Week 5.3 - Electronic Enclosure
CHALLENGE: To create workflow in Ansys Workbench and to simplify geometry for ICEPAK and create high quality Non-conformal mesh and solve it for forced convection case with 30CFM for fan.
ICEPAK Geometry Cleanup:
1. Initially the electronics cabinet was examined for simplification, unnecessary components are removed.
2. The fan portion is removed and replaced by simplified ICEPAK fan to make simulation easier.
3. All portions of geometry is simplified into icepak geometries and grouped based on type. so that while meshing it will be easier to create Nonconformal mesh.
MESHING:
1. All complex components have been allocated as separate assemblies and meshed separately.
2. Initial mesh have been generated and visualized to further improves mesh quality.
3. based on the initial mesh refinements have been carried out it's effect have been seen in mesh count.
4. efforts have been taken to control mesh count and alos to increase mesh quality.
5. Finally mesh with superior quality have been generated
6. face alignment is 0.18 and skewness is 0.1 which is higher than recommended mesh quality in ICEPAK.
Fig 01: Mesh view from Z Axis
Fig 02: Mesh view from y Axis
Fig 03: Mesh view from y Axis
Fig 04: Mesh quality
CASE SETUP:
1. To all die's 5watts of heat generation is given as BC.
2. BGA has the heat generation of 30watts.
3. fan has the cfm is 31.
4. case have been solved with psedo transient to ensure proper convergence. as divegence have been noted in initial case.
RESULTS:
ass flow rates:
Specified Calculated
--------- ----------
Opening 0 kg/s -0.000854535 kg/s
Opening.1 0 kg/s -0.000886364 kg/s
Opening.2 0 kg/s -0.000790849 kg/s
Opening.3 0 kg/s -0.000868884 kg/s
Opening.4 0 kg/s -0.000899145 kg/s
Opening.5 0 kg/s -0.000801534 kg/s
Opening.6 0 kg/s -0.000827754 kg/s
Opening.7 0 kg/s -0.000876164 kg/s
Opening.8 0 kg/s -0.000799287 kg/s
Opening.9 0 kg/s -0.000781036 kg/s
Opening.10 0 kg/s -0.000836588 kg/s
Opening.11 0 kg/s -0.000797498 kg/s
Opening.12 0 kg/s -0.00076506 kg/s
Opening.13 0 kg/s -0.000803152 kg/s
Opening.14 0 kg/s -0.000792276 kg/s
Opening.15 0 kg/s -0.00076278 kg/s
Opening.16 0 kg/s -0.000784727 kg/s
Opening.17 0 kg/s -0.000785732 kg/s
Opening.18 0 kg/s -0.000744704 kg/s
Opening.19 0 kg/s -0.00075967 kg/s
Opening.20 0 kg/s -0.00077397 kg/s
fan.2 0.0169917 kg/s 0.0169917 kg/s
Volume flow rates:
Specified Calculated
--------- ----------
Opening n/a -0.00073578 m3/s
Opening.1 n/a -0.000763186 m3/s
Opening.2 n/a -0.000680945 m3/s
Opening.3 n/a -0.000748135 m3/s
Opening.4 n/a -0.000774191 m3/s
Opening.5 n/a -0.000690145 m3/s
Opening.6 n/a -0.000712721 m3/s
Opening.7 n/a -0.000754403 m3/s
Opening.8 n/a -0.00068821 m3/s
Opening.9 n/a -0.000672495 m3/s
Opening.10 n/a -0.000720327 m3/s
Opening.11 n/a -0.000686669 m3/s
Opening.12 n/a -0.00065874 m3/s
