Agent skill

thermal-analysis

Electronic system thermal modeling and analysis skill for junction temperature calculation, heat sink selection, thermal resistance networks, and safe operating area verification.

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Additional technical details for this skill

author
babysitter-sdk
version
1.0.0

SKILL.md

Thermal Analysis Skill

Electronic system thermal modeling and analysis for reliable component operation.

Purpose

This skill provides comprehensive capabilities for thermal analysis of electronic systems, from component-level junction temperature calculations to system-level thermal management design. It supports heat sink selection, thermal interface material evaluation, and safe operating area verification.

Capabilities

Junction-to-Ambient Thermal Resistance

  • Thermal resistance network modeling
  • Junction-to-case (theta_jc) calculations
  • Case-to-sink (theta_cs) with TIM analysis
  • Sink-to-ambient (theta_sa) characterization
  • Total thermal path analysis

Heat Sink Selection and Optimization

  • Natural convection heat sink sizing
  • Forced convection performance estimation
  • Fin optimization for given constraints
  • Heat sink comparison and selection
  • Custom heat sink specification
  • Mounting and interface considerations

Forced Convection Analysis

  • Fan airflow requirements calculation
  • Pressure drop through enclosures
  • Flow impedance matching
  • Thermal resistance vs airflow curves
  • Fan operating point determination

PCB Thermal Analysis

  • Copper spreading resistance calculation
  • Via thermal conductivity
  • Multi-layer board thermal modeling
  • Hot spot identification
  • Thermal relief pad analysis

Thermal Interface Material Selection

  • TIM thermal conductivity requirements
  • Contact resistance estimation
  • Phase change vs thermal grease vs gap pads
  • Bond line thickness effects
  • Long-term reliability considerations

Transient Thermal Analysis

  • Thermal time constant determination
  • Pulse power handling
  • Foster and Cauer RC network models
  • Transient thermal impedance curves
  • Peak temperature prediction

Safe Operating Area Verification

  • SOA curve interpretation
  • DC and pulsed operation limits
  • Secondary breakdown considerations
  • Thermal runaway detection
  • Derating for reliability

Derating Curve Application

  • Temperature-based power derating
  • Maximum junction temperature limits
  • Reliability vs performance tradeoffs
  • Component-specific derating guidelines

CFD Simulation Setup Guidance

  • Boundary condition definition
  • Mesh requirements for electronics
  • Turbulence model selection
  • Radiation modeling considerations
  • Results validation approaches

Prerequisites

Installation

bash
pip install numpy scipy matplotlib pandas

Optional Dependencies

bash
# For advanced thermal modeling
pip install CoolProp  # Fluid properties

# For optimization
pip install scipy

# For visualization
pip install plotly

Usage Patterns

Thermal Resistance Network Analysis

python
import numpy as np
from dataclasses import dataclass
from typing import List, Optional

@dataclass
class ThermalComponent:
    """Represents a thermal resistance element"""
    name: str
    theta: float  # Thermal resistance (C/W)
    power: float = 0.0  # Power dissipation (W)

class ThermalNetwork:
    """1D thermal resistance network for electronics"""

    def __init__(self):
        self.components: List[ThermalComponent] = []
        self.ambient_temp = 25.0  # Celsius

    def add_resistance(self, name: str, theta: float, power: float = 0.0):
        self.components.append(ThermalComponent(name, theta, power))

    def calculate_temperatures(self, total_power: float) -> dict:
        """Calculate temperature at each node"""
        temperatures = {'ambient': self.ambient_temp}
        current_temp = self.ambient_temp

        # Work from ambient back to junction
        for comp in reversed(self.components):
            delta_t = total_power * comp.theta
            current_temp += delta_t
            temperatures[comp.name] = current_temp

        return temperatures

    def total_thermal_resistance(self) -> float:
        return sum(c.theta for c in self.components)

    def max_power_for_tj(self, tj_max: float) -> float:
        """Calculate max power for given junction temperature"""
        theta_ja = self.total_thermal_resistance()
        return (tj_max - self.ambient_temp) / theta_ja

# Example: MOSFET thermal analysis
network = ThermalNetwork()
network.ambient_temp = 40.0  # Elevated ambient

# Add thermal path components
network.add_resistance('theta_jc', 0.5)   # Junction to case
network.add_resistance('theta_cs', 0.2)   # Case to sink (TIM)
network.add_resistance('theta_sa', 2.0)   # Sink to ambient

