While developing a portable mini android based computer, the client of Eaton had experienced issues with its new product’s reliability. The mini computer was configured to shut down when temperatures inside reached 45°C and was doing so unexpectedly during charging. For the client, time was critical as the manufacturing line was stopped to resolve this issue.
Quickly detect failure shutdown by analyzing current solution and design and make suggestions to solve the issue.
Over a weekend, Eaton developed a thermal model of the existing product and verified the model through physical testing in their lab.
Eaton conducted a CFD simulation for various concept solutions that examined heat isolation and heat transfer within the device.
Eaton discovered that:
Charging increased the battery temperature by 5.3°C but the increase in temperature is due to heat conducted from the PCB to the battery
PCB temperature results indicated that it heats up earlier than the battery to more than 45°C and results in system shutdown
With minor adjustments to the design, Eaton was able to isolate components for the product to operate in all modes
The client took Eaton’s suggestions to adjust the layout in the device to prevent future shutdown during charging and returned to manufacturing with limited delay.
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