Electronics Thermal Management Driven Design of an IP65-Rated Motor Inverter

Thermal management of electronic components packaged inside an IP65 rated enclosure is of prime importance in industrial applications. Electrical enclosure protects the multiple board configurations such as inverter, power, controller board components, busbars, and various power dissipating components from harsh environments. Industrial environments often experience relatively warm ambient conditions, and the electronic components housed in the enclosure dissipate heat, due to which the enclosures and the components require thermal management as well as reduction of internal ambient temperatures. Design of Experiments based thermal simulation approach with MOSFET arrangement, Heat sink design, Enclosure Volume, Copper and Aluminum Spreader, Power density, and Printed Circuit Board (PCB) type were considered to optimize air temperature inside the IP65 enclosure to ensure conducive operating temperature for controller board and electronic components through the different modes of heat transfer viz. conduction, natural convection and radiation using Ansys ICEPAK. MOSFET’s with the parallel arrangement, IP65 enclosure molded heat sink with rectangular fins on both enclosures, specific enclosure volume to satisfy the power density, Copper spreader to conduct heat to the enclosure, optimized power density value and selecting Aluminum clad PCB which improves the heat transfer were the contributors towards achieving a conducive operating temperature inside the IP-65 rated Motor Inverter enclosure. A reduction of 52 ℃ was achieved in internal ambient temperature inside the IP65 enclosure between baseline and final design parameters, which met the operative temperature requirements of the electronic components inside the IP-65 rated Motor Inverter.

Effect of Two Radial Fins on Heat Transfer and Flow Structure in a Horizontal Annulus

Laminar natural convection in a cylindrical annular cavity filled with air and provided with two fins is studied numerically using the discretization of the governing equations with the Centered Finite Difference method based on the Alternating Direction Implicit (ADI) scheme. The fins are attached to the inner cylinder of radius ri (hot wall of temperature Ti). The outer cylinder of radius ro is maintained at a temperature To (To < Ti). Two values of the dimensionless thickness of the fins are considered: 0.015 and 0.203. We consider a low fin height equal to 0.078 and medium fin heights equal to 0.093 and 0.203. The position of the fin is 0.82π and the radius ratio is equal to 2. The effect of Rayleigh number, Ra, on the flow structure and heat transfer is analyzed for a range of Ra from 103 to 104. The results for established flow structures and heat transfer at low height indicate that the flow regime that occurs is unicellular for all Ra and fin thickness; in addition, the heat transfer rate increases with increasing Rayleigh number and is the same for both thicknesses. At median fin heights 0.093 and 0.203, the increase of Rayleigh number leads to transitions of flow structure which correspond to significant variations of the heat transfer. The critical Rayleigh numbers, Rac.app and Rac.disp corresponding to the appearance of the bicellular flow regime and its disappearance, are determined and their influence on the change of heat transfer rate is analyzed.

Efficiency Enhancement of Photovoltaic Panels Using an Optimised Air Cooled Heat Sink

Solar panels that use photovoltaic (PV) cells are popular for converting solar radiation into electricity. One of the major problems impacting the performance of PV panels is the overheating caused by excessive solar radiation and high ambient temperatures, which degrades the efficiency of the PV panels remarkably. To overcome this issue, an aluminum heat sink was used to dissipate unwanted heat from PV cells. The dimensions of the heat sink were determined considering the optimal fin spacing that fulfils hot climatic conditions. In this study, the effects of cooling on the efficiency and power output of a PV panel were studied experimentally. Two PV modules were used: one without and one with a heat sink. The experiments ran for 11 hours from 6:00 a.m. to 5:30 p.m. where temperature readings in the rear and front of both PV modules were recorded at an interval of 15 minutes using sensors and an Arduino microprocessor. Results are recorded for both panels simultaneously for analysis, temperate comparison, and for power and efficiency calculations. A maximum increase in the solar to electrical conversion efficiency of 35% and almost 55% in the power output were achieved with the use of a heat sink, while temperatures at the front and back of the panel were reduced by 9% and 11%, respectively.

