SPEC SHEET S-04 · REV A · UPDATED SEP 2026

S-04 · THERMAL

Will it overheat? Temperatures and margins you can put in front of an approver.

Steady and transient thermal analysis of electronics, electrical equipment, enclosures and structures — every heat source traced to a datasheet, every boundary condition stated, and every temperature compared with the limit that matters.

ρcₚ ∂T/∂t = ∇·(k∇T) + q̇T_max vs. T_limitmargin [K]

Submit a Problem Statement Sample report outline ↓

[✓] NDA before data exchange[✓] Fixed scope & price[✓] Independent internal check

FIG. 1 — Heat spreading from a source SCHEMATIC coldhot

S-04 · AT A GLANCESPEC

TYPICAL SCOPE: Power electronics, electrical cabinets and switchgear, transformers, enclosures, heat sinks, structures
DELIVERABLE: Signed PDF report, temperature and margin tables, field plots; temperature fields for FEA on request
LEAD TIME: Agreed in the written scope
ANALYSES: Steady · transient · CHT with CFD · thermal–electric · thermal stress
CONFIDENTIALITY: NDA signed before any file is exchanged
QUALITY: Energy balance and hand check in every report

Get a scoped quote →

01 / WHEN YOU NEED IT

Questions this analysis answers.

Thermal problems cost twice: once in derated or failed components, and again in oversized cooling you pay for on every unit.

We start from the limit that matters — a junction temperature, an insulation class, a touch temperature — and build the model around the heat path that decides it.

Q1Will every component stay below its temperature limit?→ Steady-state thermal + margins

Q2How long can it run at overload before it overheats?→ Transient thermal, duty cycles

Q3Is the heat sink or fan big enough — or too big?→ Cooling design & sizing

Q4Why is this part running hot in the field?→ Root cause with measured data

Q5Will temperature differences crack the joint?→ Thermal stress → S-01

Q6Is the surface safe to touch?→ Touch-temperature check

02 / DELIVERABLES

What you receive. In writing, before we start.

Each item is listed in the scope document you sign off. Nothing on this list is a surprise at the end.

PDF

Technical report

Scope, heat loads, assumptions, model, results and conclusions. Signed and revision-controlled.

XLSX · PDF

Temperature & margin tables

Temperature and margin to the limit for every critical component, per operating point.

IN REPORT

Temperature field plots

Temperatures and heat paths on the surfaces and sections that explain the result.

ON REQUEST

Temperature fields for FEA

Mapped temperature fields for thermal-stress analysis.

APPENDIX

Verification appendix

Mesh study, energy balance, resistance-network hand check, sensitivity to h and contact resistance.

IN REPORT

Design recommendations

Where the heat gets stuck, and which change — material, contact, fin or airflow — lowers T_max.

2 H ONLINE

Results review meeting

A walk-through with your engineers. Questions answered and recorded in the final revision.

Revision round

Re-run for design changes within the agreed scope, with a revision log in the report.

03 / METHODS

The right analysis for the question — not the most expensive one.

Conduction, convection and radiation are modelled as far as they change the answer — and the convection side comes either from correlations or from a coupled CFD model, stated in the report.

FIG. 0 — Heat front spreading from a source (schematic)

ANALYSISUSE IT WHENKEY OUTPUTTYPICAL REFERENCE

Steady-state conductionContinuous operation; convection known from correlationsTemperature field, heat flow paths, marginsCorrelations stated in report

Transient thermalStart-up, overload, duty cycles, thermal inertiaTemperature history, time to limit, time constantTime-step study included

Conjugate heat transferConvection drives the answer — fans, enclosures, heat sinksSolid and fluid temperatures, h from the flow→ with S-02 CFD

Thermal–electric (Joule)Busbars, contacts, conductors, heatersCurrent density, I²R losses, temperature

Radiation & solar loadOutdoor enclosures, high-temperature equipmentSurface temperatures incl. radiation exchangeSite data · emissivities stated

Thermal stressTemperature differences or mismatched expansionThermal strains and stresses, fatigue from cycling→ with S-01 Structural

Test correlationThermocouple or thermal-camera data availableMeasured vs. predicted, updated model→ with your test data

FIG. 2 — The heat path — thermal resistances in seriesSCHEMATIC

Every kelvin between the junction and the air is a resistance times the heat flow. The model finds which resistance dominates — the one worth spending money on. (Illustrative values.)

FIG. 3 — Transient heating — the time constant τSCHEMATIC

A body heated at constant power reaches 63 % of its final rise after one time constant and 95 % after three. Short overloads are safe only if they end well before that.

04 / PROCESS & TIMELINE

From problem statement to signed report.

Five steps, each with a clear hand-off. You always know what we need from you and what you get back.

