Design method of motor controller liquid cooling plate fin column layout mode

Abstract

The invention relates to a liquid cooling plate fin column layout mode design method which comprises the following steps: determining the range of porosity according to geometric parameters of a liquid cooling plate installation space and heat flux parameters generated by a heat source; according to the maximum output power of the cooling liquid circulating pump, the maximum flow speed of a cooling liquid inlet is obtained, and the mass flow is obtained; selecting a plurality of porosities in the determined range of the porosities, and determining the types of the porosities; according to the target demand, the porosity, the mass flow and the porosity type, obtaining a fin column spacing ratio and a fin column array mode, and generating a plurality of liquid cooling plate fin column layout alternative schemes; and verifying the plurality of liquid cooling plate fin column layout alternative schemes by using the comprehensive performance indexes to obtain a liquid cooling plate fin column layout design scheme. According to the method, a multi-parameter matching target can be combined, heat dissipation can be effectively improved, the junction temperature of the device can be effectively reduced, accurate guidance and design reference are provided for multiple scenes, and the problem that heat dissipation energy consumption is difficult to balance in the prior art is solved.

Description

Technical Field

[0001] This invention relates to the field of thermal management of power electronic devices, and specifically to a design method for the layout of liquid-cooled plate fins. Background Technology

[0002] Insulated-gate bipolar transistors (IGBTs), as core components of high-power power electronic devices, generate extremely high heat flux densities during operation. In high-power applications such as new energy vehicles, rail transportation, and large-scale energy storage power stations, the high heat flux density generated by IGBTs can easily lead to a rapid increase in their junction temperature, resulting in problems such as thermal stress failure, dynamic performance degradation, and shortened lifespan. Liquid cooling technology, with its advantages of high heat dissipation performance and stable temperature control, is widely used in the thermal management systems of high-power IGBT modules.

[0003] As the core heat exchange component of liquid cooling technology, the structural design of the liquid cooling plate directly determines the thermal-hydraulic performance of the liquid cooling system. Therefore, research on finned liquid cooling plates has become a hot topic in this field. Currently, researchers mainly focus on optimizing the shape of the fins (such as rectangular, wave-shaped, and biomimetic fractal structures), their distribution density, and their array configuration, attempting to balance thermal performance and flow resistance by adjusting structural parameters. Simultaneously, by introducing computational fluid dynamics (CFD) simulations, thermo-fluid-solid multiphysics coupling analysis, and machine learning algorithms, they aim to achieve multi-objective optimization of heat dissipation efficiency, system pressure drop, and liquid cooling plate weight, and explore customized design solutions for different application areas such as aerospace, new energy vehicle batteries, and industrial cooling.

[0004] However, in the design practice of finned liquid cooling plates, there are still several technical bottlenecks, as follows:

[0005] 1) The inherent contradiction between thermal performance and flow resistance is difficult to effectively balance. The core function of finned liquid cooling plates is to enhance heat transfer and guide the flow field through the finned structure. However, there is a natural coupling contradiction between improving heat dissipation performance and controlling flow resistance. In current design practices, it is difficult to achieve efficient synergy between the two. For example, if a staggered finned layout is used directly to enhance heat transfer, although it can improve the convective heat transfer coefficient by disrupting the coolant flow boundary layer and enhancing turbulence, its complex flow field structure will lead to a sharp increase in coolant flow resistance, directly increasing the energy consumption of the pumping system, which contradicts the energy-saving requirements of scenarios such as new energy vehicles and rail transit. On the other hand, if an inline finned layout is used directly to reduce flow resistance, this layout is prone to forming a stable laminar boundary layer under low flow velocity conditions, resulting in a significant reduction in the heat transfer coefficient. When the power density of the IGBT module exceeds the critical value, heat cannot be dissipated in time, causing the junction temperature of the device to exceed the safety threshold. Therefore, in the current design process, it is easy to fall into the design dilemma of "high energy consumption for high-efficiency heat transfer and insufficient heat transfer for low-resistance flow".

[0006] 2) Insufficient design specificity and adaptability. The performance of finned liquid cooling plates is significantly affected by core parameters such as porosity; even slight changes in these parameters can lead to substantial differences in performance indicators. Furthermore, different application scenarios have significantly different requirements for liquid cooling plates. Current design methods often rely on single parameters or single objectives for layout optimization, resulting in discrepancies between the designed liquid cooling plates' performance and actual requirements under real-world conditions. For example, there is a lack of efficient heat dissipation layouts for high-porosity, low-flow-rate scenarios, while low-porosity, high-flow-rate scenarios struggle to balance heat dissipation and pressure drop control, leading to a high degree of design uncertainty. Therefore, in actual production design, it is usually necessary to first design a scheme, and then optimize and iterate the scheme based on simulation analysis results. This method involves numerous design iterations, long computation times, and makes it difficult to quickly obtain a design scheme with optimal overall performance.