Numerical Study of Natural Convection in a Triangular Enclosure as an Attic for Different Geometries and Boundary Conditions

In this paper, natural convection in an attic is numerically investigated. The geometry of the problem is considered to be a triangular enclosure. ANSYS Fluent software is used for modeling and numerical solution. This study is for steady state. Four right-angled triangles with height to base ratios of 2, 1, 0.5 and 0.25 are considered. The behavior of various parameters related to its performance, including temperature distribution and velocity vectors are evaluated, and graphs for the Nusselt number have been drawn. Also, in this study, the effect of geometric shape of enclosure with different height-to-base ratios has been evaluated for three types of boundary conditions of winter, summer day and one another state. It can be concluded that as the bottom side temperature and ratio of base to height of the enclosure increases, the convective effects become more prominent and circulation happened.

Modeling Non-Darcy Natural Convection Flow of a Micropolar Dusty Fluid with Convective Boundary Condition

A numerical approach of the effectiveness of numerous parameters on magnetohydrodynamic (MHD) natural convection heat and mass transfer problem of a dusty micropolar fluid in a non-Darcy porous regime is prepared in the current paper. In addition, a convective boundary condition is scrutinized into the micropolar dusty fluid model. The governing boundary layer equations are converted utilizing similarity transformations to a system of dimensionless equations to be convenient for numerical treatment. The resulting equations for fluid phase and dust phases of momentum, angular momentum, energy, and concentration with the appropriate boundary conditions are solved numerically applying the Runge-Kutta method of fourth-order. In accordance with the numerical study, it is obtained that the magnitude of the velocity of both fluid phase and particle phase reduces with an increasing magnetic parameter, the mass concentration of the dust particles, and Forchheimer number. While rises due to an increment in convective parameter and Darcy number. Also, the results refer that high values of the magnetic parameter, convective parameter, and Forchheimer number support the temperature distributions. However, deterioration occurs as the mass concentration of the dust particles and Darcy number increases. The angular velocity behavior is described by progress when studying the effect of the magnetic parameter and microrotation parameter.

Lattice Boltzmann Simulation of MHD Natural Convection Heat Transfer of Cu-Water Nanofluid in a Linearly/Sinusoidally Heated Cavity

In this numerical study, natural convection of Cu–water nanofluid in a cavity submitted to different heating modes on its vertical walls is analyzed. Maxwell-Garnetts (MG) and Brinkman models have been utilized for calculating the effective thermal conductivity and dynamic viscosity of nanofluid, respectively. Influences of Rayleigh number (Ra = 103−106), nanoparticle volume concentration (f = 0-0.04) and Hartmann number (Ha = 0-90) on the flow and heat transfer characteristics have been examined. The results indicate that the Hartmann number influences the heat transfer at Ra = 106 more than other Raleigh numbers, as the least effect is observed at Ra = 103. Moreover, the results show that the solid volume fraction has a significant influence on heat transfer, depending on the value of Hartmann, heat generation or absorption coefficient and Rayleigh numbers.

Numerical and Experimental Investigation of Air Distribution System of Larder Type Refrigerator

