Banish PCB Thermal Problems with State-of-the-art Thermal Simulation

Company Confidential – Copyright ©2014 Slide 1
Banish PCB Thermal Problems with
State-of-the-art Thermal Simulation
Tom Gregory
6SigmaET Product Specialist

Every increasing complexity
12 Layer Boards Hundreds of components Thousands of nets
Increased Power
Density
Higher Frequency
Signals

PCB Design Challenges
Signal Integrity Power Integrity
Design for
assembly
Design for
manufacture
Design for test
Electromagnetic
Compatibility
Size Weight Cost
Mechanical
Constraints
Thermal

Why is Thermal Design Critical?
The thermal design of equipment has an impact on the:
 Performance
 Reliability
 Safety
Can you afford to make a mistake with thermal design?
 Overheating IT equipment caused Outlook and Hotmail shutdown – March 2013
 Xbox 360 thermal failure cost Microsoft $1 billion
 Ford Hybrid cars – Overheating electronics led to recall
 Sony phone Overheating Issues - Unresponsive Touch Screen

Cost of Fixing a Design Issue
Idea Design Prototype Manufacture Recall
Cost
Design Stage
Based on: ‘Error Cost Escalation Through the Project Life Cycle’ NASA Johnson Space Center

What is the Impact of a Thermal Design Issue?
Cost
 PCB redesign
 Enclosure redesign
 Additional components – heatsinks, fans
Time
 Part redesign
 Missed project deadlines
 Market opportunity missed

How can Thermal Simulation Help?
What is thermal simulation of electronics?
Prediction of:
 Temperature
 Airflow
Using computational fluid dynamics (CFD)
How can thermal simulation help you make better engineering decisions?
 Visual representation of the temperature and airflow to quickly highlight issues
 Identify overheating components before a prototype is created
 Experiment with solutions without having to prototype

Design Create Prototype Measure/Test
Fix issues
Release
Trial and Error

When should you use thermal simulation?
Simulation throughout the engineering design process
Simulation of
design concept
Simulation of
preliminary
designs
Simulation of
final design
Create prototype Verification Release

Thermal
Simulation
Software
Mechanical
Engineer
Electronic
Engineer
Specification
Product
Thermal Simulation Data Flow

What are the Benefits of using Thermal Simulation?
Save Money, Save Time!
 Perform thermal design of parts and equipment early in the design cycle
 Verify thermal design before manufacture
 Enables innovation

“But Thermal Simulation is Complicated!”
Past Current

- 6SigmaET was launch in 2009 to solve many of technical and usability challenges of existing thermal
simulation tools.
- A CFD thermal simulation tool specifically designed for the electronics industry
6SigmaET:
• Used by engineers from across the world, including Cisco, Motorola, and Bosch
• Solves for conduction, convection and radiation
Introducing 6SigmaET

Simulation Across the Electronics Industry

Intuitive Model Creation

Unique Insight

Integration with Design Tools
Import Mechanical CAD
 Import all major CAD formats
 Automatic gridding of CAD objects
 Convert to intelligent ET objects
 Simulation results plotted directly on to the CAD geometry
Import PCB Designs
 Import PCB design data through the IDF, IDX and XFL file formats
 Component positions, layer and trace information can all be imported

6SigmaET
Intelligent
Objects know what they are and how to behave
Powerful
Solve bigger. Solve faster. Solve more
Automatic
Reduce time, minimize errors
Connected
Seamlessly integrated into your design process

Modelling Objects Parametrically Defined Intelligently Placed
Parent Child
Relationship
Intelligent

Parent Child
Relationship
Intelligent

Powerful
Complex CAD
Geometry
Complex and
Detailed Models
Scalable Parallel
Solver

Automatic
Automatic Grid
Generation
Automatic Collision
and Error Detection
Automatic Report
Generation
Modelling Error

Mechanical CAD PCB Design Import Power Reporting
Connected
Reference
Designator
Power (W)
U1 5
U2 2
U3 0.2
U4 0.7

Revolutionary Solver
- Revolutionary new solver which will enable you to solve
faster, larger and in more detail than ever before
- New Gridding technique reduces the number of grid cells
required to calculate an accurate solution
- Reduces the computing resources required to solve
models

- Remove many of the limitations and inefficiencies of
existing unstructured solvers.
- Automatic grid generation refines solution grid only
where necessary to create an accurate solution.
- Complex curved geometry is no problem
- Reduces the requirement for simplification of CAD
Geometry.
Unstructured Grid

Conclusion
• 6SigmaET is designed exclusively for thermal simulation of electronics equipment and
components
• 6SigmaET is intuitive and easy to use and with R9 is even easier
• Built-in intelligence reduces the time it takes to build your model
• Importing PCB design and Mechanical CAD is simple
• Complex tasks like grid generation are automatic
• Revolutionary new solver which will enable you to solve faster, larger and in more detail than ever
before

Visit at stand J32 for a demo of
6SigmaET

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