aerospace webinar 2

8/8/2019 Aerospace Webinar 2

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Complex

Electronics CoolingAnalysis

ElectroFlo®



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



Introduction to ElectroFlo®◦

Liquid Cooled Motor Controller◦ Component Definition

◦ Joulean/Trace Heating

◦ Coldplate Modeling (Liquid Cooling)

◦ Results

◦

ContentsContents



Why do Electronics GetWhy do Electronics GetHot?Hot?

Complexity

Compactness

Cost Factors



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



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



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



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



◦ 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



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



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



◦ 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



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



◦ 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



Model ResultsModel Results

Postprocessing

Animation and Color plots for all variablesWatch streamlines developingOver 100 post processing tools



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!



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



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

[email protected]

Questions/CommentsQuestions/Comments

aerospace webinar 2

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