012 day

Scoping call

FROM YOUProblem statement, drawings, limits

FROM USNDA, list of questions and missing data
022 days

Scope & fixed quote

FROM YOUHeat losses, cooling data, operating points

FROM USWritten scope, assumptions, acceptance criteria, price
037 days

Model & solve

FROM YOUCAD, materials, interface data

FROM USInterim check-in: heat paths and first temperatures
042 days

Verify & check

FROM YOUNothing — internal step

FROM USEnergy balance, hand check, sensitivity, second-engineer review
052 days

Report & review

FROM YOUYour comments on the draft

FROM USSigned report, files, review meeting

05 / INPUTS

What we need from you.

REQUIRED

[✓]Geometry — STEP / IGES / Parasolid, or dimensioned drawings
[✓]Heat sources — losses per component at the operating points
[✓]Material data — conductivity, heat capacity, emissivity; interface materials
[✓]Cooling — fans, flow rates, heat sinks, ambient and solar conditions
[✓]Temperature limits and acceptance criteria
[✓]The decision the result feeds, and the deadline

HELPFUL IF AVAILABLE

[+]Measured temperatures or thermal-camera images
[+]Duty cycles and load profiles
[+]Fan curves and datasheets
[+]Previous calculations or test reports
[+]Comments from your customer or approver

INCOMPLETE DATA?Most projects start that way.We list what's missing in the scoping call. Anything we have to assume is recorded in the report's assumption register — never hidden in the model.

BADGERMECX

CONFIDENTIAL

TECHNICAL REPORT · TR-[####] · REV A Equipment — Steady-state & transient thermal assessment

CLIENT[Client]

PROJECT[Project / PO no.]

GOVERNING STANDARDTemperature limits / standard

ISSUE DATE[DD MMM YYYY]

REVDATEDESCRIPTIONBYCHK A[date]First issue for approval[XX][XX]

PREPARED[Name] · [Date]

CHECKED[Name] · [Date]

APPROVED[Name] · [Date]

BADGERMECX — ADVANCED ENGINEERING SOLUTIONSPAGE 1 / [NN]

BADGERMECX

TR-[####] · REV A

Contents

1Scope and the decision it supports[p]

2Inputs and assumption register[p]

3Heat loads and thermal model[p]

4Steady-state temperatures[p]

5Transient response and thermal stress[p]

6Comparison with limits and variants[p]

7Conclusions and recommendations[p]

AVerification (mesh, energy balance, hand-calc)[p]

BInput register and revision log[p]

SUMMARY · One-paragraph answer to the question in section 1: pass / fail, governing location, margin.

CONFIDENTIAL — [CLIENT]PAGE 2 / [NN]

BADGERMECX

TR-[####] · REV A

3 · Heat loads and thermal model

Heat sources come from datasheet losses at the governing operating point. Conduction paths, contact resistances and the cooling boundary are listed below; each value is referenced to the input register (Appendix B).

HEAT SOURCEq [W]LIMITSOURCE [Power module][___]T_j ≤ [___] °C[Datasheet] [Transformer][___][class] · [___] °C[Datasheet] [PCB / electronics][___][___] °C[Spec] Solar load[___] W/m²—[Site data]

BOUNDARY CONDITIONS

Ambient     T_a = [__] °C  (worst case, [source])
Convection  h = [__] W/m²K  or from CFD (CHT)
Radiation   ε = [0.__] on painted surfaces
Contacts    R″ = [__] mm²K/W  (TIM, bolted joints)

CONFIDENTIAL — [CLIENT]PAGE [p] / [NN]

BADGERMECX

TR-[####] · REV A

4 · Steady-state temperatures

Fig. 4.1 — Temperature, base plate, worst case · [result image selected in CMS]

COMPONENTT [°C]LIMIT [°C]MARGIN [Power module] T_j[___][___][__] K [Transformer] hot spot[___][___][__] K Touchable surface[___][___][__] K

GOVERNING · [Component] · T_a = [__] °C · [operating point] margin [__] K ✓

CONFIDENTIAL — [CLIENT]PAGE [p] / [NN]

BADGERMECX

TR-[####] · REV A

5 · Transient and thermal stress

Start-up from T_a = [__] °C at full load for [__] min, then [duty cycle]. The time to reach the limit and the peak gradient are reported; the temperature field is mapped to the structural model for thermal stress.

Fig. 5.1 — Temperature rise vs. time, [component] (form of the result)

QUANTITYRESULTLIMITOK Time constant τ[__] min—— Peak T during cycle[___] °C[___] °C[✓] Thermal stress, [joint][___] MPa→ S-01—

CONFIDENTIAL — [CLIENT]PAGE [p] / [NN]

BADGERMECX

TR-[####] · REV A

Appendix A · Verification evidence

Fig. A.1 — Mesh independence of the governing result (illustrative)

V1Mesh independence of T_max[X] K

V2Energy balance — heat in vs. heat out[X]%

V3Resistance-network hand checkΔ [X] K

V4Sensitivity to h / contact resistance±[X] K

CONFIDENTIAL — [CLIENT]PAGE [p] / [NN]

06 / THE REPORT

See the report before you buy it.

