Method for optimizing heat dissipation structure of motor controller and heat dissipation structure

Abstract

The application discloses an optimization method of a motor controller heat dissipation structure and the heat dissipation structure, and relates to the technical field of cooling and heat dissipation, and comprises the following steps: a physical simulation model of the heat dissipation structure is designed based on initial influence factors; the variation range of the influence factors is determined respectively; one of the influence factors is changed by using a control variable method; the influence of the change of the influence factor on the heat dissipation performance and energy consumption of the heat dissipation structure is analyzed, and an actual factor level table is generated; an original orthogonal experiment group is constructed based on an orthogonal experiment; an experiment group containing unreasonable influence parameters in the original orthogonal experiment group is excluded, and an actual orthogonal experiment group is obtained; thermal simulation is carried out on the actual orthogonal experiment group, and the highest temperature simulation result of an IGBT module and the static pressure difference simulation result of a radiator of each experiment group are obtained; and the influence factor with the minimum comprehensive index of heat dissipation performance and energy consumption and the combination of the levels of the influence factor are determined according to all the simulation results.

Description

Technical Field

[0001] This invention relates to the field of cooling and heat dissipation technology, specifically to an optimization method and heat dissipation structure for a motor controller. Background Technology

[0002] With the rapid development of vehicle electrification, the stability and heat dissipation of motor controllers, as one of the key components of electric vehicles, are becoming increasingly important. As the drive component of electric vehicles, the design of high-power motor controllers must fully consider issues such as structure and heat dissipation. This is because the IGBT, as its core component, has an extremely high heat density and generates a large amount of heat. If heat dissipation is not effective, the IGBT module can easily burn out, ultimately affecting the control performance and lifespan of the high-power motor controller.

[0003] There are two main methods for cooling electric vehicle motor controllers: air cooling and liquid cooling. Air cooling is suitable for cooling small-capacity power modules, but its efficiency is relatively low and it is difficult to meet the cooling requirements of high power density. Liquid cooling is suitable for larger-capacity power modules. One side of the liquid cooling radiator is the mounting surface, and the fluid undergoes convective heat exchange inside the radiator. With reasonable flow channel design and turbulence column design, the radiator structure can be made small in size and light in weight, while increasing the heat exchange capacity.

[0004] However, existing liquid cooling structures are mostly designed to work with IGBT modules, based on the shape of the heat sink or baffle column. Since there are many factors that determine the heat dissipation effect of the heat dissipation structure, it is difficult to achieve the best heat dissipation effect by using this type of design method.

[0005] Chinese patent CN114530646B discloses a power module with consistent temperature and its heat sink design method. This method compensates for the rise in chip temperature caused by the rise in coolant temperature by changing the parameters of the heat sink's turbulence column, so that the temperature of the power half-bridge composed of the chips is consistent, which is beneficial to improving the output performance of the power half-bridge. However, this method still does not take into account the relevant influencing factors in the heat dissipation structure, such as the heat dissipation channel, so the performance of the final heat dissipation structure cannot reach the optimal state. In addition, this method aims to improve the heat dissipation effect, but it pays little attention to the energy consumption of the heat sink, and ultimately it is difficult to achieve the goal of strong heat dissipation capacity and low energy consumption of the motor controller heat sink.

[0006] Therefore, we propose a method to improve the performance of the designed heat dissipation structure. Summary of the Invention

[0007] The purpose of this invention is to provide an optimization method and a heat dissipation structure for a motor controller, which can effectively improve the performance of the designed heat dissipation structure.

[0008] This invention is achieved through the following technical solution:

[0009] An optimization method for the heat dissipation structure of a motor controller includes:

[0010] Based on the influencing factors in the initial radiator, the influencing factors in the turbulence column, and the coolant flow rate, a physical simulation model of the heat dissipation structure is designed.

[0011] Determine the influencing factors in the radiator, the influencing factors in the turbulence column, and the range of coolant flow rate variation;

[0012] The method of controlling variables was used to change one of the influencing factors, and the impact of the change of the influencing factor on the heat dissipation performance and energy consumption of the heat dissipation structure was analyzed, and a table of actual factor levels was generated.