# Calculate temperatures
power = 50.0  # Watts
temps = network.calculate_temperatures(power)
print(f"Junction temperature: {temps['theta_jc']:.1f}C")
print(f"Case temperature: {temps['theta_cs']:.1f}C")
print(f"Sink temperature: {temps['theta_sa']:.1f}C")

# Maximum power calculation
tj_max = 150.0  # Maximum junction temp from datasheet
max_power = network.max_power_for_tj(tj_max)
print(f"Maximum power at Tambient={network.ambient_temp}C: {max_power:.1f}W")

Heat Sink Selection

python
import numpy as np

class HeatSinkCalculator:
    """Heat sink thermal calculations"""

    @staticmethod
    def natural_convection_theta(length_mm: float, width_mm: float,
                                  height_mm: float, num_fins: int,
                                  fin_thickness_mm: float = 1.5) -> float:
        """Estimate thermal resistance for extruded aluminum heat sink
        using natural convection correlation"""

        # Convert to meters
        L = length_mm / 1000
        W = width_mm / 1000
        H = height_mm / 1000
        t_fin = fin_thickness_mm / 1000

        # Base area
        A_base = L * W

        # Fin spacing
        s = (W - num_fins * t_fin) / (num_fins - 1) if num_fins > 1 else W

        # Fin surface area (both sides)
        A_fins = 2 * num_fins * L * H

        # Total surface area
        A_total = A_base + A_fins

        # Natural convection coefficient estimate (typical for vertical fins)
        h = 10  # W/(m^2*K) typical for natural convection

        # Fin efficiency (simplified)
        k_al = 200  # W/(m*K) for aluminum
        m = np.sqrt(2 * h / (k_al * t_fin))
        eta_fin = np.tanh(m * H) / (m * H)

        # Effective area
        A_eff = A_base + eta_fin * A_fins

        # Thermal resistance
        theta_sa = 1 / (h * A_eff)

        return theta_sa

    @staticmethod
    def forced_convection_theta(theta_natural: float, velocity_m_s: float) -> float:
        """Estimate forced convection thermal resistance
        based on natural convection value and air velocity"""

        # Empirical correlation: forced convection much better than natural
        # Typical improvement factor
        velocity_factor = np.sqrt(velocity_m_s / 0.25)  # Normalized to typical natural
        improvement = min(velocity_factor * 3, 10)  # Cap at 10x improvement

        return theta_natural / improvement

# Example: Select heat sink for 75W dissipation
calculator = HeatSinkCalculator()

# Heat sink candidates
candidates = [
    {'name': 'Small', 'L': 50, 'W': 50, 'H': 25, 'fins': 10},
    {'name': 'Medium', 'L': 75, 'W': 75, 'H': 35, 'fins': 15},
    {'name': 'Large', 'L': 100, 'W': 100, 'H': 50, 'fins': 20},
]

power = 75  # Watts
tj_max = 125
ta = 40
theta_jc = 0.3
theta_cs = 0.15

required_theta_sa = (tj_max - ta) / power - theta_jc - theta_cs
print(f"Required theta_sa: {required_theta_sa:.2f} C/W")

print("\nHeat sink comparison (natural convection):")
for hs in candidates:
    theta = calculator.natural_convection_theta(
        hs['L'], hs['W'], hs['H'], hs['fins']
    )
    tj = ta + power * (theta_jc + theta_cs + theta)
    status = "OK" if tj <= tj_max else "FAIL"
    print(f"{hs['name']}: theta_sa={theta:.2f} C/W, Tj={tj:.1f}C [{status}]")

Transient Thermal Analysis

python
import numpy as np
import matplotlib.pyplot as plt

class TransientThermal:
    """Transient thermal analysis using Foster RC network"""

    def __init__(self, tau_values: List[float], r_values: List[float]):
        """
        Initialize with Foster network parameters
        tau_values: Time constants in seconds
        r_values: Thermal resistance contributions in C/W
        """
        self.tau = np.array(tau_values)
        self.r = np.array(r_values)

    def thermal_impedance(self, time: float) -> float:
        """Calculate Zth(t) at given time"""
        zth = np.sum(self.r * (1 - np.exp(-time / self.tau)))
        return zth

    def temperature_rise(self, power: float, time: float) -> float:
        """Calculate temperature rise for constant power"""
        return power * self.thermal_impedance(time)

    def pulsed_power_analysis(self, power: float, t_on: float, t_off: float,
                              num_pulses: int) -> np.ndarray:
        """Analyze temperature for pulsed power"""
        dt = min(t_on, t_off) / 100
        total_time = num_pulses * (t_on + t_off)
        time = np.arange(0, total_time, dt)

