What is product simulation
- A virtual product design validation process
- Computer-based calculation
- For estimating and verifying the product properties
(thermal, mechanical…) or comparing different designs
Why we need product simulation
- Evaluate the feasibility of the design throughout the whole product development stages
- Accelerate the R&D process
- Save the sample preparation time and cost
What can we get from the product simulation
Thermal properties
Thermal resistance (℃/W)
Temperature plot
Fluid dynamics properties
1.Heatsink P-Q curve
2.Radiator P-Q curve
3.Fan P-Q curve
4.Pump P-Q curve
Mechanical properties
Product deformation under specific spring loading
What product can we simulate
- Component level
1. Air cooler: 1U, 2U, 3U, active, passive, heat pipes, VC, etc.
2. Liquid cooler: cold plate, radiator, fans - System level
1. Sever chassis
2. Sever cabinet
3. PC case
Information needed for the simulation
1. Product 3D design files (3D CAD)
2. Product materials specification
3. Environment: ambient temperature, air flow rate
4. Heater power and materials
5. Fan & pump properties if needed
6. Other specified information
A new simulation run is needed if any of the items above is changed.
Simulation time
- 3D file pre-processing and simulation environment set up
Usually 0.5 hrs.~2.5 hrs., depends on the product complexity
Component level simulation
Air cooler: Usually 10~30 mins for each run
Liquid cooler: Usually 1~3 hrs. for each run - System level simulation
Usually 4hrs. ~ 1 day for each run
Simulation procedure
1. Sales and engineers collect product requirement from the clients
2. Perform the product simulation run according to the product requirement
3. Send simulation results to client for reviewing
4. Revise the product and run the simulation if there’s any feedback from client
5. Physical sample prepare and test
6. Revise the product and run the simulation based on the physical sample test (if needed)
Case example（An air cooler project）
- Component level
1. Air cooler: 1U, 2U, 3U, active, passive, heat pipes, VC, etc.
2. Liquid cooler: cold plate, radiator, fans - System levClient requirement: aim to beat a market model A
Simulation tools used when performing
1. Thermal resistance simulation at the initial design stage
2. Fin pitch/thickness optimization
3. Fin tower size optimization
4. Heat pipe position arrangement optimization - Simulation results and physical sample test on the thermal resistance(℃/W)
