Optimization of Heatsink Design for Enhanced Thermal Management in LED-Based Optical Wireless Communication Systems for In-Pipe Inspection Robots

This study examines the design, simulation, and experimental evaluation of heatsinks for LED arrays in optical wireless communication, specifically for in-pipe inspection robots. Computational Fluid Dynamics (CFD) with SolidWorks optimized heatsink thermal performance under various airflow conditions. Simulations indicated increased airflow significantly lowers temperatures, suggesting fin spacing and airflow channel improvements. Experimental comparisons between an improved heatsink and a conventional starboard heatsink validated the simulations. The improved heatsink showed superior thermal management, achieving higher output power (4.93 mW vs. 4.21 mW at 300 mA) and greater frequency bandwidth (14.80 MHz vs. 14.65 MHz). These findings were based on output power and frequency bandwidth measurements under different cooling conditions. Incorporating the optimized heatsink into the Pipe Bot project enhanced communication performance and extended LED lifespan. Effective thermal management allowed LEDs to operate more efficiently, resulting in higher output power, increased frequency bandwidth, and reduced thermal stress. This paper highlights the critical role of heatsink design in optimizing LED-based optical communication systems.