[0013] Based on orthogonal experiments, an original orthogonal experimental group was constructed according to the actual factor level table;

[0014] Exclude experimental groups containing unreasonable influencing parameters from the original orthogonal experimental groups to obtain the actual orthogonal experimental groups;

[0015] Thermal simulations were performed on the actual orthogonal experimental groups to obtain the simulation results of the maximum temperature of the IGBT module and the static pressure difference of the heat sink for each experimental group.

[0016] Based on all simulation results, the factors that minimize the comprehensive index of heat dissipation performance and energy consumption, and the combination of their levels, are determined.

[0017] Furthermore, the influencing factors in the heat sink include the substrate thickness, flow channel size parameters, number of flow channels, inlet and outlet diameters, and partition thickness.

[0018] Furthermore, the influencing factors of the baffle columns include the shape, height, and arrangement of the baffle columns.

[0019] Furthermore, the process of generating the actual factor level table specifically includes:

[0020] Establish a set of control variables for each influencing factor, and conduct thermal simulations under the same initial simulation conditions of pressure, temperature, coolant type, and IGBT thermal power consumption.

[0021] Based on the simulation results, we analyzed the changes in the maximum temperature of the IGBT module and the static pressure difference of the heat sink when each influencing factor changed within its preset range.

[0022] Excluding factors such as the change in the maximum temperature of the IGBT module and the change in the static pressure difference of the heat sink, which are both less than 10% of the difference between their respective maximum and minimum values, the remaining factors are considered as the main factors.

[0023] For each major influencing factor, establish an original factor level table;

[0024] By excluding the variation of each major influencing factor within its preset range, the table of actual factor levels is obtained, which shows the level at which the highest temperature of the IGBT module exceeds its allowable value, or the static pressure difference of the heat sink exceeds the upper limit of the static pressure difference required by the design.

[0025] Furthermore, the process of determining the factors that minimize the comprehensive index of heat dissipation performance and energy consumption, and the combination of their levels, specifically includes:

[0026] The simulation results for each experimental group were normalized using the following formula:

[0027]

[0028] Where x′ represents the normalized value; x represents the original value; x min x represents the minimum value of the data; max Indicates the maximum value of the data;

[0029] For all experimental groups, the comprehensive performance index of the radiator was calculated using the following formula. The experimental group with the smallest comprehensive performance value was selected as the structure and parameters with the optimal comprehensive performance index of heat dissipation and energy saving:

[0030] A = m1x1′ + m2x2′;

[0031] In the formula, A represents the overall performance value of the heat sink; m1 and m2 represent weights, and m1+m2=1; x1′ represents the normalized value of the maximum temperature of the IGBT module; and x2′ represents the normalized value of the static pressure difference of the heat sink.

[0032] A heat dissipation structure for a motor controller is characterized by being obtained based on the optimization method of the above-mentioned heat dissipation structure for a motor controller, comprising a heat sink and baffle columns; the heat sink comprises a substrate, a heat dissipation channel is formed on one side of the substrate, and multiple baffle columns are distributed in the heat dissipation channel, and the baffle columns are all perpendicular to the surface of the substrate; the other side of the substrate is fixedly connected to an IGBT module, and the installation position of the IGBT module corresponds to the heat dissipation channel.

[0033] Furthermore, the heat dissipation channel includes an inlet straight section, a turbulence section, an outlet straight section, and a U-shaped connecting section. The head end of the inlet straight section is connected to the water inlet on the side of the substrate, the end end of the inlet straight section is connected to the head end of the turbulence section through a U-shaped connecting section, the end end of the turbulence section is connected to the head end of the outlet straight section through a U-shaped connecting section, and the end end of the outlet straight section is connected to the water outlet of the substrate.

[0034] The location of the turbulence section corresponds to the IGBT module, and multiple turbulence columns are distributed within the turbulence section.