[0007] Therefore, how to quickly and efficiently design a liquid-cooled plate fin column layout with optimal thermal-hydraulic performance for the specific needs of different application fields has always been a problem that needs to be solved by those skilled in the art. Summary of the Invention

[0008] This invention provides a design method for the layout of liquid-cooled plate fins in motor controllers. This method, tailored to different specific scenarios, adheres to the core layout principle of ensuring the spanwise spacing is greater than the flow-wise spacing. By combining porosity, mass flow rate, and multi-dimensional parameter matching with target requirements (high heat dissipation, low energy consumption, and overall performance), it not only effectively improves heat dissipation performance, reduces junction temperatures of IGBTs and other devices, avoids thermal stress failure, and extends device lifespan, but also ensures optimal overall performance under various operating conditions. It provides precise layout guidance for diverse scenarios such as compact spaces, high-flow forced convection, and balanced performance, offering a clear theoretical basis and engineering reference for liquid-cooled plate fin structure design. This method completely solves the problems of balancing heat dissipation and energy consumption, blind layout design, and insufficient scenario adaptability.

[0009] The objective of this invention is achieved through the following approach:

[0010] A design method for a liquid-cooled plate fin layout of a motor controller includes the following steps:

[0011] 1) Determine the range of porosity based on the geometric parameters of the liquid cooling plate installation space and the heat flux parameters generated by the heat source;

[0012] 2) Based on the maximum output power of the coolant circulation pump, obtain the maximum flow velocity at the coolant inlet, and based on the maximum flow velocity at the coolant inlet, obtain the mass flow rate;

[0013] 3) Within the range of porosity determined in step 1), select several porosities and determine the porosity type of the corresponding porosity;

[0014] 4) Based on the target requirements, porosity, mass flow rate, and porosity type, the fin-pillar spacing ratio and fin-pillar array method are obtained, and several alternative liquid-cooled plate fin-pillar layout schemes are generated based on the inherent parameters of the fin-pillars.

[0015] 5) Using comprehensive performance indicators, the multiple liquid-cooled plate fin column layout alternatives in step 4) are verified to obtain the liquid-cooled plate fin column layout design scheme.

[0016] Preferably, in step 3), the fin spacing ratio is the ratio of the spanwise spacing of the fins to the flowwise spacing of the fins, and the spanwise spacing of the fins is greater than the flowwise spacing of the fins.

[0017] Preferably, in step 3), the specific method for determining the array configuration of the fins based on the target requirements, porosity, and mass flow rate is as follows:

[0018] 4-1) If the porosity type is low porosity and the mass flow rate is high, then the array method of the fin columns is determined to be an inline array.

[0019] 4-2) If the porosity type is low porosity and the mass flow rate is low, then the array configuration of the fins should be determined based on the target requirements:

[0020] ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array.

[0021] ②If the target requirements are low energy consumption and comprehensive performance, then the array configuration of the fins is a straight-line array;

[0022] 4-3) If the porosity type is high porosity and the mass flow rate is high, then the array configuration of the fins should be determined according to the target requirements:

[0023] ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array.

[0024] ②If the target requirements are low energy consumption and comprehensive performance, then the array configuration of the fins is a straight-line array;

[0025] 4-4) If the porosity type is high porosity and the mass flow rate is low, then the array configuration of the fins should be determined based on the target requirements:

[0026] ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array.

[0027] ②If the target requirements are low energy consumption and comprehensive performance, then the array method of the fins is a straight array.

[0028] Preferably, when the porosity is ≤0.733, the porosity type is low porosity; when the porosity is >0.733, the porosity type is high porosity.

[0029] Preferably, when the mass flow rate is ≥0.12kg / s, the mass flow rate type is high flow rate, and when the mass flow rate is <0.12kg / s, the mass flow rate type is low flow rate.

[0030] Preferably, in step 5), the obtained alternative liquid-cooled plate fin layout schemes are verified using comprehensive performance indicators, and the liquid-cooled plate fin layout design scheme is obtained as follows:

[0031] If the comprehensive performance index is ≥1, then the alternative liquid-cooled plate fin column layout scheme shall be adopted as the liquid-cooled plate fin column layout design scheme.

