Design & planning
- Create detailed blueprints and thermal schematics.
- Engage the engineering cohort for sign-off.
- Deliverable: finalized design package.
Cooling architecture
Complete Breakdown: Cooling System for the Magnetic Inertia Platform
A field-ready thermal management program engineered to protect high-density magnetic inertia flywheel modules. This playbook aligns procurement, assembly, and validation so your deployment team can deliver reliable cooling performance under peak load conditions.
667
Precision-machined cooling plates staged per platform
500 L/h
High-flow circulation across dual loops for core & buffer zones
24/7
Continuous thermal monitoring pathway for mission-critical uptime
Program anchors
- Blueprint-driven integration sequencing
- Single-source component sourcing optionality
- Thermal sensors and analytics-ready controls
- Commissioning scripts for leak and load testing
Materials and partner-ready specifications
Align procurement teams with vetted dimensions, performance ranges, and suggested manufacturing partners to keep builds moving at enterprise velocity.
| Component | Specifications | Supplier alignment |
|---|---|---|
| Cooling plates | Aluminum or copper • 100×150×5 mm • Deburred edges | EKWB · AlphaCool |
| Cooling channels & tubing | Flexible, heat-resistant silicone • 10 mm ID • Cut-to-fit layout | Digi-Key · Mouser Electronics |
| Radiators | Aluminum or copper • 120×240×30 mm • High-dissipation fins | EKWB · AlphaCool · Noctua |
| Pumps | High-flow, low-noise • 500 L/h • Dual-loop ready | EKWB · AlphaCool |
| Fans | 120×120×25 mm • 2000 RPM • PWM control | Noctua · Corsair |
| Thermal pads | Silicone-based, high conductivity • 1 mm thickness | Arctic · Thermal Grizzly |
| Coolant | Water/glycol mixture • 1 L per loop • Anti-corrosive additives | EKWB · Corsair |
Nine-phase assembly and validation sequence
Guide technical teams from blueprint creation to operational sign-off. Each card highlights primary tasks, tooling requirements, and tangible deliverables for stakeholder review.
Sourcing
- Secure each component from approved vendors.
- Confirm lead times and logistics windows.
- Deliverable: verified receiving manifest.
Plate preparation
- Cut plates to 100×150×5 mm tolerances.
- Deburr edges to ensure smooth thermal contact.
- Deliverable: staging-ready plate inventory.
Plate installation
- Apply thermal pads to both plate surfaces.
- Integrate plates between prismatic cells.
- Deliverable: thermally balanced module stacks.
Tubing integration
- Cut tubing lengths to match the system topology.
- Route channels through plates, radiators, and pumps.
- Deliverable: sealed circulation network.
Radiator mounting
- Secure radiators to the frame with reinforced brackets.
- Bond radiators into the primary tubing path.
- Deliverable: dissipative array aligned to flow.
Pump deployment
- Mount pumps within vibration-damped frames.
- Integrate electrical controls and redundancy relays.
- Deliverable: pumps positioned and powered.
Fan integration
- Mount fans to radiators with countersunk fasteners.
- Calibrate PWM controls for adaptive airflow.
- Deliverable: airflow optimized across radiators.
Fill & validation
- Charge loops with water/glycol coolant mixture.
- Run leak diagnostics and thermal performance checks.
- Deliverable: certified, leak-free cooling system.
Investment snapshot for a full system build
Plan budgets with transparent labor and material costs. Figures reflect a full deployment cycle inclusive of engineering oversight, fabrication, and commissioning personnel.
Labor breakdown
- Project manager: $44,800
- Design engineers: $78,400
- Mechanical engineers: $78,400
- Technicians: $112,000
Material breakdown
- Cooling plates: $20,010 (667 × $30)
- Cooling channels & tubing: $2,000
- Radiators: $400 (4 × $100)
- Pumps: $600 (2 × $300)
- Fans: $200 (4 × $50)
- Thermal pads: $200
- Coolant: $100
Total program investment
$337,110
$313,600 labor • $23,510 materials
Mission-ready conclusion
Executing this cooling roadmap equips every magnetic inertia installation with resilient thermal protection. From blueprint validation to leak-free commissioning, the Ioncore methodology keeps your energy platform performant, scalable, and safeguarded for long-term operation.