[0035] Furthermore, the turbulence section is designed as a continuous U-shaped structure, and the width of the straight section in the turbulence section is greater than the width of the U-shaped connecting section.

[0036] Furthermore, the straight section is connected to the U-shaped connecting section via a trapezoidal connecting part.

[0037] Furthermore, the density of the turbulence columns at both ends of the straight section is greater than the density of the turbulence columns in the middle of the straight section.

[0038] The technical solution of the present invention has at least the following advantages and beneficial effects:

[0039] This invention discloses an optimization method and heat dissipation structure for a motor controller. By combining the influencing factors in the radiator, the influencing factors in the turbulence column, and the coolant flow rate that affect the heat dissipation effect and energy consumption, a physical simulation model is constructed, so that the physical simulation model can accurately simulate the operating effect of the actual heat dissipation structure.

[0040] In addition, the main factors affecting the performance and energy consumption of the heat dissipation structure can be obtained by using the controlled variable method. Then, based on orthogonal experiments and corresponding calculations, the combination of factors and their levels that minimize the comprehensive index of heat dissipation performance and energy consumption can be obtained. The heat dissipation structure designed based on the combination of these factors and their levels will have the best comprehensive performance in terms of heat dissipation and energy saving. By fully combining the influencing factors of the heat dissipation structure, the heat dissipation structure with the best comprehensive performance can be optimized. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of a method flow of the present invention;

[0042] Figure 2 This is a line graph showing the changes in the maximum temperature of the IGBT and the static pressure difference of the radiator due to the changes in various influencing factors in this invention.

[0043] Figure 3 This is a schematic diagram of a heat dissipation structure according to the present invention.

[0044] Reference numerals: 1 Radiator; 11, Base plate; 111, Inlet; 112, Outlet; 12, Heat dissipation channel; 121, Inlet straight section; 122, Turbulence section; 1221, Straight section; 1222, U-shaped connection section; 123, Outlet straight section; 124, U-shaped connection section; 2, Turbulence column. Detailed Implementation

[0045] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0046] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0047] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0048] In the description of this invention, it should be noted that if terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," or "outer" (excluding "horizontal" related to "factor" or "influencing factor") indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use, they are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0049] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0050] Example 1

[0051] As attached Figure 1 The method for optimizing the heat dissipation structure of a motor controller, as shown, includes:

[0052] S1. Based on the influencing factors in the initial radiator 1, the influencing factors in the turbulence column 2, and the coolant flow rate, design a physical simulation model of the heat dissipation structure;

[0053] The physical simulation model was designed using Solidworks based on the space size requirements of the motor controller (length * width * height greater than 198mm * 196mm * 17mm) and heat dissipation requirements (the allowable operating temperature of the IGBT is 90℃).

[0054] Determine the influencing factors in radiator 1, the influencing factors in turbulence column 2, and the range of coolant flow rate variation;

[0055] Specifically, the influencing factors in the heat sink 1 include the substrate thickness, flow channel size parameters, number of flow channels, inlet and outlet diameters, and baffle thickness of the heat sink 1; the influencing factors in the baffle column 2 include the shape, height, and arrangement of the baffle column.

[0056] The influencing factors in radiator 1, the influencing factors in turbulence column 2, the range of coolant flow rate, and the baseline values ​​of each influencing factor are shown in Table 1. It should be noted that coolant flow rate is also an influencing factor.

[0057] Table 1. Baseline values ​​and ranges of variation for each influencing factor.

[0058]

[0059] S2. Using the controlled variable method, change one of the influencing factors, analyze the impact of the change in the influencing factor on the heat dissipation performance and energy consumption of the heat dissipation structure, and generate a table of actual factor levels;

[0060] When using the controlled variable method, only one factor is changed each time, while the other factors remain unchanged. The effects of 10 factors, including substrate thickness, flow channel width, flow channel length, number of flow channels, inlet and outlet diameter, baffle thickness, shape of turbulence column, height of turbulence column, arrangement of turbulence column, and coolant flow rate, on the maximum temperature of the IGBT module and the static pressure difference of the radiator are analyzed. The main influencing factors and their levels on the heat dissipation effect and energy consumption of radiator 1 are screened out.