[0032] If the overall performance index is less than 1, then this alternative liquid-cooled plate fin column layout scheme shall not be used as the liquid-cooled plate fin column layout design scheme.

[0033] Preferably, the expression for the comprehensive performance index is as follows:

[0034]

[0035] In the formula, TP is the comprehensive performance index, and N is the total performance index. u Let N be the Nusselt number. u0 denoted as the baseline Nusselt number corresponding to the baseline model scheme, f is the friction factor, and f0 is the friction factor corresponding to the baseline model scheme.

[0036] Preferably, the inherent parameters of the fin column include the fin column cross-sectional dimensions, fin column height, and fin column position.

[0037] Preferably, in step 1), the step of obtaining the porosity range includes:

[0038] 1-1) Determine the fin density range of the liquid cooling plate based on the geometric dimensions of the installation space and the amount of heat flux generated by the heat source;

[0039] 1-2) Using the density range of the fins, the porosity range is obtained as follows:

[0040]

[0041] In the formula, ε is the porosity, S is the total area of ​​the fin array region, and S1 is the total cross-sectional area of ​​the fin.

[0042] The beneficial effects of this invention are as follows:

[0043] A design method for a liquid-cooled plate fin layout of a motor controller includes the following steps:

[0044] 1) Determine the range of porosity based on the geometric parameters of the liquid cooling plate installation space and the heat flux parameters generated by the heat source;

[0045] 2) Based on the maximum output power of the coolant circulation pump, obtain the maximum flow velocity at the coolant inlet, and based on the maximum flow velocity at the coolant inlet, obtain the mass flow rate;

[0046] 3) Within the range of porosity determined in step 1), select several porosities and determine the porosity type of the corresponding porosity;

[0047] 4) Based on the target requirements, porosity, mass flow rate, and porosity type, the fin-pillar spacing ratio and fin-pillar array method are obtained, and several alternative liquid-cooled plate fin-pillar layout schemes are generated based on the inherent parameters of the fin-pillars.

[0048] 5) Using comprehensive performance indicators, the multiple liquid-cooled plate fin column layout alternatives in step 4) are verified to obtain the liquid-cooled plate fin column layout design scheme.

[0049] The design method of this invention precisely correlates the installation space of the liquid cooling plate, the heat flux generated by the heat source, and the porosity type. It also determines the flow rate and mass flow rate by combining the ultimate power of the coolant circulation pump. Then, it matches the fin spacing ratio and array method according to the target requirements. Finally, it determines multiple preliminary layout schemes by combining the inherent parameters of the fins. Based on the comprehensive performance indicators, it outputs a liquid cooling plate fin layout design scheme that meets the requirements. This method can effectively avoid the blindness of the design, ensure that the layout is adapted to the actual hardware limits and scenario requirements, and effectively balance heat dissipation efficiency and energy consumption, providing a clear and executable optimal design path for engineering applications.

[0050] Preferably, in step 3), the fin spacing ratio is the ratio of the spanwise spacing of the fins to the flowwise spacing of the fins, and the spanwise spacing of the fins is greater than the flowwise spacing of the fins.

[0051] This invention consistently adopts a design concept where the spanwise spacing of the fins is greater than the flowwise spacing of the fins. This fundamentally avoids the defects of a significantly increased system pressure drop and no gain in heat dissipation performance caused by a layout where the spanwise spacing is less than the flowwise spacing. At the same time, by adapting this spacing ratio to the fin array method, precise optimization of thermal-hydraulic performance can be achieved.

[0052] Preferably, in step 3), the specific method for determining the array configuration of the fins based on the target requirements, porosity, and mass flow rate is as follows:

[0053] 4-1) If the porosity type is low porosity and the mass flow rate is high, then the array method of the fin columns is determined to be an inline array.

[0054] 4-2) If the porosity type is low porosity and the mass flow rate is low, then the array configuration of the fins should be determined based on the target requirements:

[0055] ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array.

[0056] ②If the target requirements are low energy consumption and comprehensive performance, then the array configuration of the fins is a straight-line array;

[0057] 4-3) If the porosity type is high porosity and the mass flow rate is high, then the array configuration of the fins should be determined according to the target requirements:

[0058] ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array.

[0059] ②If the target requirements are low energy consumption and comprehensive performance, then the array configuration of the fins is a straight-line array;

[0060] 4-4) If the porosity type is high porosity and the mass flow rate is low, then the array configuration of the fins should be determined based on the target requirements:

[0061] ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array.

