OPTIMISING THE PERFORMANCE OF HEAT SINKS THROUGH THE USE OF HIGH-VALUE DESIGN TOOLS
THE CHALLENGE There has been a seismic shift towards electrification and a significant increase in the use of power electronics as the UK looks to achieve the Government’s net zero target by 2050. Given the global transition from combustion engines to electric motor propulsion, industries such as automotive, aerospace and the rail sector are continually trying to find ways of improving the power density for their existing systems. The challenge for the MTC was to use smart design tools such as topology optimisation to optimise an off-the-shelf heat sink, such as those found in a variable speed drive. The aim was to improve the heat transfer away from the electronic components, therefore allowing for enhanced thermal performance and a reduction in the overall weight.
MTC’S SOLUTION To address the challenge, engineers at the MTC utilised high-value design tools that could achieve the desired performance benefits for the proof-of-concept demonstrator. First, the team reverse engineered the initial design using traditional CAD software. COMSOL Multiphysics® topology optimisation was then used to remove the fins on the cross-sectional shape of the heat sink and optimised with a dendritic design to allow for a greater flow of air. Additional design work was conducted, applying a fractal approach to mimic the behaviour seen in nature and extend upon the output of the optimisation. Further design changes were made to fully utilise the additive manufacturing design freedom. This included the addition of dimples to improve the surface texturing of the heat sink which further improved the heat transfer with a reduction in the pressure drop.
This project is a great example of the power of collaboration here at the MTC. By working together and utilising the expertise across technology themes, we’ve been able to deliver a demonstrator that could have a significant impact on UK manufacturing. More specifically, our industrial members in the motorsport and aerospace industries will benefit by using this novel design methodology and will see marked gains through the enhancement in the thermal performance of their power electronics systems.
Dan Walton Technology Manager, Electrification, MTC
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