Simulation of Airflow Through a Test Chamber

An apparent anomaly was resolved and a correction was devised.

A computational-simulation study of the flow of air through a thermo-anemometer chamber was performed to resolve what originally seemed to be an anomaly in the measurement data obtained by use of the chamber. The thermo-anemometer chamber is a test chamber used to measure the rate of generation of heat by a device placed within it. In the original application that produced the apparent anomaly that prompted this study, the chamber was used to measure the power dissipation (as manifested by heating) in an operating power-supply inductor. The apparent anomaly was that the heating of the inductor as calculated from the measurements made by use of the chamber seemed unrealistically high.

Figure 1. The Thermo-Anemometer Chamber is an instrumented box equipped with an inlet blower and with instrumentation for measuring inlet temperature and outlet temperature and airflow speed. This is a simplified view representative of the computational model used to simulate the air flow in the chamber.
The thermo-anemometer chamber (see Figure 1) includes a thermally insulating box with inlet and outlet holes. A blower at the inlet forces air through the box. There are a thermo-anemometer and a thermometer at the outlet and a thermometer at the inlet. In principle, the rate of generation of heat by a power-supply inductor or other device in the chamber can be calculated from the outlet area, the outlet air speed (as measured by the thermoanemometer), the barometric pressure, the relative humidity, the inlet and outlet air temperatures, and the specific heat of air and water vapor. For the purpose of computational simulation, the chamber is deemed to be also equipped with an outlet tube that serves to average the flow somewhat and to help suppress vortices, which could be problematic for interpretation of simulation data.

Figure 2. This Color-Coded Plot of Axial Velocity in a meridional plane at the outlet shows the effects of laminar flow at the outlet.
The simulation of airflow in the chamber was performed by use of a computational fluid dynamics program called COSMOSFlowWorks. As a compromise between avoiding computational anomalies (necessitating a fine mesh) and avoiding excessive computation time (necessitating a coarse mesh), the chamber was divided into a computational mesh of 48,000 cells. The inlet flow speed was assumed to be constant at 5.1 m/s. Computations were performed for a series of outlet diameters ranging from 2 to 4" (5.08 to 10.16 cm).

The simulation results revealed the source of the apparent anomaly to be a combination of Bernoulli-like and laminar-flow effects at the outlet. For example, in Figure 2, which depicts results for the case in which the inlet and outlet diameters are both 3" (7.62 cm), the axial velocity at the edge of the outlet is reduced and the axial velocity in the center of the outlet exceeds the inlet velocity; the effect on the axial velocity averaged across the outlet area is equivalent to that of reducing the outlet diameter. This effect causes the thermoanemometer, located in the center of the outlet, to read a speed greater than the cross-sectional average, so that the use of this speed in estimating the heat-dissipation rate gives rise to an unrealistically high value. The simulation results make it possible to calculate an effective reduced diameter of the outlet port to correct the apparent anomaly.

This work was done by Gregory K. Ovrebo of the Army Research Laboratory.

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This article first appeared in the April, 2009 issue of Defense Tech Briefs Magazine (Vol. 3 No. 2).

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Overview

The document titled "Simulation of Air Flow Through a Test Chamber" by Gregory K. Ovrebo, published in December 2007, presents a comprehensive study on the airflow dynamics within a test chamber designed to measure heat dissipation from inductors, which are critical components in high-power electronics. Conducted by the U.S. Army Research Laboratory (ARL), the research aims to enhance the understanding of thermal management in high-density power conversion systems, particularly for military applications.

The report begins with an introduction that outlines the significance of high-power inductors and the necessity for effective cooling mechanisms to ensure their optimal performance. The study employs computer simulations, specifically using Cosmos FloWorks, to model the airflow patterns and velocities within the test chamber. This simulation approach allows for a qualitative analysis of the air movement, which is crucial for accurately measuring the heat dissipated by the inductors during operation.

In the methodology section, the document details the preparation of the model and the parameters set for the simulation. The airflow simulation results are presented, showcasing the air velocity at the chamber's outlet port and providing insights into how the airflow interacts with the inductors. These findings are essential for developing correction factors that improve the accuracy of power dissipation measurements in high-power electric components.

The results section highlights key findings from the simulations, emphasizing the importance of airflow in maintaining the thermal stability of inductors. The report concludes by summarizing the implications of the research for future developments in high-power electronics and thermal management strategies. It underscores the potential for these simulations to inform design choices and optimize the performance of inductors in various applications.

Overall, the document serves as a valuable resource for researchers and engineers in the field of high-power electronics, offering insights into airflow dynamics and their impact on thermal management. The findings contribute to the ongoing efforts to enhance the reliability and efficiency of power conversion systems, particularly in military contexts where performance and durability are paramount. The report is approved for public release, ensuring that the knowledge gained can be disseminated and utilized by a broader audience.