The Diploma thesis is focused on reballing of BGA packages with the device PACE TF 2700. It describes the general types of BGA packages, their defects, importance of thermal management to the solder techniques, where it is also talked about the meaning of solders and fluxes for the joint. The work informs about the most common methods of reballing, the proper handling of components and the current situation with BGA stencils on the market. It briefly describes the device operation of PACE TF 2700, that is working on the convection and IR principle of heating components. It deals with the manufacturing of the template, dummy BGA packages, the test plates, creation of the thermo profile, comparing and examining the defects and their causes, which had the most significant impact on the results. The achievements would serve for comparing them with the results of the future laboratory exercises or as a subject for further works.

Ein Brennstoffzellenfahrzeug besteht aus vielen Teilsystemen, zu denen neben der Brennstoffzelle auch Hybridbatterie, Wärmepumpe, Tanksystem, Fahrgastzelle sowie Traktionsmaschine und Leistungselektronik gehören. Jedes dieser Systeme hat bezüglich Temperaturen und Kühl- bzw. Erwärmungsbedarf, je nach Betriebspunkt, unterschiedliche Anforderungen und benötigt für den Betrieb ein Thermomanagementsystem. Im Rahmen der aktuellen Forschungen wird untersucht, ob durch die Verwendung eines aktiven Thermomanagementmoduls die Teilsysteme des Fahrzeugs derart verknüpft werden können, sodass eine Effizienzsteigerung des Gesamtsystems erreicht werden kann. Da sich je nach Betriebszustand und Umgebungsbedingungen Größe und Richtung der Wärmeströme ändern, wird mittels eines simulationsbasierten Ansatzes eine Strategie für die Regelung des Thermomanagementmoduls entwickelt. In dieser Veröffentlichung soll dargestellt werden, welche Vorüberlegungen getroffen wurden, um ein Konzept für ein ganzheitliches Energiemanagement für ein Brennstoffzellenfahrzeug zu entwickeln.

<p>Due to increasing regulation on emissions and shifting consumer preferences, the wide adoption of battery electric vehicles (BEV) hinges on research and development of technologies that can extend system range. This can be accomplished either by increasing the battery size or via more efficient operation of the electrical and thermal systems. This thesis endeavours to accomplish the latter through comparative investigation of BEV integrated thermal management system (ITMS) performance across a range of ambient conditions (-20 °C to 40 °C), cabin setpoints (18 °C to 24 °C), and six different ITMS architectures. A dynamic ITMS modelling framework for a long-range electric vehicle is established with comprehensive sub models for the operation of the drive train, power electronics, battery, vapor compression cycle components, and cabin conditioning. This modelling framework is used to construct a baseline thermal management system, as well as for adaptation to four common systems. Additionally, a novel low-temperature waste heat recovery (LT WHR) system is proposed and shown to have potential benefits at low ambient temperatures through the reduction of the necessary cabin ventilation loading. While this system shows performance improvements, the regular WHR system offers the greatest benefit for long-range BEV drive cycles in terms of system range and transient response. With an optimal thermal management system found for long range BEV’s this system is then used as a boundary condition for a study on cooling of the battery. Battery conditioning, health, and as a result their along cell and system lifetime remains an additional concern of consumers as well as thermal systems engineers seeking to ensure safety and ensure longevity of EV battery cells. Three typical coolant flow orientations are studied to compare them under different flow conditions and thermal interface material performance. The battery cooling model is then coupled to the previously established dynamic modelling environment to demonstrate the added modelling capability (and necessity) for incorporating module-level cooling performance in both battery cooling studies and transient ITMS environments. </p>