Almost all of the domestic refrigerators operate on the principle of the vapor compression refrigeration cycle and removal of heat from the refrigerator cabinets is done via one of the two methods: natural convection or forced convection. In this study, airflow and temperature distributions inside a 375L no-frost type larder cabinet, in which cooling is provided by forced convection, are evaluated both experimentally and numerically. Airflow rate, compressor capacity and temperature distribution in the cooling chamber are known to be some of the most important factors that affect the cooling performance and energy consumption of a refrigerator. The objective of this study is to evaluate the original temperature distribution in the larder cabinet, and investigate for better temperature distribution solutions throughout the refrigerator domain via system optimizations that could provide uniform temperature distribution. The flow visualization and airflow velocity measurements inside the original refrigerator are performed via Stereoscopic Particle Image Velocimetry (SPIV). In addition, airflow and temperature distributions are investigated numerically with Ansys Fluent. In order to study the heat transfer inside the aforementioned refrigerator, forced convection theories covering the following cases are applied: closed rectangular cavity representing heat transfer inside the refrigerating compartment. The cavity volume has been represented with finite volume elements and is solved computationally with appropriate momentum and energy equations (Navier-Stokes equations). The 3D model is analyzed as transient, with k-ε turbulence model and SIMPLE pressure-velocity coupling for turbulent flow situation. The results obtained with the 3D numerical simulations are in quite good agreement with the experimental airflow measurements using the SPIV technique. After Computational Fluid Dynamics (CFD) analysis of the baseline case, the effects of three parameters: compressor capacity, fan rotational speed and type of shelf (glass or wire) are studied on the energy consumption; pull down time, temperature distributions in the cabinet. For each case, energy consumption based on experimental results is calculated. After the analysis, the main effective parameters for temperature distribution inside a cabin and energy consumption based on CFD simulation are determined and simulation results are supplied for Design of Experiments (DOE) as input data for optimization. The best configuration with minimum energy consumption that provides minimum temperature difference between the shelves inside the cabinet is determined.

MHD Natural Convection Flow of Tangent Hyperbolic Nanofluid Past a Vertical Permeable Cone

In this paper, a non-similraity analysis has been presented to exhibit the two-dimensional boundary layer flow of magnetohydrodynamic (MHD) natural convection of tangent hyperbolic nanofluid nearby a vertical permeable cone in the presence of variable wall temperature impact. The mutated boundary layer nonlinear governing equations are solved numerically by the an efficient implicit finite difference procedure. For both nanofluid effective viscosity and nanofluid thermal conductivity, a number of experimental relations have been recognized. For characterizing the nanofluid, the compatible nanoparticle volume fraction model has been used. Nusselt number and skin friction coefficient are calculated for some values of Weissenberg number W, surface temperature exponent n, magnetic field parameter Mg, power law index m and Prandtl number Pr as functions of suction parameter. The rate of heat transfer from a vertical permeable cone in a regular fluid is less than that in nanofluids. A best convection has been presented by Copper nanoparticle among all the used nanoparticles.

Experimental Investigation of Heat Pipe with Annular Fins under Natural Convection at Different Inclinations

Heat pipe is characterised as superconductor of heat because of its excellent heat removal ability. The operation of several engineering system results in generation of heat. This may cause several overheating problems and lead to failure of the systems. To overcome this problem and to achieve desired rate of heat dissipation, there is need to study the performance of heat pipe with annular fins under free convection at different inclinations. This study demonstrates the effect of different mass flow rate of hot fluid into evaporator section on the condenser side heat transfer coefficient with annular fins under natural convection at different inclinations. In this study annular fins are used for the experimental work having dimensions of length of fin, thickness of fin and spacing of fin as 10 mm, 1 mm and 6 mm, respectively. The main aim of present study is to discover at what inclination angles the maximum heat transfer coefficient shall be achieved. The heat transfer coefficient on the external surface of heat pipe condenser section is determined by experimental method and then predicted by empirical correlations. The results obtained from experimental and Churchill and Chu relation for laminar are in fair agreement with not more than 22% deviation. It is elucidated the maximum heat transfer coefficient of 31.2 W/(m2-K) at 25˚ tilt angle and minimal condenser heat transfer coefficient of 26.4 W/(m2-K) is seen at 45˚ tilt angle and 200 ml/min mass flow rate. Inclination angle also affects the thermal performance of heat pipe. Beyond 25o inclination, heat transport rate starts to decrease.