[0062] ②If the target requirements are low energy consumption and comprehensive performance, then the array method of the fins is a straight array.

[0063] This invention achieves the following beneficial effects by establishing a precise correspondence between porosity, mass flow rate, target requirements, and fin array configuration: 1. It completely avoids the blind selection of array configuration, clarifying the design direction through a combination of quantified parameters, eliminating the need for trial and error based on experience; 2. It maximizes the adaptation to performance requirements under different operating conditions, namely, inline configuration is selected for low porosity and high flow rate scenarios, which can significantly reduce pressure drop while ensuring heat dissipation; under low / high porosity conditions, staggered configuration is selected for high heat dissipation requirements to enhance fluid mixing and improve heat transfer, while inline configuration is selected for low energy consumption and comprehensive performance requirements to reduce pumping power consumption, precisely balancing heat dissipation efficiency and energy consumption; 3. It can provide clear array selection criteria for diverse application scenarios (such as compact spaces, high-flow industrial cooling, and balanced heat dissipation in data centers), ensuring that the liquid cooling plate can achieve optimal thermal-hydraulic performance under various operating conditions.

[0064] Preferably, when the porosity is ≤0.733, the porosity type is low porosity; when the porosity is >0.733, the porosity type is high porosity.

[0065] This invention, by clearly defining quantitative classification standards for porosity types, avoids layout design deviations caused by subjective porosity classification. Through the correlation logic of porosity type, mass flow rate, target requirements, and array method, subsequent porosity-based fin column layouts can accurately match parameters, ensuring the pertinence of the design scheme. At the same time, by limiting the range of porosity, it can effectively match the optimization requirements of liquid-cooled plate fin column density and flow channel space, stably supporting the optimization of thermal-hydraulic performance, avoiding insufficient heat exchange area or abnormal flow resistance caused by unclear porosity ranges, and providing key parameter guarantees for achieving a balance between heat dissipation and energy consumption.

[0066] Preferably, when the mass flow rate is ≥0.12kg / s, the mass flow rate type is high flow rate, and when the mass flow rate is <0.12kg / s, the mass flow rate type is low flow rate.

[0067] This invention provides clear parameter support for layout selection under different flow conditions by defining high and low mass flow rate quantitative classification standards, avoiding blind design. At the same time, the critical value is consistent with the thermal-hydraulic performance characteristics of the liquid cooling plate, which can stably match the heat dissipation and energy consumption balance requirements under different flow rates. It can prevent insufficient heat exchange or energy consumption surge due to unclear flow rate classification, thereby ensuring the optimal performance of the liquid cooling plate under various operating conditions.

[0068] Preferably, in step 5), the obtained alternative liquid-cooled plate fin layout schemes are verified using comprehensive performance indicators, and the liquid-cooled plate fin layout design scheme is obtained as follows:

[0069] If the comprehensive performance index is ≥1, then the alternative liquid-cooled plate fin column layout scheme shall be adopted as the liquid-cooled plate fin column layout design scheme.

[0070] If the overall performance index is less than 1, then this alternative liquid-cooled plate fin column layout scheme shall not be used as the liquid-cooled plate fin column layout design scheme.

[0071] Preferably, the expression for the comprehensive performance index is as follows:

[0072]

[0073] In the formula, TP is the comprehensive performance index, and N is the total performance index. u Let N be the Nusselt number. u0 denoted as the baseline Nusselt number corresponding to the baseline model scheme, f is the friction factor, and f0 is the friction factor corresponding to the baseline model scheme.

[0074] By introducing the comprehensive performance index TP and its quantitative calculation formula, the present invention transforms the balance relationship of "heat dissipation - energy consumption" into comparable numerical values, thereby avoiding deviation in judgment caused by a single performance index (such as only looking at heat dissipation or pressure drop), and ensuring that the obtained thermal - hydraulic performance meets the requirements of the layout scheme with an objective basis. That is to say, through the accurate screening of the TP value, a scheme that not only meets the heat dissipation requirements but also controls energy consumption is selected to exclude invalid designs with excellent single - performance but poor comprehensive performance; in addition, it can also provide a unified standard for the performance comparison of different layout schemes, making the evaluation of the comprehensive performance of liquid - cooling plates in engineering applications more consistent and repeatable, and ensuring the reliability and optimality of the final layout scheme.