Opening.13 n/a -0.000691538 m3/s
Opening.14 n/a -0.000682173 m3/s
Opening.15 n/a -0.000656776 m3/s
Opening.16 n/a -0.000675673 m3/s
Opening.17 n/a -0.000676539 m3/s
Opening.18 n/a -0.000641212 m3/s
Opening.19 n/a -0.000654099 m3/s
Opening.20 n/a -0.000666411 m3/s
fan.2 31 cfm 0.0146304 m3/s
Heat flows for objects with power specified:
Object Specified Calculated
BGA 10 W 10.0005 W
DIE_AF0 3 W 2.99997 W
DIE_AF0.1 3 W 2.99998 W
DIE_AF0.2 3 W 2.99999 W
DIE_AF0.3 3 W 2.99997 W
DIE_AF0.4 3 W 2.99998 W
DIE_AF0.5 3 W 2.99997 W
Heat flows for openings, walls, grilles, and fans:
Opening -0.962177 W
Opening.1 -0.681656 W
Opening.2 -1.54747 W
Opening.3 -0.737899 W
Opening.4 -0.3552 W
Opening.5 -1.20798 W
Opening.6 -0.854876 W
Opening.7 -0.481623 W
Opening.8 -1.00576 W
Opening.9 -1.15406 W
Opening.10 -0.844932 W
Opening.11 -0.975648 W
Opening.12 -1.55332 W
Opening.13 -1.28135 W
Opening.14 -1.10492 W
Opening.15 -2.13094 W
Opening.16 -1.71691 W
Opening.17 -1.5046 W
Opening.18 -2.34498 W
Opening.19 -2.02926 W
Opening.20 -2.26317 W
fan.2 -0.000661474 W
Maximum temperatures:
Housing 28.133 C
Housing.1 28.9947 C
Housing.2 28.2376 C
Housing.3 28.2908 C
Housing.4 29.0096 C
Housing.5 29.5948 C
Housing.6 28.5561 C
Housing.7 28.3517 C
Housing.8 29.2141 C
Housing.9 28.9059 C
Housing.10 29.0831 C
Housing.11 28.8429 C
Housing.12 29.1072 C
Housing.13 28.6086 C
Housing.14 28.6667 C
Housing.15 28.712 C
Housing.16 29.2254 C
Housing.17 29.6167 C
Housing.18 29.6625 C
Housing.19 29.2012 C
Housing.20 29.1846 C
Housing.21 28.9919 C
Housing.22 29.7693 C
Housing.23 29.5886 C
Housing.24 29.762 C
Housing.25 29.1507 C
Housing.26 29.495 C
Housing.27 28.9109 C
Housing.28 29.0395 C
Housing.29 28.8897 C
Housing.30 28.2721 C
Housing.31 28.3218 C
Housing.32 28.1612 C
Housing.33 28.8836 C
Housing.34 28.1115 C
Housing.35 28.6951 C
Housing.36 28.2644 C
Housing.37 28.8739 C
Housing.38 28.0494 C
Housing.39 28.62 C
Housing.40 28.8167 C
Housing.41 28.3752 C
Housing.42 28.8225 C
Housing.43 28.8736 C
Housing.44 28.2478 C
Housing.45 28.1788 C
Housing.46 28.4309 C
Housing.47 28.1831 C
Housing.48 28.4368 C
Housing.49 28.4478 C
Housing.50 28.2916 C
Housing.51 29.0467 C
Housing.52 28.7716 C
Housing.53 29.0545 C
Housing.54 28.5822 C
Housing.55 28.5747 C
Housing.56 28.7525 C
Housing.57 28.5738 C
Housing.58 28.8343 C
Housing.59 28.4153 C
Housing.60 28.6213 C
Housing.61 28.2975 C
Housing.62 28.441 C
Housing.63 28.2585 C
Housing.64 28.1424 C
Housing.65 28.2563 C
Housing.66 28.4749 C
Housing.67 28.3174 C
Housing.68 28.407 C
Housing.69 28.172 C
Housing.70 28.7368 C
Housing.71 28.757 C
Housing.72 28.8785 C
Housing.73 28.7587 C
Housing.74 28.9407 C
Housing.75 28.989 C
Housing.76 28.6287 C
Housing.77 28.8026 C
Housing.78 28.7082 C
Housing.79 28.866 C
Housing.80 28.9911 C
Housing.81 29.071 C
Housing.82 29.1173 C
Housing.83 29.0497 C
