Improving the Robustness, Thermal and Noise Performance of a Radio Transmitter Fan Tray

Abstract: With the growing demand of compact radio transmitters, so do the need for silent and efficient thermal management systems. Given the restricted form-factor, ensuring robustness of a unit with a detachable fan tray imposes a challenge. In this thesis the authors were tasked with creating a new design solution where the robustness, thermal and noise performance of the cooling system is revised. The project was initiated with an investigation of the baseline product, the AIR5322, to identify areas of in need of improvement. The initial goal was to design an integrated fan tray that would not require in-field maintenance. A literature study was performed to evaluate common integrated cooling solutions in compact electronic devices, which was then followed by concept generation study. These were then ranked based on Pugh’s selection method. An integrated solution was deemed not feasible due to the average lifespan of common fans used in this type of product. A CAD model of said design was created, for which a prototype was manufactured by Ericsson. The final design consisted of a set of 80mm Noctua (NF-A8) fans in a new fan tray, retrofitted onto a modified stock AIR5322 heatsink. Experimental tests were conducted where heat dissipation, noise generation and mechanical robustness was tested. The results concluded that the prototype design managed to reduce the temperature of the entire unit, up to 17°C cooler and lower the sound levels by up to 18 dB. The prototype, despite halving the number of fans, retained the single fan failure redundancy, as running just one fan allowed for performance that was equal to or better than the reference solution at full capacity. The prototype was deemed robust enough to withstand the drop test, which was performed at −18°C. Additional work would include to incorporate fans with an appropriate IP rating and to fully complete the testing using a climate chamber and performing impact testing.