[0075] Preferably, the inherent parameters of the finned columns include the finned - column cross - section size, finned - column height, and finned - column position.

[0076] The above - mentioned inherent parameters of the finned columns can provide complete and crucial basic parameter support for the layout design of the liquid - cooling plate finned columns, avoiding incomplete layout design or deviation from actual processing and heat - transfer requirements due to the lack of inherent parameters (such as the cross - section size affecting the heat - exchange area and flow - channel space, the height related to the heat - transfer efficiency, and the position ensuring the integrity of the array). Brief Description of the Drawings

[0077] Figure 1 is the flowchart of the layout design of the liquid - cooling plate finned columns in the embodiment of the present invention;

[0078] Figure 2 is the structural schematic diagram of the liquid - cooling plate in the embodiment of the present invention;

[0079] Figure 3 is the schematic diagram of the flow direction and span pitch;

[0080] Figure 4 is the streamline diagram of the coolant in the in - line arrangement under high and low porosity in the embodiment of the present invention;

[0081] Figure 5 is the coolant flow diagram with low porosity, where (a) is staggered; (b) is inline;

[0082] Figure 6 is the change of the maximum temperature with the mass flow rate for the designs of Ly / b > Lx / a and Ly / b < Lx / a;

[0083] Figure 7 is the change of the pressure drop with the mass flow rate in the designs of Ly / b > Lx / a and Ly / b < Lx / a;

[0084] Figure 8 is the change of the TP value with the mass flow velocity in the designs of Ly / b > Lx / a and Ly / b < Lx / a;

[0085] Figure 9This is a flowchart of the present invention;

[0086] In the attached diagram, 1-inlet, 2-outlet, 3-fin column, 4-IGBT heat source, 5-inlet channel, 6-outlet channel. Detailed Implementation

[0087] like Figures 1 to 8 As shown, a design method for a liquid-cooled plate fin layout of a motor controller includes the following steps:

[0088] 1) Based on the geometric dimensions of the liquid cooling plate installation space and the magnitude of the heat flux generated by the heat source, the porosity range is calculated. The steps for obtaining the porosity range include:

[0089] 1-1) Determine the maximum number of fins that can be arranged based on the geometric dimensions of the liquid cooling plate installation space (such as the height of the flow channel and the plane area), and determine the need to increase the fin density to improve the convective heat transfer area based on the heat flux generated by the heat source (such as the IGBT module). The two together determine the fin density range of the liquid cooling plate (i.e., the number of fins per unit area, or the ratio of the total cross-sectional area of ​​the fins to the total area of ​​the fin array region).

[0090] 1-2) Using the density range of the fins, the porosity range is obtained as follows:

[0091]

[0092] In the formula, ε is the porosity, S is the total area of ​​the fin array region, and S1 is the total cross-sectional area of ​​the fin.

[0093] 2) Based on the maximum output power of the coolant circulation pump that determines the maximum drivable fluid pressure and flow rate, the maximum flow rate of the coolant inlet is obtained. The maximum flow rate of the coolant inlet ensures that the operating conditions do not exceed the power carrying capacity of the pump. Based on the obtained flow rate, the mass flow rate m is calculated and divided into two categories: high flow rate and low flow rate.

[0094] When the mass flow rate m ≥ 0.12 kg / s, the mass flow rate type is high flow rate; when the mass flow rate m < 0.12 kg / s, the mass flow rate type is low flow rate. Here, 0.12 is the experimental calibration value.

[0095] 3) Within the range of porosity determined in step 1), several porosities are selected, and the porosity types corresponding to the porosities are determined. Among them, the porosity types include two types: low porosity and high porosity. When the porosity ≤ 0.733, the porosity type is low porosity; when the porosity > 0.733, the porosity type is high porosity. Here, 0.733 is the experimentally calibrated value. When the porosity is lower than this value, the pressure drop increases significantly, and the lowest pressure drop under various layouts obtained through simulation is close to 10,000 Pa.

[0096] 4) According to the target requirements, porosity, mass flow rate, and porosity type, the fin-to-fin spacing ratio and fin array pattern are obtained, and several alternative layouts of the liquid-cooled plate fins are generated based on the inherent parameters of the fins. Among them, the inherent parameters of the fins include the fin cross-sectional dimensions, fin height, and fin position. The target requirements include high heat dissipation target, low energy consumption target, and comprehensive performance target:

[0097] High heat dissipation target: This target aims to maximize heat dissipation, that is, to prioritize improving the heat transfer efficiency;

[0098] Low energy consumption target: The focus is on reducing energy consumption, that is, to prioritize reducing the fluid pressure drop (reducing pump work);

[0099] Comprehensive performance target: It is necessary to consider various performances such as heat dissipation and energy consumption, that is, to pursue the optimal overall performance.

