Use of Flow Network Modeling for the Design of an Intricate Cooling Manifold

The automatic test equipment designed at Teradyne requires various cooling systems to prevent the internal circuit boards from overheating. One of the water-based cooling systems includes the use of an intricate manifold. The manifold serves as the base for the mounting of the numerous liquid cooling modules spaced between circuit boards. The efficient circulation of water through this manifold is critical for the proper operation of the liquid cooling modules. The following study uses the technique of Flow Network Modeling (FNM) for a comparative study of the flow distribution in a variety of cooling manifold designs. Each of the manifold designs is modeled as a network of links and components. The FNM technique allows for the prediction of pressure differentials and volumetric flow rates at critical locations in the manifold. In the optimal design, pressure differentials between elements in the system should be at a minimum. However, due to the complexity of the manifold, this task is difficult. FNM technique allowed rapid and accurate comparison of the relative performance of different designs and suggested different design improvements. Thus, the results of the simulation aided in achieving an optimal design. Incorporation of the FNM-based analysis improved the efficiency of the manifold design process by reducing prototype design time, and design and experimental testing costs.