace Heating Coldplate Modeling (Liquid Cooling)

Results

Contents

Why do Electronics Get Hot?Complexity

Compactness

Cost Factors

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Benefits of Thermal AnalysisLow CostMuch lower cost than experimental investigationSpeedStudy many different scenarios and optimize your designCompleteness of ResultsResults available for entire system; not just at sensor locationsNo inaccessible locationsNo inaccuracies as a result of probe interferenceModeling Difficult ConditionsStudy worst case and other scenariosA Stitch in Time Saves Nine

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Very fast and stable solverPatented Automated Radiation NetworkAutomatically calculates heat from voltage calculationUsed globally with customers in US, South America, Europe and AsiaEasy to use and full-featured

ElectroFlo Finds Solutions for Complex Electronics Cooling ProblemsUtilizes many years of aerospace experience

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GeometryColdplate, components, traces and other conductors from sources in various formats.Heat GenerationTwo main contributors:Switching Devices and other Component lossesCurrent flow in traces and connectorsInternal Heat TransferConductionInternal natural convection (using CFD)Internal thermal radiationCooling to AmbientAmbient natural convection, conduction and radiationCooling through Liquid Channels of Coldplate

Sample model of Motor Controller

Example: Thermal Analysis of a Liquid Cooled Motor Controller

Geometry DefinitionGeometry can be created within ElectroFlo or read in from CAD

Boundary Conditions (BCs)Thermal Resistance Planes are created to isolate different sections of componentUsing manufacture data (i.e. junction to case resistance), thermal links are created with a given resistanceFunctions and Tables can be used to accurately depict the power dissipation of the devices.

Saving to Component LibraryOnce 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

Defining IGBTs and other Complex Components

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Switching StackDue to complexity of components, simplified models of the IGBTs and Diodes are created using variable Power Dissipation valuesComponent DefinitionsDefine components in your terms

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Circuit DefinitionGeometry is defined like any other package, but materials have electrical properties as well as thermal propertiesElectrical Links can be added (with optional Heat Generation)Electrical Connection Regions are automatically determinedFixed/Variable Electrical Resistance planes can be added

Voltage CalculationVoltage Field is incrementally determined as electrical resistance varies with temperatureVoltage inputs (Current and Voltage) can vary with time

Power Dissipation (Thermal Losses)From the voltage field, ElectroFlo calculates the power dissipation for the electrical circuitDetermines local hot spots, within both traces and simple components

Electrical Calculation to Determine Power Dissipation within Traces and Leads

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Temperature Results

Fuse ModelAll heat comes from Voltage Field calculationFuse will blow if it reaches a set temperatureUser can look at transient case of what will happen in the time immediately following the blown fuse.Electrical Calculation to Determine Power Dissipation within Traces and LeadsElectrical Resistance PlanesAluminum StandoffsFuse Case

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Trace HeatingAll heat comes from Voltage Field calculationShows local Hot Spots within layerAccurately capture transient effectUse Links to model vias without overloading your modelElectrical Calculation to determine Power Dissipation within Traces and LeadsDont miss the Hot Spots

Temperature PlotPower Dissipation Plot

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Define GeometryDefine the size and shape of the channelCreate coolant path by either reading in file, or clicking on screen

Pressure CalculationUser can set fixed/variable flowrate Solver will calculate the flowrate based on the pump and pressure loss through the modelCoolant through ElectroFlo model can be part of larger system

Heat TransferHeat is removed by the coolant path and the fluid temperature increases as it travels through the Coldplate

Optimizing your DesignUser can quick change the coolant path, or channel properties with having to modify the rest of the modelHeat Exchanger Model for Determining Cooling through Coldplate Channels

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Coldplate ModelSolved assuming fixed volumetric flowrate through channelsBy creating full system model, you can get very accurate transients and solve for thermal soak back issues

Heat Exchanger Model for determining cooling through Coldplate ChannelsThe right tool for the job

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Model Results PostprocessingAnimation and Color plots for all variables Watch streamlines developing Over 100 post processing tools

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Create Automated ReportsTransient GraphsHottest ComponentsSee where your heat is goingReport is customizableUse your Company Template in PowerPoint

Model ResultsStop spending most of your time creating reports, just automate it!

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Introduction to ElectroFloA Stitch in Time Saves NineLiquid Cooled Motor ControllerComponent DefinitionDefine components in your termsJoulean/Trace HeatingDont miss the Hot SpotsColdplate Modeling (Liquid Cooling)The right tool for the jobResultsStop spending most of your time creating reports, automate it!Contents Revisited

Join us next time when we see how this model fits into a rack system with three other liquid cooled electronics boxes

Thank youHamish Lewishlewis@tesint.comQuestions/Comments

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