Das Thermomanagement in Brennstoffzellenfahrzeugen (FCEV) stellt eine komplexe Herausforderung dar. Insbesondere, wenn im Zuge thermischer Optimierungen, wie sie bereits im Bereich batterieelektrischer Fahrzeuge etabliert sind, komplexe Verschaltungen der beteiligten Fahrzeugsysteme vorgenommen werden. Im Rahmen des Forschungsprojektes HZwo:InTherm wurden an der TU Chemnitz verschiedene Ansätze zur Simulation von Thermomanagementstrukturen in Brennstoffzellenfahrzeugen (FCEV) sowohl in Matlab/Simulink als auch in KULI untersucht. Augenmerk lag hierbei auf einem stabilen Zusammenspiel der Teilsysteme Brennstoffzelle, Hybridbatterie, Tanksystem, Wärmepumpe, Fahrgastzelle sowie Traktionsmaschine und Leistungselektronik. Als besondere Herausforderung zeigte sich hierbei die Simulation geschlossener Kühlkreisläufe mit inkompressiblem Kühlmedium sowie die Umsetzung eines möglichst generalisierten Modellaufbaus für die implementierten Teilmodelle. Im Rahmen dieses Beitrags sollen sowohl die Modellierungsansätze als auch die erzielten Ergebnisse vorgestellt und diskutiert werden. / Thermal management in fuel cell electric vehicles (FCEV) poses a complex challenge. Especially for thermal optimisations with complex interconnections, as it is already state of the art in battery electric vehicles. Within the research project HZwo:InTherm different approaches for the simulation of thermal management systems of FCEV have been under investigation, in both Matlab/Simulink as well as in KULI. Focus was the stable interaction of the subsystems fuel cell, hybrid battery, tank system, heat pump, passenger cabin as well as traction motors and inverters. A particular challenge is the simulation of a closed coolant loop with incompressible coolant liquid and its model realization with generalized model structures for the different parts of the model. This article presents both the modelling approach as well as the simulation results.

Within the company Infinera, there is a need for an improved thermal design of an existing chassis product for use in telecommunications for distribution of services within the Edge &amp; Metro network. To enable an optimized airflow design of the chassis, there is a need of analyzingdifferent simulation cases performed in FloTHERM. Mechanical and electrical airflow design has been examined in different cases that cover the system requirements.Thermal analyzes of the product have been performed using the FloTHERM tool, and changes and improvements to the design have been performed via the CAD SolidWorks software tool.Problem formulation for this thesis is to further develop the design of the chassis for improved airflow for electrical and optical components that are placed in an existing chassis for the temperature range of 0-70 ℃ according to the industry standard NEBS (Level 3). The slot-in card has been analyzed in a worst-case scenario to identify the most critical components on the PCB board. The result that has been achieved is six different simulation cases with different airflow designs and models of fans that are adapted to today's existing chassis. An updated final version based on simulation results has been modeled as a proposal for the product in the CAD program. A 2D drawing of the design of the product is included as an appendix.The conclusion of this work has shown an improved airflow design on a chassis with a side-byside airflow configuration with the use of four replaceable fans within a fan bay. A bypass block ontop of the cover has shown good results as a cooling method on electrical and optical components. In this work, due to limited time, the bypass block has not been completed as a 3D modeling part. This will be continued as a suggested future work. In addition, a front-to-side airflow design has been analyzed in FloTHERM, this can also be further developed and investigated in more detail in future work for an optimized airflow design of the chassis.Keywords: Airflow systems for electronics, thermal management, telecommunication equipment, airflow resistance, cooling of electronics. Keywords: Airflow systems for electronics, thermal management, telecommunication equipment, airflow resistance, cooling of electronics. / Inom företaget Infinera finns det ett behov av en förbättrad termisk design av en existerande chassiprodukt för användning inom telekommunikation för distribution av tjänster inom Edge &amp;Metro nätverk. För att kunna optimera luftflödet av chassit behövs termiska simuleringar utförastillsammans med mekaniska och elektroniska designflöden för att kunna undersöka luftflödet i olika situationer som täcker systemkraven. Termiska analyser på produkten har utförts genom simuleringsverktyget FloTHERM, samtförändringar och förbättringar av konstruktionen har utförts via programverktyget CAD SolidWorks. Problemformulering för det här examensarbetet är att vidareutveckla designen för chassit för ett förbättrat luftflöde för elektriska och optiska komponenter som placeras i ett existerande chassitför temperaturområdet 0–70 ℃. Samt att chassit förhåller sig till bransch standarden NEBS (Nivå 3) och analyseras i värsta utfallscenariot av ett slott-in kort.Det resultat som har uppnåtts är sex olika utfall av chassit med olika luftflödes design och modeller av fläktar som är anpassade för dagens chassiprodukt med uppföljda kravkriterier. En uppdaterad slutgiltig version baserat på simuleringsresultat har modellerats som förslag på produkten i CAD programmet. En 3D ritning på designen av produkten medföljs som bilaga. Slutsatsen för det här arbetet i syfte till ett förbättrad luftflödes design är ett chassi med en sida-tillsida luftflödes design med fyra utbytbara fläktar i ett utbytbart fläktpaket. Ett nedsänkt tak i chassit ovanför kortet har visat goda resultat som en kylningsmetod på elektriska och optiska komponenter. I detta arbete, på grund av begränsad tid, har ett nedsänkt tak inte fullföljts som en 3D modellering som en tillhörande del av chassit. Ett sänkt innertak kommer att behövaskompletteras i ett fortsatt arbete för framtiden. Även en luftflödesdesign som har undersökts framifrån-till-sida av chassit i FloTHERM kan vidareutvecklas och undersökas närmare i ett framtida arbete för en optimerad luftflödesdesign av chassi produkten. Nyckelord: Luftflödessystem för elektronik, termisk hantering, telekommunikations applikationer, luftflödesmotstånd, kylning av elektronik. Nyckelord: Luftflödessystem för elektronik, termisk hantering, telekommunikations applikationer, luftflödesmotstånd, kylning av elektronik