[0061] Specifically:

[0062] S21. Thermal simulation based on the control variable method. Establish control variable groups for each influencing factor, and perform thermal simulations using SolidWorks software.

[0063] The same initial conditions were used for the Heatsink 1 model in the SolidWorks thermal simulation:

[0064] 1) The initial ambient pressure was 101.325 kPa and the initial temperature was 20.05℃;

[0065] 2) The coolant type is water;

[0066] 3) The thermal dissipation of the IGBT is 3 × 4170W;

[0067] 4) The export environmental pressure is 101.325 kPa.

[0068] S22. Screening of Key Influencing Factors. Based on the simulation results, the changes in the maximum temperature of the IGBT module and the static pressure difference of the heat sink when each influencing factor varies within its preset range are analyzed, as shown in Table 2:

[0069] Table 2. Changes in various influencing factors on the maximum temperature and static pressure difference of the IGBT.

[0070]

[0071] Based on the data in Table 2, plot a line graph showing the changes in the maximum temperature of the IGBT and the static pressure difference of the radiator. Figure 2 As shown in the figure, the changes in the maximum temperature of the IGBT module and the change in the static pressure difference of the radiator due to the flow channel length and baffle thickness are both less than 10% of the difference between the maximum and minimum values ​​of the changes of each influencing factor. That is, the changes in the maximum temperature of the IGBT module due to these two factors are both less than 6.87℃ and the changes in the static pressure difference of the radiator are both less than 45918.89Pa, so they are all excluded. The shape of the baffle column, the flow channel width, the substrate thickness, the number of flow channels, the height of the baffle column, the inlet and outlet diameters, the coolant flow rate, and the arrangement of the baffle column are taken as the main influencing factors.

[0072] S23. Screening of Levels for Major Influencing Factors. A table of initial factor levels was created for each major influencing factor, as shown in Table 3:

[0073] Table 3. Levels of Original Factors

[0074]

[0075] After excluding situations where the maximum temperature of the IGBT module exceeds its allowable value or the static pressure difference of the radiator exceeds the upper limit of the design requirement when each major influencing factor varies within its preset range, the following factors were excluded: the shape of the turbulence columns (circular and teardrop); the width of the flow channel (24.8 mm); the thickness of the substrate (15 mm); the height of the turbulence columns (12 mm); the inlet and outlet diameters (6 mm); the coolant flow rate (42 L / min); and the arrangement of the turbulence columns (both guide + turbulence and turbulence + guide). The final table of actual factor levels is shown in Table 4.

[0076] Table 4. Actual Factor Levels

[0077]

[0078] S3. Based on the orthogonal experimental design method, an original orthogonal experimental group was constructed according to the actual factor level table; specifically, the original orthogonal experimental group was constructed using Minitab, as shown in Table 5. The specific level of each factor is represented by a combination of letters and numbers, and its value can be obtained from Table 4.

[0079] Table 5 Original Orthogonal Experimental Groups

[0080]

[0081]

[0082] S4. Exclude experimental groups containing unreasonable influencing parameters from the original orthogonal experimental groups to obtain the actual orthogonal experimental groups; that is, exclude group numbers 1, 2, 3, 4, 5, 6, 8, 9, 10, 11, 12, 13, 14, 15, 20, 24, 27, and 31 in Table 5. The actual orthogonal experimental groups used for thermal simulation are shown in Table 6.

[0083] Table 6. Actual Orthogonal Experimental Groups

[0084]

[0085]

[0086] S5. Thermal simulations were performed on the actual orthogonal experimental groups to obtain the simulation results of the highest temperature of the IGBT module and the static pressure difference of the heat sink for each experimental group; as shown in Table 7:

[0087] Table 7 Simulation Results of Orthogonal Experimental Groups

[0088]

[0089] S6. Based on all simulation results, determine the combination of factors and their levels that minimize the comprehensive index of heat dissipation performance and energy consumption;

[0090] S61. Normalization of simulation results:

[0091] The simulation results of the highest temperature of the IGBT module and the static pressure difference of the heat sink for each experimental group were normalized according to the following formula.