Housing.84 29.254 C
Housing.85 28.8828 C
Housing.86 28.9611 C
Housing.87 28.846 C
Housing.88 28.9622 C
Housing.89 28.9285 C
Housing.90 28.483 C
Housing.91 28.6717 C
Housing.92 28.556 C
Housing.93 28.8072 C
Housing.94 28.4642 C
Housing.95 28.5296 C
Housing.96 28.459 C
Housing.97 28.6961 C
Housing.98 28.2654 C
Housing.99 28.454 C
Housing.100 28.2353 C
Housing.101 28.9298 C
Housing.102 28.9489 C
Housing.103 29.144 C
PWB 29.3921 C
BGA 29.3917 C
BGA-Heat-Sink 29.3336 C
BGA-Heat-Sink.1 29.3591 C
BGA-Heat-Sink.2 29.3451 C
BGA-Heat-Sink.3 29.3651 C
BGA-Heat-Sink.4 29.363 C
BGA-Heat-Sink.5 29.3726 C
BGA-Heat-Sink.6 28.9754 C
BGA-Heat-Sink.7 29.0677 C
BGA-Heat-Sink.8 29.0064 C
BGA-Heat-Sink.9 28.8796 C
BGA-Heat-Sink.10 28.9098 C
BGA-Heat-Sink.11 28.7917 C
BGA-Heat-Sink.12 28.8176 C
BGA-Heat-Sink.13 29.2265 C
BGA-Heat-Sink.14 29.1518 C
BGA-Heat-Sink.15 29.1799 C
BGA-Heat-Sink.16 29.2885 C
BGA-Heat-Sink.17 29.2507 C
BGA-Heat-Sink.18 29.307 C
BGA-Heat-Sink.19 29.0977 C
BGA-Heat-Sink.20 28.7622 C
Housing.104 26.9808 C
Housing.105 27.3662 C
Housing.106 28.4728 C
Housing.107 28.1567 C
Housing.108 27.1231 C
Housing.109 27.1438 C
Capacitor 26.6498 C
Capacitor.1 25.9935 C
Capacitor.2 26.4512 C
DIE_AF0 29.9301 C
HS_AF0 29.8734 C
LEAD_1_AF0 29.3523 C
LEAD_1_AF0.1 29.4334 C
LEAD_1_AF0.2 29.3392 C
LEAD_1_AF0.3 29.296 C
LEAD_1_AF0.4 29.3641 C
LEAD_1_AF0.5 29.4339 C
LEAD_1_AF0.6 29.4359 C
LEAD_1_AF0.7 29.3743 C
LEAD_1_AF0.8 29.3068 C
T0220_Case 29.4101 C
T0220_Case.1 29.3281 C
T0220_Case.2 29.6376 C
T0220_Case.3 29.6957 C
T0220_Case.4 29.7006 C
T0220_Case.5 29.6855 C
T0220_Case.6 29.7266 C
T0220_Case.7 29.7338 C
T0220_Case.8 29.694 C
T0220_Case.9 29.696 C
T0220_Case.10 29.9301 C
T0220_Case.11 29.3451 C
T0220_Case.12 29.5639 C
T0220_Case.13 29.4206 C
T0220_Case.14 29.848 C
T0220_Case.15 29.5683 C
DIE_AF0.1 29.7406 C
HS_AF0.1 29.6857 C
LEAD_1_AF0.9 29.147 C
LEAD_1_AF0.10 29.2371 C
LEAD_1_AF0.11 29.1338 C
LEAD_1_AF0.12 29.1059 C
LEAD_1_AF0.13 29.1687 C
LEAD_1_AF0.14 29.233 C
LEAD_1_AF0.15 29.2297 C
LEAD_1_AF0.16 29.1572 C
LEAD_1_AF0.17 29.0868 C
T0220_Case.16 29.2281 C
T0220_Case.17 29.1454 C
T0220_Case.18 29.4464 C
T0220_Case.19 29.5168 C
T0220_Case.20 29.5079 C
T0220_Case.21 29.4941 C
T0220_Case.22 29.5405 C
T0220_Case.23 29.5429 C
T0220_Case.24 29.506 C
T0220_Case.25 29.5018 C
T0220_Case.26 29.7406 C
T0220_Case.27 29.658 C
T0220_Case.28 29.3837 C
T0220_Case.29 29.1326 C
T0220_Case.30 29.3739 C
T0220_Case.31 29.2137 C
DIE_AF0.2 29.7485 C
HS_AF0.2 29.6931 C
LEAD_1_AF0.18 29.156 C
LEAD_1_AF0.19 29.2488 C
LEAD_1_AF0.20 29.1704 C
LEAD_1_AF0.21 29.1244 C
LEAD_1_AF0.22 29.1921 C
LEAD_1_AF0.23 29.252 C
LEAD_1_AF0.24 29.2485 C
LEAD_1_AF0.25 29.1796 C
LEAD_1_AF0.26 29.1057 C
T0220_Case.32 29.2202 C
T0220_Case.33 29.1379 C
T0220_Case.34 29.2372 C
T0220_Case.35 29.4546 C
T0220_Case.36 29.5103 C
T0220_Case.37 29.5252 C