This thesis explores the possibility of using an optimal control scheme called Model Predictive Control (MPC), to control climatization systems for electric vehicles. Some components of electric vehicles, for example the batteries and power electronics, are sensitive to temperature and for this reason it is important that their temperature is well regulated. Furthermore, like all vehicles, the cab also needs to be heated and cooled. One of the weaknesses of electric vehicles is their range, for this reason it is important that the temperature control is energy efficient. Once the range of electric vehicles is increased the down sides compared to traditional combustion engine vehicles decrease, which could lead to an increase in the usage of electric vehicles. This could in turn lead to a decrease of greenhouse gas emission in the transportation sector. With the help of MPC it is possible for the controller to take more factors into consideration when controlling the system than just temperature and in this thesis the power consumption and noise are also taken into consideration. A simple model where parts of the climate system’s circuits were seen as point masses was developed, with nonlinear heat transfers occurring between them, which in turn were controlled by actuators such as fans, pumps and valves. The model was created using Simulink and MATLAB, and the MPC toolbox was used to develop nonlinear MPC controllers to control the climate system. A standard nonlinear MPC, a nonlinear MPC with custom cost functions and a PI controller where all developed and compared in simulations of a cooling scenario. The controllers were designed to control the temperatures of the battery, power electronics and the cab of an electric vehicle. The results of the thesis indicate that MPC could reduce power consumption for the climate control system, it was however not possible to draw any final conclusions as the PI controller that the MPC controllers were compared to was not well optimized for the system. The MPC controllers could benefit from further work, most importantly by applying a more sophisticated tuning method to the controller weights. What was certain was that it is possible to apply this type of centralized controller to very complex systems and achieve robustness without external logic. Even with the controller keeping track of six different temperatures and controlling 15 actuators, the control loop runs much faster than real time on a modern computer which shows promise with regard to implementing it on an embedded system.

京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第21129号 / 工博第4493号 / 新制||工||1698(附属図書館) / 京都大学大学院工学研究科化学工学専攻 / (主査)教授 宮原 稔, 教授 山本 量一, 教授 佐野 紀彰 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

