Optimization of forced-air cooling system for accurate design of power converters

Finding a global optimum of power converters requires models of all its parts (semiconductors, filters and cooling system), rules to describe the interactions between the different parts, an optimality criterion and optimization routines to converge towards the best design. In this paper we implement a model of forced-air cooling system to be used in such a design process. Heat exchange between fins and forced air is described, and fluid mechanics are used to account for the interactions between the fan and the heat sink. Using these descriptions, it is shown how a given performance index can be maximized using optimization routines. The developed model is experimentally verified in the case of a custom heat sink designed with this process. Finally, we investigate the influence of different parameters such as the fan power and characteristic, base plate, heat sink dimensions and materials.