[0092]

[0093] Where x′ represents the normalized value; x represents the original value; x min x represents the minimum value of the data; max This represents the maximum value of the data; and the results are shown in Table 8:

[0094] Table 8 Normalization Results

[0095]

[0096] S62. Determination of the optimal structure and parameters for comprehensive heat dissipation and energy saving performance:

[0097] For all experimental groups, the comprehensive performance index of radiator 1 was calculated using the following formula, where m1 = 0.6 and m2 = 0.4.

[0098] A = m1x1′ + m2x2′;

[0099] In the formula, A represents the comprehensive performance value of heat sink 1; m1 and m2 represent weights, and m1 + m2 = 1; x1′ represents the normalized value of the highest temperature of the IGBT module; x2′ represents the normalized value of the static pressure difference of the heat sink; the results are shown in Table 9. The 4th group with the smallest comprehensive performance value was selected as the structure and parameters with the best comprehensive performance index of heat dissipation and energy saving, that is, adopting an elliptical turbulence column shape, a flow channel width of 26.8mm, a substrate thickness of 6mm, a number of flow channels of 6, a turbulence column height of 18mm, an inlet and outlet diameter of 12mm, a coolant flow rate of 18L / min, and a turbulence column arrangement of guide + turbulence + guide;

[0100] Table 9. Comprehensive performance values ​​of each experimental group

[0101]

[0102] Example 2

[0103] like Figure 3 The illustrated heat dissipation structure for a motor controller is based on an optimization method for heat dissipation structure of a motor controller. It includes a heat sink 1 and baffle columns 2. The heat sink 1 includes a base plate 11. A heat dissipation channel 12 is formed on one side of the base plate 11. Multiple baffle columns 2 are distributed in the heat dissipation channel 12, and the baffle columns 2 are all perpendicular to the surface of the base plate 11. The other side of the base plate 11 is fixedly connected to an IGBT module, and the installation position of the IGBT module corresponds to the heat dissipation channel 12.

[0104] The heat emitted by the IGBT module mounted on the other side of the substrate 11 will be transferred to the substrate 11, and the heat dissipation will be completed through the full contact between the turbulence column 2 in the heat dissipation channel 12 and the coolant. In addition, the substrate 11 is made of 6061 aluminum alloy, which has high thermal conductivity and can effectively conduct the heat of the IGBT to the surface of the heat sink 1 for heat dissipation.

[0105] It should be noted that the baffle column 2 is fixedly installed inside the heat dissipation channel 12, that is, it is directly fixedly connected to the substrate 11. Therefore, the heat dissipated by the IGBT module will be transferred to the baffle column 2 through the substrate 11, and the flow of cooling water will carry away the heat of the baffle column 2, thus completing the cooling and heat dissipation operation. In addition, a cover plate will be provided on the substrate 11 to seal the heat dissipation channel 12.

[0106] Example 3

[0107] The heat dissipation channel 12 includes an inlet straight section 121, a turbulence section 122, an outlet straight section 123, and a U-shaped connecting section 124. The head end of the inlet straight section 121 is connected to the water inlet 111 on the side of the substrate 11. The end end of the inlet straight section 121 is connected to the head end of the turbulence section 122 through a U-shaped connecting section 124. The end end of the turbulence section 122 is connected to the head end of the outlet straight section 123 through a U-shaped connecting section 124. The end end of the outlet straight section 123 is connected to the water outlet 112 of the substrate 11.

[0108] That is, no baffle columns 2 are set in the inlet straight section 121 and the outlet straight section 123. In order to ensure that the cooling water enters and flows out of the heat dissipation channel 12 without obstruction and to ensure that the cooling water flows more smoothly in the heat dissipation channel 12, in addition, the inlet straight section 121, the baffle section 122 and the outlet straight section 123 are connected together by two U-shaped connecting sections, so that the whole heat dissipation channel is a continuous U-shaped structure, which increases the flow distance of the cooling water and improves the heat dissipation effect of the radiator 1.