Mixed Convection Heat Transfer of Copper Oxide-Heat Transfer Oil Nanofluid in Vertical Tube

In this paper, experiments were conducted to investigate the heat transfer of Copper Oxide-Heat Transfer Oil (CuO-HTO) nanofluid laminar flow in vertical smooth and microfin tubes as the surface temperature is constant. The effect of adding the nanoparticle to base fluid and Richardson number on the heat transfer enhancement is investigated as Richardson number increases from 0.1 to 0.7. The experimental results demonstrate that the combined forced-natural convection heat transfer rate may be improved significantly with an increment of mass nanoparticle concentration from 0% to 1.5%. In this experiment, a correlation is also proposed to predict the mixed convection heat transfer rate of CuO-HTO nanofluid flow. The maximum deviation of both correlations is less than 14%. Moreover, a correlation is presented to estimate the Nusselt number inside vertical smooth and microfin tubes as Rayleigh number is between 2´105 and 6.8´106 with the maximum deviation of 12%.

Numerical Solution of Transient Natural Convection in Vertical Heated Rectangular Channel between Two Vertical Parallel MTR-Type Fuel Plates

The aim of this paper is to perform, by mean of the finite volume method, a numerical solution of the transient natural convection in a narrow rectangular channel between two vertical parallel Material Testing Reactor (MTR)-type fuel plates, imposed under a heat flux with a cosine shape to determine the margin of the nuclear core power at which the natural convection cooling mode can ensure a safe core cooling, where the cladding temperature should not reach a specific safety limits (90 °C). For this purpose, a computer program is developed to determine the principal parameters related to the nuclear core safety, such as the temperature distribution in the fuel plate and in the coolant (light water) as a function of the reactor core power. Throughout the obtained results, we noticed that the core power should not reach 400 kW, to ensure a safe passive residual heat removing from the nuclear core by the upward natural convection cooling mode.

Steady State Natural Convection in Vertical Heated Rectangular Channel between Two Vertical Parallel MTR-Type Fuel Plates

The aim of this paper is to perform an analytic solution of steady state natural convection in a narrow rectangular channel between two vertical parallel MTR-type fuel plates, imposed under a cosine shape heat flux to determine the margin of the nuclear core power at which the natural convection cooling mode can ensure a safe core cooling, where the cladding temperature should not be reach the specific safety limits (90 °C). For this purpose, a simple computer program is developed to determine the principal parameter related to the nuclear core safety such as the temperature distribution in the fuel plate and in the coolant (light water) as a function of the reactor power. Our results are validated throughout a comparison against the results of another published work, which is considered like a reference of this study.

Optimization of Design Parameters for Wire Mesh Fin Arrays as a Heat Sink Using Taguchi Method

Heat transfer enhancement objects like extended surfaces, fins etc. are chosen for their thermal performance as well as for other design parameters depending on various applications. The present paper is on experimental study to investigate the heat transfer enhancement through wire mesh fin arrays equipped with horizontal base plate. The data used in performance analysis were obtained experimentally for the material (mild steel) for different heat inputs such as 40, 60, 80, 100 and 120 watt, by varying wire mesh diameter, fin height and spacing between two fin arrays. Using the Taguchi experimental design method, optimum design parameters and their levels were investigated. Average heat transfer coefficient was considered as a performance characteristic parameter. An L9 (33) orthogonal array was selected as an experimental plan. Optimum results were found by experimenting. It is observed that the wire mesh diameter and fin height have a higher impact on heat transfer coefficient as compared to spacing between two fin arrays.

Analyses of Natural Convection Heat Transfer from a Heated Cylinder Mounted in Vertical Duct

Experiments are conducted to analyze the steady-state and the power-on transient natural convection heat transfer from a horizontal cylinder mounted in a vertical up flow circular duct. The heat flux ranges from 177 W/m2 to 2426 W/m2 and the Rayleigh number ranges from 1×104 to 4.35×104. For natural air flow and constant heat flux condition, the effects of heat transfer around the cylinder under steady-state condition are investigated. The steady-state results compare favorably with that of the available data. The effects of transient heat transfer data on different angular position of the thermocouple (0o, 90o, 180o) are also reported. It is observed that the transient heat transfer around the cylinder is strongly affected by the position of thermocouples. In the transient region, the rate of heat transfer obtained at 90o and 180o are higher than that of stagnation point (0o). Finally, the dependence of the average Nusselt number on Rayleigh number for steady and transient natural convection heat transfer are analyzed, and a correlation equation is presented.

