R&D of module and service structure
-Super module concept -
Takashi Kohriki
Content• Concept• Module(4 Hybrid-connectors)• Module (2 Hybrid-connectors)• Hybrid-Service connection• SuperModule - detail• SuperFrame• SuperModule
• End view at Z=0• End view at end• Bracket on cylinder• SuperModule on cylinder• SuperModule installation• Next step
Drawings are made with 9-chips modules for availability of CAD drawing components.
Super module concept• Fabricate and test individual mo
dules• Thin module - front-back correla
tion• Basic concept is to mount the m
odules on to cylinder• Overlapping geometry without s
ensitive gap• Module replaceability is critical• Make a row of modules into a u
nit with super-frame• Unit is testable with cooling loop
s included• Cooling might be required in bot
h sides as the heat density is 4 times higher
• Make the thermal contact of the modules and the cooling plates better
• Make the cooling pipe to slide so that the move of the pipe should not be transmitted to the module
• Mass of the super-frame could be compensated with– elimination of dog-legs of
the service harness
– reduction the number of brackets - slender and one per two modules
– Carbon-carbon cooling blocks instead of Al blocks
– length of the cooling pipe is twice, but compensated with smaller diameter and no solder (of the cooling block)
Module (4 Hybrid-connectors)
Module (2 Hybrid-connectors)
Hybrid-Service connectionMass reduction in the connection(1)Not to use a connector,two methods: (a)direct soldering,no Al conductor (b)wire-bonding,thick wire,with reinforcement(2)Use a miniature connector,three methods: (a)ZIF FPC-connector (b)Low-profile PCB-PCB connector(a la PIXEL) (c) Low-profile PCB-PCB connector(a la SCT)Note:all are similar once a reinforcement piece is included(3)Reduce the number of connectors (a)4 connectors/module(2 connectors x2 sides) (b)2 connectors/module(1 connectors x2 sides)
SuperModule - detail
SuperFrame
SuperModule
End view at Z=0
End view at end
Bracket on cylinder
SuperModule on cylinder
SuperModule installation
Next step• Calculation/estimation of the diameter of the c
ooling pipe• Thermal and Mechanical FEA calculation• Design of the service cables/harness
– Number of traces, including DCS
• Investigation of the connectors in industry• Minimization of parts• Tabulation of materials, comparison• Design of the hybrids• Manufacturing of the super-frame model for m
echanical and thermal measurements– Optimization of 3rd mounting points