[0109] The position of the turbulence section 122 corresponds to the IGBT module, and multiple turbulence columns 2 are distributed within the turbulence section 122. The turbulence section 122 and the turbulence columns 2 can effectively absorb the heat emitted by the IGBT module, and the heat is then carried away by the cooling water, thereby completing the heat dissipation and cooling of the IGBT module.

[0110] Furthermore, the turbulence section 122 is designed as a continuous U-shaped structure, and the width of the straight section 1221 in the turbulence section 122 is greater than the width of the U-shaped connecting section 1222. That is, the overall heat dissipation channel is still a continuous U-shaped structure, and there are six straight sections 1221 in the turbulence section 122. The straight sections 1221 at both ends of the turbulence section 122 are connected to the corresponding inlet straight section 121 or outlet straight section 123 through the U-shaped connecting section 1222, which greatly increases the flow distance of the cooling water and the coverage area of ​​the heat dissipation channel 12. This allows for the installation of more IGBT modules on the substrate 11, thereby improving the overall heat dissipation effect of the radiator 1.

[0111] In addition, the straight section 1221 of the turbulence section 122 is connected to the U-shaped connecting section 1222 through the trapezoidal connecting part. The trapezoidal connecting part can make the transition between the straight section 1221 and the U-shaped connecting part 1222 of the turbulence section 122 smoother, and avoid blockage during the flow of cooling water. It should be noted that the trapezoidal connecting part is also provided with turbulence columns 2 to slow down the flow rate of cooling water and prevent the cooling water from impacting the turbulence section 122 due to excessive flow rate.

[0112] As needed, the density of the turbulence columns 2 at both ends of the straight section 1221 is greater than that in the middle of the straight section 1221. Since the IGBT module is generally installed in the center of the substrate 11, the heat received in the middle of the turbulence section 122 is often the greatest. Therefore, the turbulence columns 2 in the middle are sparsely arranged, which can slightly increase the flow rate of the cooling water, that is, improve the cooling effect of this part of the turbulence section 122. Meanwhile, the cooling water flow rate in the densely arranged turbulence columns 2 is still low, and the heat received in the corresponding part is also low. This makes the overall heat dissipation effect of the radiator 1 basically the same, ensuring that the ambient temperature around the IGBT module will not fluctuate too much, which helps the IGBT module to operate stably.

[0113] It is important to note that the arrangement of the 1221 turbulence columns 2 in the straight section is a combination of flow guidance and turbulence. That is, the turbulence columns 2 in the flow guidance section are arranged in an orderly matrix, while the turbulence columns 2 in the turbulence section are arranged in an alternating pattern. In addition, this arrangement of turbulence columns 2 can effectively disturb the cooling water in the flow, thereby preventing particulate matter in the cooling water from depositing inside the heat exchanger and reducing the risk of blockage.