A signed, revision-controlled report of 60 pages on average. Every temperature is traced to an operating point, a heat load from a named datasheet and a boundary condition with its source.

T1
Assumption registerEvery assumption — above all contact resistances and h values — numbered and justified.
T2
Heat-load traceabilityEach heat source names its operating point and the datasheet it comes from.
T3
Verification evidenceEnergy balance, resistance-network hand check and mesh study — included, not just claimed.
T4
Reproducible modelSolver, version, material data, boundary conditions and correlations are stated.
T5
Plain-language conclusionOne page a manager can read: within limits or not, the margin, and what to change.

07 / APPLICATIONS

Typical equipment and structures.

Electrical cabinets & switchgearBusbars · breakers · temperature rise

Power electronicsInverters · converters · heat sinks

Transformers & reactorsHot spot · cooling · overload

Enclosures & housingsNatural convection · fans · solar load

Data-center equipmentRack inlet temperatures · airflow

Battery & e-drive componentsCell temperatures · cooling plates

StructuresThermal actions · expansion · fire

Medical & lab equipmentTouch temperature · internal hot spots

08 / STANDARDS

Checked to the clause your approver reads.

Temperature limits and verification methods come from the standard your equipment is designed or certified to — cited in the report.

STANDARDWHAT WE USE IT FOR

IEC 61439-1Low-voltage switchgear assemblies — temperature-rise verification

IEC 60076-2Power transformers — temperature rise

IEC 62368-1Equipment safety — touch-temperature limits

JEDEC JESD51Thermal characterisation of electronic packages (θ_JA, θ_JC)

EN 1991-1-5Thermal actions on structures

ASHRAE TC 9.9Thermal guidelines for data processing environments

09 / HOW TO ENGAGE

Three ways to work with us.

Prices are fixed per written scope. You pay for the answer to a defined question, not for open-ended hours.

E-01PROJECT

Fixed-scope project

BEST FOR: A defined part or structure with a clear question
PRICE: Fixed quote after scoping

Start with a problem statement

E-02RETAINER

Engineering retainer

BEST FOR: Design teams with recurring analysis needs
PRICE: Quoted per scope

Discuss a retainer

E-03REVIEW

Third-party review

BEST FOR: Checking an FEA or hand calculation done by someone else
PRICE: Fixed quote

Request a review

10 / FAQ

Asked before every project.

Something else? Ask it in the problem statement — the answer comes with the scope.

Which software do you use?

Tessera — the solver we build — runs the free calculators on this site today, each published with its reference cases. For project work the solver is chosen against the standard the result must satisfy, and named in the written scope. Every report states the solver, version, material data and how convection was modelled.

Do we need CFD, or is a thermal model enough?

If convection can be described by correlations — a wall, a fin, a known airflow — a thermal model is enough. If the airflow itself decides the result, we couple it with CFD (S-02).

Our component datasheet only gives losses at one point. Is that enough?

Often yes. We use the worst credible operating point and state it; if the answer is close to the limit, we ask for more data or run a sensitivity.

Can you use our thermocouple or thermal-camera data?

Yes — measured temperatures are used to calibrate contact resistances and h values, and the comparison is reported.

Can the temperatures feed a structural check?

Yes — the temperature field is mapped to the FE model for thermal stress. See S-01 Structural.

How is the price set?

Per written scope: number of components and operating points, and whether transient, CHT or thermal-stress analysis is needed.

RELATED CAPABILITIESAll services →

S-01 · STRUCTURAL Structural / FEA σ_vM ≤ f_y / γ_M0 Spec sheet →

S-02 · FLUID CFD ∇·(ρuu) = −∇p + ∇·τ Spec sheet →

S-03 · DYNAMICS NVH & Dynamics [K − ω²M]{φ} = 0 Spec sheet →

S-05 · ACOUSTIC Acoustics ∇²p − (1/c²) ∂²p/∂t² = 0 Spec sheet →

S-06 · CONCEPT Concept & Design min f(x) s.t. g(x) ≤ 0 Spec sheet →

11 / PROBLEM STATEMENT

Send the heat load. Get a written scope back.

Tell us what heats up, how it is cooled and which temperature it must stay below. We reply with questions or a fixed scope.

[✓] NDA before data exchange
[✓] Response within [X] business day(s)
[✓] Scope, assumptions & acceptance criteria in writing

Will it overheat? Temperatures and margins you can put in front of an approver.

Questions this analysis answers.

What you receive. In writing, before we start.

Technical report

Temperature & margin tables

Temperature field plots

Temperature fields for FEA

Verification appendix

Design recommendations

Results review meeting

Revision round

The right analysis for the question — not the most expensive one.

From problem statement to signed report.

Scoping call

Scope & fixed quote

Model & solve

Verify & check

Report & review

What we need from you.

See the report before you buy it.

Typical equipment and structures.

Checked to the clause your approver reads.

Three ways to work with us.

Fixed-scope project

Engineering retainer

Third-party review

Asked before every project.

Send the heat load. Get a written scope back.