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Enclosure Design + Cooling Solutions Process

The Enclosure Design Service is a process by which ElectroThermal Design creates a mechanical apparatus for a power electronics product, with a focus on thermal management. The Cooling Solutions Service is an add on that will be necessary if it is determined that the product will not remain in thermal equilibrium under natural convection conditions.

 

The process can be broken down into three design stages: proof of concept, parametric refinement, and finalization. At the conclusion of each stage ETD will host a brief product development meeting with the customer, where we will assess progress and discuss next steps.

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Before Enclosure Design can commence, the customer is required to provide ETD with a list of prerequisite data.

Metals, plastics, PCB substrates, etc.​​

Components that dissipate heat (in watts)

Ambient temp, sun exposure, altitude, etc.

Ambient air flow, mounting interface, etc.

Capped run time, transient power output, etc.

FETs, diodes, sensors, etc. of 

  1.  Materials​

  2.  Heat sources

  3.  Environmental conditions

  4.  Boundary conditions

  5.  Transient conditions

  6.  Components of interest​

Prerequisites

1. Preliminary 3D models and/or drawings of the components to be housed by the enclosure

The customer must provide CAD files for components such as:

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2. Interconnectivity Diagram

A description of how the products components connect with one another (for layout purposes).

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3. Thermodynamic variables to be defined​

  • ​​PCBs

  • Subassemblies

  • Connectors

  • Cables

4. Design Constraints

  1. Spatial limitations​

  2.  Thermal limitations

  3.  Weight limitations

  4.  Mounting preference

  5.  Cooling limitations

  6.  Required standards

Must fit in a predefined space/footprint​

Maximum operating temperatures

Maximum weight

Type of fastener, hole pattern, etc.

Fan restrictions, liquid cooling restrictions, etc.

MIL spec, IP ratings, etc.

Once all prerequisites are in order, ETD will being the first stage of design.

Design Stages

Stage 1: Proof of Concept

To begin the design process ETD will first generate one or more low resolution, draft housings/layouts. These are typically  rough concept models, quick and easy to generate. Each of the drafts will then be run through a series of thermal simulations, configured according to the prerequisite data supplied by the customer. The purpose of this is to test the overall viability of the concept the customer has in mind. At the end of this stage we aim to answer the following questions:

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1. What is the optimal enclosure size/geometry in relation to total power dissipation (heat load)?

2.  What are the viable electromechanical layouts pertaining to interconnectivity and heatsinking?

3. What type of cooling system, if any, is right for the job?

Stage 2: Parametric Refinement

Following the completion of our proof of concept, we are able to head into the second stage with a blueprint in hand. In this stage we focus on refining the top one or two performing concept models. This is achieved through parametric iteration. For example, if our concept model is equipped with a heatsink, one of the parameters we would work to optimize is the fin profile. By modeling then simulating an array of heatsinks featuring various fin heights, fin widths, and total number of fins, we can predict which fin profile will be optimal. At the end of this stage the design will begin to take its final form.

Stage 3: Finalization

After parametric refinement our concept has evolved into a working design. The third and final stage is where the smaller details are are taken care of, and a comprehensive review is conducted. The unit will receive a few final touches such as  chamfers, fillets, labels, etchings, etc. This is also when all documentation will be generated including drawing packages and the final thermal report. Lastly, ETD will hold a very thorough design review with the customer. If both parties are satisfied with the result, then ETD will close out the project and provide the following deliverables to the customer:

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1. Thermal Analysis Report

2. Part and Assembly Drawing Packages (.dwg, .dxf, .pdf)

3. Part and Assembly Models (.stp)

4. Sourcing of Metalwork (if requested)

5. Technical Explosion Animation (if requested)

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