[0114] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An optimization method for the heat dissipation structure of a motor controller, characterized in that: include: Based on all influencing factors in the initial radiator (1), all influencing factors in the turbulence column (2), and the coolant flow rate, a physical simulation model of the heat dissipation structure is designed; Determine all influencing factors in the radiator (1), all influencing factors in the turbulence column (2), and the range of coolant flow rate variation; Among them, all the influencing factors in the heat sink (1) include the substrate thickness, flow channel size parameters, number of flow channels, inlet and outlet diameters and partition thickness of the heat sink; All influencing factors in the deflector column (2), including the shape, height and arrangement of the deflector column; The method of controlling variables was used to change one of the influencing factors, and the impact of the change of the influencing factor on the heat dissipation performance and energy consumption of the heat dissipation structure was analyzed, and a table of actual factor levels was generated. Based on orthogonal experiments, an original orthogonal experimental group was constructed according to the actual factor level table; Exclude experimental groups containing unreasonable influencing parameters from the original orthogonal experimental groups to obtain the actual orthogonal experimental groups; Thermal simulations were performed on the actual orthogonal experimental groups to obtain the simulation results of the maximum temperature of the IGBT module and the static pressure difference of the heat sink for each experimental group. Based on all simulation results, the factors with the highest comprehensive index of heat dissipation performance and energy consumption, and the combinations of their results, are determined. The optimized heat dissipation structure of the motor controller using this optimization method includes a heat sink (1) and a baffle column (2). The heat sink (1) includes a base plate (11). A heat dissipation channel (12) is opened on one side of the base plate (11). Multiple baffle columns (2) are distributed in the heat dissipation channel (12), and the baffle columns (2) are all perpendicular to the surface of the base plate (11). The other side of the base plate (11) is fixedly connected to the IGBT module, and the installation position of the IGBT module corresponds to the heat dissipation channel (12). The heat dissipation channel (12) includes an inlet straight section (121), a turbulence section (122), an outlet straight section (123), and a U-shaped connecting section (124). The head end of the inlet straight section (121) is connected to the water inlet (111) on the side of the substrate (11). The end of the inlet straight section (121) is connected to the head end of the turbulence section (122) through a U-shaped connecting section (124). The end of the turbulence section (122) is connected to the head end of the outlet straight section (123) through a U-shaped connecting section (124). The end of the outlet straight section (123) is connected to the water outlet (112) of the substrate (11). The location of the turbulence section (122) corresponds to the IGBT module, and multiple turbulence columns (2) are distributed within the turbulence section (122).

2. The method for optimizing the heat dissipation structure of the motor controller according to claim 1, characterized in that: The process of generating the actual factor level table specifically includes: Establish a set of control variables for each influencing factor, and conduct thermal simulations under the same initial simulation conditions of pressure, temperature, coolant type, and IGBT thermal power consumption. Based on the simulation results, we analyzed the changes in the maximum temperature of the IGBT module and the static pressure difference of the heat sink when each influencing factor changes within its respective allowable range. Excluding factors such as the change in the maximum temperature of the IGBT module and the change in the static pressure difference of the heat sink, which are both less than 10% of the difference between their respective maximum and minimum values, the remaining factors are considered as the main factors. For each major influencing factor, establish an original factor level table; After eliminating the main influencing factors that cause the maximum temperature of the IGBT module to exceed its allowable value, or the static pressure difference of the heat sink to exceed the upper limit of the static pressure difference required by the design, the actual factor level table is obtained.

3. The method for optimizing the heat dissipation structure of the motor controller according to claim 1, characterized in that: The process of determining the combination of factors and their results that result in the highest comprehensive index of heat dissipation performance and energy consumption specifically includes: The simulation results for each experimental group were normalized using the following formula: ； in, The value represents the normalized data; x represents the original value. This represents the minimum value of the data. Indicates the maximum value of the data; For all experimental groups, the comprehensive performance index of the radiator (1) was calculated according to the following formula. The experimental group with the smallest comprehensive performance value was selected as the structure and parameters with the optimal comprehensive performance index of heat dissipation and energy saving: ； In the formula, A represents the comprehensive performance value of the radiator (1); , Indicates weight, and ; This represents the normalized value of the highest temperature of the IGBT module; This represents the normalized value of the static pressure difference of the radiator.

4. The heat dissipation structure for the motor controller according to claim 1, characterized in that: The turbulence section (122) is designed as a continuous U-shaped structure, and the width of the straight section in the turbulence section (122) is greater than the width of the U-shaped connecting section.

5. The heat dissipation structure for the motor controller according to claim 4, characterized in that: The straight section of the turbulence section (122) is connected to the U-shaped connecting section through the trapezoidal connecting part.

6. The heat dissipation structure for the motor controller according to claim 5, characterized in that: The turbulence columns (2) located at both ends of the straight section of the turbulence section (122) are densely arranged, while the turbulence columns (2) located in the middle of the turbulence section (122) are sparsely arranged.

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