A Non-Linear Eddy Viscosity Model for Turbulent Natural Convection in Geophysical Flows

Eddy viscosity models in turbulence modeling can be mainly classified as linear and nonlinear models. Linear formulations are simple and require less computational resources but have the disadvantage that they cannot predict actual flow pattern in complex geophysical flows where streamline curvature and swirling motion are predominant. A constitutive equation of Reynolds stress anisotropy is adopted for the formulation of eddy viscosity including all the possible higher order terms quadratic in the mean velocity gradients, and a simplified model is developed for actual oceanic flows where only the vertical velocity gradients are important. The new model is incorporated into the one dimensional General Ocean Turbulence Model (GOTM). Two realistic oceanic test cases (OWS Papa and FLEX' 76) have been investigated. The new model predictions match well with the observational data and are better in comparison to the predictions of the two equation k-epsilon model. The proposed model can be easily incorporated in the three dimensional Princeton Ocean Model (POM) to simulate a wide range of oceanic processes. Practically, this model can be implemented in the coastal regions where trasverse shear induces higher vorticity, and for prediction of flow in estuaries and lakes, where depth is comparatively less. The model predictions of marine turbulence and other related data (e.g. Sea surface temperature, Surface heat flux and vertical temperature profile) can be utilized in short term ocean and climate forecasting and warning systems.

Unsteady Natural Convection Heat and Mass Transfer of Non-Newtonian Casson Fluid along a Vertical Wavy Surface

Detailed numerical calculations are illustrated in our investigation for unsteady natural convection heat and mass transfer of non-Newtonian Casson fluid along a vertical wavy surface. The surface of the plate is kept at a constant temperature and uniform concentration. To transform the complex wavy surface to a flat plate, a simple coordinate transformation is employed. The resulting partial differential equations are solved using the fully implicit finite difference method with SUR procedure. Flow and heat transfer characteristics are investigated for a wide range of values of the Casson parameter, the dimensionless time parameter, the buoyancy ratio and the amplitude-wavelength parameter. It is found that, the variations of the Casson parameter have significant effects on the fluid motion, heat and mass transfer. Also, the maximum and minimum values of the local Nusselt and Sherwood numbers increase by increase either the Casson parameter or the buoyancy ratio.

Evaluation of Heat Transfer and Entropy Generation by Al2O3-Water Nanofluid

In this numerical work, natural convection and entropy generation of Al2O3–water nanofluid in square cavity have been studied. A two-dimensional steady laminar natural convection in a differentially heated square cavity of length L, filled with a nanofluid is investigated numerically. The horizontal walls are considered adiabatic. Vertical walls corresponding to x=0 and x=L are respectively maintained at hot temperature, Th and cold temperature, Tc. The resolution is performed by the CFD code "FLUENT" in combination with GAMBIT as mesh generator. These simulations are performed by maintaining the Rayleigh numbers varied as 103 ≤ Ra ≤ 106, while the solid volume fraction varied from 1% to 5%, the particle size is fixed at dp=33 nm and a range of the temperature from 20 to 70 °C. We used models of thermophysical nanofluids properties based on experimental measurements for studying the effect of adding solid particle into water in natural convection heat transfer and entropy generation of nanofluid. Such as models of thermal conductivity and dynamic viscosity which are dependent on solid volume fraction, particle size and temperature. The average Nusselt number is calculated at the hot wall of the cavity in a different solid volume fraction. The most important results is that at low temperatures (less than 40 °C), the addition of nanosolids Al2O3 into water leads to a decrease in heat transfer and entropy generation instead of the expected increase, whereas at high temperature, heat transfer and entropy generation increase with the addition of nanosolids. This behavior is due to the contradictory effects of viscosity and thermal conductivity of the nanofluid. These effects are discussed in this work.

