A thermal management design challenge was an integrated vision system that generates 10 watts of heat. Additionally, because Motionloft lives outside in the sun, solar loading added significantly more heat. Our engineers managed the heat by a mix of conductive, convective, and radiant techniques. Then we optimized the product for cost and reliability.
Solar Loading
Motionloft lives outside in the sun, so solar loading was a significant factor. To be operational in the sun in Phoenix, Arizona, we had to manage the heat. Solar loading adds about 1000 Watts of additional heat per square meter to the system. This solar exposure is added to the heat generated by the device itself.
Wet / Cold Weather Resistance and Thermal Management for Motionloft
Weather resistance and thermal management were the most difficult challenges on the Motionloft project. It is an attractive product that is very weather rugged and has an integrated water seal running around the perimeter. We created a universal mounting pattern on the backside that allows it to use multiple brackets for mounting on the wall and the ceiling, indoor or outdoor.
Heat Management Starts with Best Practices
Our experienced engineers know how to move heat from here to there (from source to sink). This is a regular part of our development process for electronic systems. We created a heat sink design that connected directly to the hot electronic components to carry the excess heat away. We follow best practices for managing heat: enclosure covers, paint, and material performance.
Optimize
Heat is managed by a mix of conductive, convective and radiant techniques, which are then optimized for cost and reliability. A few general examples follow.
Image Source: ANSYS (https://www.ansys.com/blog/smart-home-technology-simulation on 10/2/2020)
Image Source: http://edge.rit.edu/edge/P15441/public/Detailed%20Design
We use thermal analysis tools such as ANSYS and SolidWorks to run heat flow simulations from source to destination to optimize system performance. For example, fin sizing can be optimized for the right amount of material usage which reduces cost and weight. This can also include a nice aesthetic as well using this technique. All came true for this product.