T0220_Case.38 29.5033 C
T0220_Case.39 29.5461 C
T0220_Case.40 29.551 C
T0220_Case.41 29.5097 C
T0220_Case.42 29.5145 C
T0220_Case.43 29.7485 C
T0220_Case.44 29.3727 C
T0220_Case.45 29.3837 C
T0220_Case.46 29.6659 C
T0220_Case.47 29.1631 C
DIE_AF0.3 30.6361 C
HS_AF0.3 30.5806 C
LEAD_1_AF0.27 30.0444 C
LEAD_1_AF0.28 30.1411 C
LEAD_1_AF0.29 30.0583 C
LEAD_1_AF0.30 30.0101 C
LEAD_1_AF0.31 30.0806 C
LEAD_1_AF0.32 30.1436 C
LEAD_1_AF0.33 30.142 C
LEAD_1_AF0.34 30.0679 C
LEAD_1_AF0.35 29.9952 C
T0220_Case.48 30.3413 C
T0220_Case.49 30.4107 C
T0220_Case.50 30.4009 C
T0220_Case.51 30.3943 C
T0220_Case.52 30.4326 C
T0220_Case.53 30.4384 C
T0220_Case.54 30.3981 C
T0220_Case.55 30.4008 C
T0220_Case.56 30.6361 C
T0220_Case.57 30.2683 C
T0220_Case.58 30.0472 C
T0220_Case.59 30.1236 C
T0220_Case.60 30.5535 C
T0220_Case.61 30.0382 C
T0220_Case.62 30.2713 C
T0220_Case.63 30.113 C
DIE_AF0.4 30.547 C
HS_AF0.4 30.488 C
LEAD_1_AF0.36 29.9688 C
LEAD_1_AF0.37 30.0589 C
LEAD_1_AF0.38 29.9707 C
LEAD_1_AF0.39 29.9214 C
LEAD_1_AF0.40 29.9917 C
LEAD_1_AF0.41 30.0585 C
LEAD_1_AF0.42 30.0611 C
LEAD_1_AF0.43 29.9926 C
LEAD_1_AF0.44 29.9265 C
T0220_Case.64 30.0277 C
T0220_Case.65 29.9517 C
T0220_Case.66 30.2558 C
T0220_Case.67 30.3142 C
T0220_Case.68 30.3202 C
T0220_Case.69 30.3064 C
T0220_Case.70 30.34 C
T0220_Case.71 30.3513 C
T0220_Case.72 30.3139 C
T0220_Case.73 30.3113 C
T0220_Case.74 30.547 C
T0220_Case.75 30.1762 C
T0220_Case.76 30.4651 C
T0220_Case.77 30.1908 C
T0220_Case.78 29.969 C
T0220_Case.79 30.0387 C
DIE_AF0.5 30.0948 C
HS_AF0.5 30.0389 C
LEAD_1_AF0.45 29.5007 C
LEAD_1_AF0.46 29.597 C
LEAD_1_AF0.47 29.504 C
LEAD_1_AF0.48 29.4568 C
LEAD_1_AF0.49 29.5233 C
LEAD_1_AF0.50 29.5915 C
LEAD_1_AF0.51 29.5921 C
LEAD_1_AF0.52 29.529 C
LEAD_1_AF0.53 29.4595 C
T0220_Case.80 29.5767 C
T0220_Case.81 29.4975 C
T0220_Case.82 29.5741 C
T0220_Case.83 29.4952 C
T0220_Case.84 29.8011 C
T0220_Case.85 29.8652 C
T0220_Case.86 29.8619 C
T0220_Case.87 29.8922 C
T0220_Case.88 29.851 C
T0220_Case.89 29.8978 C
T0220_Case.90 29.8595 C
T0220_Case.91 29.8583 C
T0220_Case.92 30.0948 C
T0220_Case.93 29.7265 C
T0220_Case.94 30.0124 C
T0220_Case.95 29.7329 C
Component 26.2735 C
Component.1 26.4809 C
Component.2 26.8547 C
Component.3 26.8585 C
Coil 26.0191 C
Coil-0 26.3995 C
Coil-0.1 26.269 C
Coil-0.2 26.4267 C
Coil-0.3 26.4997 C
Coil-1 26.0288 C
Coil-1.1 26.0181 C
Coil-1.2 26.0318 C
Coil-1.3 26.0225 C
Coil-2 26.4055 C
Coil.1 26.3678 C
Coil.2 26.0069 C
Coil.3 26.29 C
Coil.4 26.2722 C
Coil.5 26.9326 C
Overall totals:
power 28.0004 W
mass flow through boundaries -9e-009 kg/s
volume flow through boundaries -7.5e-009 m3/s
IMPRESSION: It is observed that temperature is not crossing 30Deg at any location hence the design is safe.
POST PROCESSING:
Fig 01: Temperatures of Components
Fig 02: Particle Tracks through electronics cabinet