If you have ever built a house, you most certainly faced issues that went beyond a carpenter's ability to solve. For these cases, ou need an architect who has the expertise to deal with the complex problems associated with building construction. The same can be said of thermal engineering. Thermodynamics is a challenging engineering specialty, as evident by the fact that applying a uniform heat distribution to even simple geometries seldom results in uniform temperature.
For those unaccustomed to thermodynamics, achieving uniform heat, within 1°C sounds straightforward. However, achieving this seemingly simple requirement often takes extreme measures and a high level of thermal engineering expertise.
Companies tackling projects with strict heating requirements often underestimate their complexity. It may be beneficial to review whether internal resources have the experience to handle these projects in an efficient manner, or whether it is more cost effective to hire specialists to help. The latter option often ends up being the quickest and least expensive course of action if the internal resources are more productive performing other tasks or if an optimized solution is required the first time. Unfortunately, it is not until a project hits a major stumbling block that companies seek input from experts.
Thermal Experts are the Cornerstone
Like an architect, good thermal engineering specialists thoroughly document and prioritize critical project requirements, at times even forcing their clients into making difficult decisions. With these critical inputs, an effective creative process is then used to bring a wide range of technical experts together to identify all potential design and technology options.
This starting point ensures that all available heater technologies, conductive materials, insulation materials, control options, manufacturing feasibilities and application specific knowledge are considered. However, only if an organization's core competency is in thermodynamic systems, is it practical to staff the internal experts whose skills are essential to quickly conceive new concepts and evaluate their potential prior to further development.
FEA in the Toolbox
Predicting a product's temperature uniformity profile can be done by utilizing complex computational engineering tools. Software such as finite element analysis (FEA), to model conduction, radiation and convection dynamics helps save both cost and schedule by determining feasibility quickly. Additionally, FEA can provide key design insights into performance-limiting effects not readily revealed by testing.
Unfortunately, lost in the software "hype" is the appreciation that good simulation software is only comparable to having a good set of carpenter tools – it increases the carpenter's effectiveness but does not turn him into an architect. While FEA results provide valuable insight relative to specific designs, they are not responsible for creative, alternative solutions. Arriving at the best solution is more than a number crunching exercise. In thermal sciences, the key is being proficient in both the use of software tools, as well as having a depth of experience to select from a multitude of heating technologies.
Many companies are unsure when a project justifies outside expertise, yet know full well the impact of a delayed product launch including delayed revenue, opportunity cost and customer dissatisfaction. Heating problems often start out being perceived as simply a need for increased heat or uniform power yet ends up as challenging development projects. When this happens, costs go up, schedules are missed and performance is below expectations. If heating is critical to product launch, getting thermal specialists on board early can greatly enhance project success.
For more information, visit Single Iteration's web site at www.singleiteration.com or call 1-866-449-6846.
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