Thermal Simulation & cooling Concepts

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PRACTICAL, EFFICIENT & INNOVATIVE

We develop, optimize, and verify climate control concepts on behalf of our clients. Where technical equipment, complex systems, and power electronics must operate safely and flawlessly, an optimally controlled heat dissipation solution is essential. Thermal simulation forms the foundation of this process. With the professional use of 3D simulation systems, we can precisely calculate the cooling requirements of a product, a specific component, or an entire system and deliver fast and reliable results.

Our primary goal is to significantly extend the lifecycles of electronic components and entire technical systems while minimizing energy consumption and reducing maintenance costs. The physics behind these processes is complex, but Delta IDL makes it visible to you by visualizing cause and effect.

Shorter Time-to-Market Through Numerical Analysis

Competitive pressure in modern industry demands increasingly shorter development cycles. A faster time-to-market is often the decisive factor in the commercial success of new products. By using Computational Fluid Dynamics (CFD) analysis, there is no longer a need to build expensive and time-consuming physical prototypes for every iteration. The advantages of numerical simulation at a glance:

Location/climate simulation: Realistische Vorhersage der thermischen Leistung ohne realen Materialeinsatz.
Prototype optimization: Quick identification and evaluation of critical areas (hotspots).
Simultaneous engineering: Simple optimization through simultaneous component modification directly on the computer.
Existing product verification: Simple and cost-effective verification of existing products and systems.
Data-driven approach: Quick results based on standardized CAD data and models.
Resource conservation: Significant cost and time savings in development, tooling, prototyping, material usage, and by eliminating the need for complex physical measurements.

Fundamentals of Heat Transfer: A Focus on Thermodynamics

To effectively manage heat transfer, it is necessary to understand and calculate the three fundamental mechanisms of heat transfer. Every component and every system interacts dynamically with its environment.

Heat Conduction

Heat conduction refers to the transfer of heat within solid materials or between components that are in direct contact with one another. Material properties, particularly thermal conductivity, play a decisive role in this process.

Heat Transfer by Convection

Convection is the transfer of heat through the flow of fluids, typically air or liquid coolants. We distinguish between natural (buoyancy caused by temperature-induced density differences) and forced convection (driven by fans or pumps). In many devices, forced convection is the primary method of heat dissipation.

Thermal Radiation

Every object emits thermal radiation depending on its temperature and surface properties. Especially at high absolute temperatures, in the absence of convection, or in a vacuum, radiation can account for a significant portion of the total heat transfer and must be included in the simulations.

Causes and Risks: Thermal Stresses

Temperature is not only a factor affecting electronic performance but also mechanical safety. When materials are heated, they expand. This process is defined by specific coefficients of expansion. If components made of different materials (for example, on a printed circuit board) are exposed to varying temperature gradients or significant temperature fluctuations, they expand to different degrees.

FEM Simulation for Structural Mechanical Analysis

While CFD analysis calculates flow patterns and temperatures, the finite element method (FEM simulation) can be used to determine the resulting mechanical effects on the design. If we know the temperature distribution of an object, the stress and behavior of the materials under heat can be accurately calculated. This can provide essential information for the design process, allowing weak points to be addressed early on through adapted geometries or alternative materials.

Thermal Simulation: Typical Applications

Thermische Simulation & Klimatisierungskonzepte

Enclosure Climate Control

Thanks to our experience and the use of 3D simulation systems, we can deliver quick results for climate control and to ensure the functionality of system integrations. This is particularly important in areas where sensitive equipment is operated in devices, enclosures, and containers, or under extreme outdoor and/or indoor conditions.

Electronic Cooling

High power dissipation places increasing demands on thermal management. CFD analysis in electronic cooling applies to virtually all aspects of component, board, enclosure, cabinet, and fan design. Only by a detailed temperature distribution analysis critical hotspots can be avoided in a timely manner.

Fan Management

Operating conditions, efficiency, and flow fields can be determined using the corresponding performance curve—with numerically precise adjustment of the actual operating point. This is helpful for the targeted selection of fan types and facilitates the adaptation or optimization of systems. Here, proper airflow management is crucial for overall performance.

Heat Sink Sizing

Using CFD for heat sink sizing allows us to analyze all relevant boundary conditions and influencing factors simultaneously, in a realistic manner, and while taking nearly all interdependencies into account. This enables us to quickly assess cooling performance even before the first prototype is manufactured from copper or aluminum.

Challenges in Today’s Thermal Management

Due to extremely high power dissipation and ever-shrinking component sizes, the demands on modern thermal management solutions are growing rapidly. Engineers regularly face the challenge of dissipating enormous heat loads in very confined spaces. Among the biggest problems are hotspots, thermal interference from adjacent heat sources, as well as inefficient airflow, recirculation, and/or air short-circuiting. Only thorough calculation and optimization can ensure long-term, trouble-free operation in these cases.

