I agree, you're a well-rounded engineer capable of solving problems with simple solutions even when they are outside of your discipline. I wish you worked for me, of course, we don't allow smoking in our building.
Excellent work Rob. Delivering 1000 units a month sounds challenging enough. This thermal problem benefitted from the application of aerodynamics. And a clever cost effective design to follow. Seems as though being multi-disciplinary is an asset to many machine designs...
Brilliant engineering indeed! The problem with laminar flow cooling is that there is always a sttagnation zone covering all the fixed surfaces, and the velocity gradient rising as you move away from those surfaces. Finding the cost-effective means of getting turbulent flow was the engineering end of the solution. Good job indeed.
I took some photo's of the only unit I had.. My original Prototype which was prior to the design completion of the said thermal solution and Origami cables. I hope this illustrates the point.
Basically I prevented the air from flowing over top the PSU which had a 1/4" gap or so by blocking that with a plastic cover and created more turbulence with a front opening that also increased the linear air velocity which significantly reduces hot spot temperature rise inside the power supply (PSU). In this case form Lambda. THis prototype was built 4 weeks after a paper napkin design spec and was later finished 3 weeks later and hand delivered to AVAYA in Denver.
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