Theoretical Model of a Flat Plate Solar Collector Integrated with Phase Change Material

The objective of this work was to develop a theoretical model to study the dynamic thermal behavior of a flat plate solar collector integrated with a phase change material (PCM). The PCM acted as a heat source for the solar system during low intensity solar radiation and night. The energy balance equations for the various components of the collector as well as for the PCM were formulated and numerically solved using MATLAB computational program. The effect of natural convection on heat during the melting process was taken into account by using an effective thermal conductivity. The model was used to investigate the effect of inlet water temperature, water mass flow rate, and PCM thickness on the outlet water temperature and the melt fraction during charging and discharging modes. A comparison with a collector without PCM was made. Results showed that charging and discharging processes of PCM have six stages. The adding of PCM caused a decrease in temperature during charge and an increase during discharge. The rise was most enhanced for higher inlet water temperature, PCM thickness and for lower mass flow rate. Analysis indicated that the complete melting time was shorter than the solidification time due to the high heat transfer coefficient during melting. The increases in PCM height and mass flow rate were not linear with the melting and solidification times.

Influence of Gravity on the Performance of Closed Loop Pulsating Heat Pipe

Closed Loop Pulsating Heat Pipe (CLPHP) is a passive two-phase heat transfer device having potential to achieve high heat transfer rates over conventional cooling techniques. It is found in electronics cooling due to its outstanding characteristics such as excellent heat transfer performance, simple, reliable, cost effective, compact structure and no external mechanical power requirement etc. Comprehensive understanding of the thermo-hydrodynamic mechanism of CLPHP is still lacking due to its contradictory results available in the literature. The present paper discusses the experimental study on 9 turn CLPHP. Inner and outer diameters of the copper tube are 2 mm and 4 mm respectively. The lengths of the evaporator, adiabatic and condenser sections are 40 mm, 100 mm and 50 mm respectively. Water is used as working fluid. The Filling Ratio (FR) is kept as 50% throughout the investigations. The gravitational effect is studied by placing the evaporator heater at different orientations such as horizontal (90 degree), vertical top (180 degree) and bottom (0 degree) as well as inclined top (135 degree) and bottom (45 degree). Heat input is supplied in the range of 10-50 Watt. Heat transfer mechanism is natural convection in the condenser section. Vacuum pump is used to evacuate the system up to 10-5 bar. The results demonstrate the influence of input heat flux and gravity on the thermal performance of the CLPHP.

Finite Volume Method for Flow Prediction Using Unstructured Meshes

In designing a low-energy-consuming buildings, the heat transfer through a large glass or wall becomes critical. Multiple layers of the window glasses and walls are employed for the high insulation. The gravity driven air flow between window glasses or wall layers is a natural heat convection phenomenon being a key of the heat transfer. For the first step of the natural heat transfer analysis, in this study the development and application of a finite volume method for the numerical computation of viscous incompressible flows is presented. It will become a part of the natural convection analysis with high-order scheme, multi-grid method, and dual-time step in the future. A finite volume method based on a fully-implicit second-order is used to discretize and solve the fluid flow on unstructured grids composed of arbitrary-shaped cells. The integrations of the governing equation are discretised in the finite volume manner using a collocated arrangement of variables. The convergence of the SIMPLE segregated algorithm for the solution of the coupled nonlinear algebraic equations is accelerated by using a sparse matrix solver such as BiCGSTAB. The method used in the present study is verified by applying it to some flows for which either the numerical solution is known or the solution can be obtained using another numerical technique available in the other researches. The accuracy of the method is assessed through the grid refinement.