Herausforderungen im heutigen Wärmemanagement

Our CFD Project Workflow: Step by Step to a Solution

To ensure the highest quality, transparency, and cost-efficiency, we follow a strictly standardized project workflow. This structured process ensures that all relevant physical boundary conditions are taken into account.

1. Customer Inquiry and Feasibility Study

Every project begins with your inquiry. You provide us with initial information about the project, model sketches, and basic parameters. We then conduct a feasibility study—in many cases, directly on-site at your facilities or in your building.

2. Detailed Proposal

Based on the initial information, we prepare a transparent proposal. This includes a project plan with a detailed estimate of the effort, time, and possible alternatives.

3. Provision of Geometry Data and Thermal Boundary Conditions

Once the order is placed, your project data forms the foundation of our simulation. To ensure an efficient workflow, we distinguish between the essential mechanical basis and the more flexible parameters:

4. Computational Model and Mesh Generation

This phase entails the actual modeling process. We generate the computational model and the computational mesh (meshing). During this process, the CAD data is prepared, data is reconciled, and missing parameters are added by our experts.

5. Current Status Analysis of the Models

The first simulation run produces the current status analysis and reveals the current thermal behavior of the proposed system. These results serve as the starting point for all further measures and techniques aimed at product optimization and temperature reduction.

6. Optimization and Variant Analysis

Based on the assessment of the current state, we develop concrete optimization proposals and conduct systematic variant analyses. In doing so, we specifically adjust parameters such as heat sink geometries, materials, fan positions, and housing openings.

7. Presentation of Results and Documentation

Transparency is important to us. We will present the calculation results to you (on-site at your facility, if desired). The presentation includes the model, a list of all boundary conditions, and a detailed explanation of the result graphs (including temperature distribution and flow vectors).

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Individuelle Evaluation Ihrer Projektanforderungen

Customized Assessment of Your Project Requirements

Every thermal system is subject to specific physical conditions. We would be happy to assess the technical feasibility and requirements of your specific project through direct consultation. Please contact us to discuss your specific thermal challenges or existing CAD data with no obligation.

To provide an initial, well-founded understanding of our methodology, we have summarized the answers to the most fundamental questions regarding CFD analysis below:

FAQ: Frequently Asked Questions About Thermal Simulation

1. What exactly is a thermal simulation (CFD analysis)?

A thermal simulation, often referred to as CFD analysis (Computational Fluid Dynamics), is a computer-aided method for calculating and visualizing temperature distributions, heat fluxes, and fluid flows (such as air or water) in and around solid objects. It helps engineers virtually optimize thermal management before physical prototypes are built.

2. At what stage of development does it make sense to use simulation?

It is worth using simulation as early as possible. Ideally, simulation should be used as early as the concept or initial design phase. The earlier thermal issues (hotspots) are identified, the more cost-effectively they can be resolved. However, even for projects that have already been completed, a retrospective analysis can reveal valuable optimization potential, thereby increasing both functional and design reliability.

3. What data is required for a conclusive simulation?

We need mechanical data, such as 3D models or CAD data, as a basis. In addition, information on the power dissipation of the components, the desired boundary conditions (such as ambient temperature), and, ideally, details about the planned materials and fan characteristics is important.

4. What happens if I don’t have all the thermal data for my components?

This is often the case in practice. If specific manufacturer specifications or material properties are missing, our experts can rely on well-founded average values, estimates, and industry-specific empirical data for unknown parameters to ensure that the model is still highly realistic.

5. How do computational fluid dynamics (CFD) and structural mechanics (FEM) work together?

CFD software primarily uses flow simulation to calculate how fluids (gases/liquids) move and how temperatures are distributed. Structural mechanics simulation typically uses the finite element method (FEM) to calculate, based on this temperature data, whether thermal stresses can lead to mechanical deformation, cracks, or component failure.

6. How does simulation help reduce development resources?

Since thermal behavior is simulated on a computer, fewer physical prototypes need to be built. This saves on materials, tooling costs, and expensive measurement and lab time. In addition, different design variants can be virtually tested and compared in a very short amount of time.

7. Can existing, already installed systems also be optimized?

Yes, that is possible. Thermal simulation is ideal for analyzing the current state of existing systems that, for example, are experiencing thermal issues in the field. We create a virtual model of the system, identify the source of the problem, and develop minimally invasive retrofit solutions (such as modified airflow paths or additional fans).

8. How long does a typical CFD project take?

The efficiency of a thermal simulation is largely determined by the quality of the data provided and the defined objectives. While we can often complete focused feasibility studies on very short notice, in-depth system optimizations require iterative refinement of the design variants. Our structured project workflow guarantees maximum transparency: We define the concrete project plan together in advance to ensure a precise handover of the results.

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