        temp_rise = np.zeros_like(time)

        for i, t in enumerate(time):
            # Superposition of pulse responses
            for pulse in range(num_pulses):
                pulse_start = pulse * (t_on + t_off)
                pulse_end = pulse_start + t_on

                if t > pulse_start:
                    # Add heating from pulse start
                    temp_rise[i] += power * self.thermal_impedance(t - pulse_start)
                if t > pulse_end:
                    # Subtract cooling from pulse end
                    temp_rise[i] -= power * self.thermal_impedance(t - pulse_end)

        return time, temp_rise

# Example: MOSFET transient thermal analysis
# Foster network parameters from datasheet
tau = [0.001, 0.01, 0.1, 1.0]  # seconds
r = [0.05, 0.1, 0.15, 0.2]    # C/W

thermal = TransientThermal(tau, r)

# Single pulse analysis
pulse_power = 100  # Watts
pulse_duration = 0.05  # 50ms

temp_rise = thermal.temperature_rise(pulse_power, pulse_duration)
print(f"Temperature rise for {pulse_power}W, {pulse_duration*1000}ms pulse: {temp_rise:.1f}C")

# Steady state
temp_steady = thermal.temperature_rise(pulse_power, 10.0)
print(f"Steady state temperature rise: {temp_steady:.1f}C")

Safe Operating Area Check

python
class SOAChecker:
    """Safe Operating Area verification"""

    def __init__(self, vds_max: float, id_max: float, pd_max: float,
                 tj_max: float, theta_jc: float):
        self.vds_max = vds_max
        self.id_max = id_max
        self.pd_max = pd_max
        self.tj_max = tj_max
        self.theta_jc = theta_jc

    def check_dc_operation(self, vds: float, id: float, tc: float) -> dict:
        """Check if operating point is within DC SOA"""
        power = vds * id
        tj = tc + power * self.theta_jc

        checks = {
            'vds_ok': vds <= self.vds_max,
            'id_ok': id <= self.id_max,
            'power_ok': power <= self.pd_max,
            'tj_ok': tj <= self.tj_max,
        }

        checks['all_ok'] = all(checks.values())
        checks['power'] = power
        checks['tj'] = tj

        return checks

    def max_current_at_voltage(self, vds: float, tc: float) -> float:
        """Calculate maximum current at given voltage and case temp"""
        # Power limit based on Tj
        max_power_thermal = (self.tj_max - tc) / self.theta_jc
        max_power = min(max_power_thermal, self.pd_max)

        # Current limited by power
        id_power = max_power / vds if vds > 0 else self.id_max

        # Take most restrictive limit
        return min(id_power, self.id_max)

# Example: MOSFET SOA check
soa = SOAChecker(
    vds_max=100,  # V
    id_max=50,    # A
    pd_max=200,   # W
    tj_max=150,   # C
    theta_jc=0.5  # C/W
)

# Check operating point
result = soa.check_dc_operation(vds=40, id=4, tc=80)
print(f"Operating point check: {result}")

# Generate SOA curve
vds_points = np.logspace(0, 2, 50)  # 1V to 100V
id_curve = [soa.max_current_at_voltage(v, 80) for v in vds_points]
print(f"Max current at Vds=40V, Tc=80C: {soa.max_current_at_voltage(40, 80):.1f}A")

Usage Guidelines

When to Use This Skill

  • Component thermal verification during design
  • Heat sink selection and specification
  • Thermal interface material selection
  • PCB thermal management design
  • Failure analysis of overheated components

Best Practices

  1. Use manufacturer thermal data when available
  2. Add margin to thermal calculations (typically 10-20%)
  3. Consider worst-case ambient temperature
  4. Account for aging of TIMs and fans
  5. Verify calculations with thermal measurements
  6. Document thermal assumptions in design reviews

Process Integration

  • ee-switching-power-supply-design (thermal management)
  • ee-motor-drive-design (power stage thermal)
  • ee-hardware-validation (thermal characterization)
  • ee-dfm-review (thermal design review)

Dependencies

  • numpy: Numerical calculations
  • scipy: Optimization for heat sink selection
  • matplotlib: Thermal visualization

References

  • Ellison, G. "Thermal Computations for Electronics"
  • Sergent & Krum, "Thermal Management Handbook"
  • Application Notes from Infineon, ON Semi, TI

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