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I detta examensarbete simuleras ett värmehanteringssystem i Matlab Simulink för en elektrisk lastbil, det för att värmehantera fordonets klimat. Där en värmepump används för nedkylning av kupé och batteri samt en PTC (elektrisk värmare) för uppvärmning av detsamma. Värmepumpen fungerar genom att kompressorn förångar R-134a kylmedlet i systemet som sedan omvandlas till vätska vid nedkylning av kondensorn som utbyter energi med omgivande luften. Vätskan skickas vidare till en mottagare som filtrerar kylmedlet för att sedan överföras till en expansionsventil som kontrollerar trycket i systemet. Vätskan går sedan till evaporatorn för att kylas ned av ett utbyte med varmare omgivande luft från kupén, därefter börjar nedkylningsproessen om. PTC värmaren har en passiv uppvärmningsfunktionaliteten som tar emot ström genom ett motstånd och värmer komponenten med hjälp av en vattencykel. Batteriets räckvidd minskar vid fel temperaturer därav kan batteriets temperatur kontrolleras i drift. Det för att teoretiskt öka räckvidden på fordonet genom att ha batteriet vid en mer gynnsam temperatur. En förstudie genomförs där data samlas in för att sedan modellera och redovisa simulerade resultat som åstadkoms för olika scenarion med uppvärmning och nedkylning. Det visar sig att systemets batteri tar för lång tid vid nedkylning och uppvärmning på grund av dess stora massa. Detta då batteriet inte når måltemperaturen under simuleringens gång som körs i 1 timme och därav inte efter komforttiden som är 10 minuter. Vidare når kupéns delar önskad temperatur inom simuleringstiden förutom under kupéns nedkylning där taket kyls långsammare än önskat. Den enda delen av kupén som uppnår komforttiden är kupéns sidor vid uppvärmning. Vilket betyder att optimeringar på systemet bör tillämpas för att åstadkomma bättre och mer realistiska resultat. / In this thesis, a thermal management system is simulated in Matlab Simulink for an battery electric truck, in order to thermally manage the vehicle's climate. A heat pump is implemented to cool down the cabin and battery while a PTC (electric heater) is implemented to heat the systems respectively. The heat pump works by the compressor vaporizing the R-134a refrigerant in the system, which is then converted to liquid when cooled by the condenser, which exchanges energy with the surrounding air. The liquid is sent further to a receiver that filters the refrigerant and is then transferred to an expansion valve that controls the pressure in the system. The liquid then goes to the evaporator to be cooled by an exchange with warmer ambient air from the vehicle cabin, after which the cooling process begins again. The PTC heater has a passive heating functionality that receives current through a resistor and heats the component using a coolant loop. The battery's range is reduced at incorrect temperatures, therefore the battery's temperature can be checked during operation. This is to theoretically increase the range of the vehicle by having the battery at a more favorable temperature. A pre-study is carried out where data is collected to then model, and present simulated results that were achieved for different scenarios with heating and cooling. It turns out that the system's battery takes too long to cool down and warm up due to its large mass. This is because the battery does not reach the target temperature during the course of the simulation, which is run for 1 hour, and therefore not after the comfort time which is 10 minutes. Furthermore, the parts of the cabin reach the desired temperature within the simulation time, except during the cooling down of the cabin, where the roof cools more slowly than desired. The only part of the cabin that achieves the comfort time is the sides of the cabin when heated. Which means that optimizations to the system should be applied in order to achieve better and more realistic results.

Aggressive demands for high power density and low-cost power modules in the automotive sector pose significant challenges to the thermal management systems. These challenges necessitate adopting highly effective cooling technologies in power modules to remain competitive in the semiconductor industry. Furthermore, the thermal management strategy must be simple, easy to integrate, compact, effective, efficient, reliable, and economical. This thesis is an effort to investigate the impact of fin geometry on the overall performance of finned-type liquid-cooled power electronic modules in electrified transportation. The cooling system's performance metrics, including thermal resistance, pressure drop, pumping power, and mass, are discussed in depth. Various cooling technologies are benchmarked. The finned-type cooling technique is chosen over other methods due to simplicity and low pressure drop. Integrated cooling or direct cooling of the module’s baseplate is selected due to considerable thermal resistance reduction because of thermal grease elimination. Potential fabrication techniques are thoroughly explored and compared in terms of mass production and prototyping suitability. Four different fin shapes, including circular (baseline), drop-shaped, symmetric convex lens, and offset strip in the staggered arrangement, are studied herein. The cooling agent is Water and Ethylene Glycol 50% volumetric mixture (WEG 50%). Typical operating conditions in electrified vehicles (EVs) such as flow rate and inlet temperature are assumed for the numerical analysis. A grid convergence study is carried out to ensure numerical solutions are within an acceptable error band. The thermal performance evaluation results showed that, on average, offset strip, drop-shaped, and the convex lens performed 39%, 20%, and 6% better than the baseline design, respectively. Additionally, the design candidates are compared in terms of mass and estimated machining cost. The results of the baseline case are verified against empirical correlations from the literature. The maximum deviation is less than 1% and 1.2% for finned-surface temperature and pressure drop, respectively. The difference is attributed to the end-wall effects. / Thesis / Master of Applied Science (MASc)