[0100] The fin-to-fin spacing ratio is specifically the ratio of the spanwise spacing Ly / b of the fins to the flowwise spacing Lx / a of the fins. Among them, in the spanwise spacing Ly / b of the fins, the spanwise spacing Ly is the adjacent spacing of the fins perpendicular to the coolant flow direction, and b is the short-axis length of the fin; in the flowwise spacing Lx / a of the fins, the flowwise spacing Lx is the adjacent spacing of the fins in the coolant flow direction, and a is the long-axis length of the fin.

[0101] And during the design process, it should always be satisfied that: the spanwise spacing Ly / b of the fins > the flowwise spacing Lx / a of the fins. The value range of the relative spanwise spacing Ly / b is 1.9 - 2.7, and the value range of the relative flowwise spacing Lx / a is 1.5 - 2.3. This is because, after comparing through comparative experiments, it can be clearly known that: the pressure drop of the fin layout with Ly / b > Lx / a is much smaller than that of the fin layout with Ly / b < Lx / a under any porosity and mass flow rate, and more importantly, the heat transfer efficiency of the staggered liquid-cooled plate under the fin layout with Ly / b > Lx / a is the same as the heat transfer capacity under the fin layout with Ly / b < Lx / a under any mass flow direction and porosity.

[0102] Specifically, the fin array pattern includes in-line array and staggered array.

[0103] In the staggered array of liquid cooling plates, after the fluid flows through the fins 3, the staggered arrangement of the fins causes the fluid to flow from the primary channel into the secondary channel, resulting in a more uniform fluid distribution and stronger flow mixing, which helps to improve the heat transfer rate. In contrast, in the inline array of liquid cooling plates, the presence of a flow channel between adjacent upper and lower fins, along with the vortex behind the fins, further reduces the distance between the lateral fins. This causes a large amount of coolant to flow through the primary channel, with only a small amount flowing through the secondary channel. Therefore, experimental verification shows that the inline array of liquid cooling plates has a lower flow mixing capacity than the staggered array, but its flow resistance is significantly lower.

[0104] The specific method for determining the array configuration of the fins based on target requirements, porosity, and mass flow rate is as follows:

[0105] 4-1) If the porosity type is low porosity and the mass flow rate is high, then the array method of the fin columns is determined to be an inline array.

[0106] This array layout can effectively improve heat transfer performance and suppress the increase in pressure drop, thereby improving the overall performance of the liquid cooling plate. Therefore, it is very suitable for scenarios that require rapid heat dissipation and controllable flow.

[0107] 4-2) If the porosity type is low porosity and the mass flow rate is low, then the array configuration of the fins should be determined based on the target requirements:

[0108] ①If the target requirement is high heat dissipation, then in order to improve heat exchange efficiency, the fin array should be an interleaved array.

[0109] ②If the target requirements are low energy consumption and overall performance, then in order to effectively reduce voltage drop and improve overall performance, the fin array should be in a straight line array.

[0110] 4-3) If the porosity type is high porosity and the mass flow rate is high, then the array configuration of the fins should be determined according to the target requirements:

[0111] ① If the target requirement is high heat dissipation, then the array of fins should be an interleaved array. This array type has the best heat transfer performance at medium to high porosity and low flow rate, which can improve heat dissipation efficiency.

[0112] ②If the target requirements are low energy consumption and overall performance, then in order to significantly reduce voltage drop and improve overall performance, the fin array should be in a straight line array.

[0113] 4-4) If the porosity type is high porosity and the mass flow rate is low, then the array configuration of the fins should be determined based on the target requirements:

[0114] ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array.

[0115] ②If the target requirements are low energy consumption and comprehensive performance, then the array method of the fins is a straight array.

[0116] In this embodiment, the specific array configuration of the fin columns is determined as described above as follows:

[0117] ① When the application scenario is a compact space (such as microelectronic devices), due to the limited space and the need for efficient heat transfer, high-density finned columns should be designed to improve heat transfer efficiency. In this case, the smaller the porosity, the better. If the fluid input flow rate (i.e., mass flow rate) is high, then an inline arrangement with a relative spanwise spacing greater than the relative flowwise spacing should be selected. This not only effectively improves heat transfer performance but also effectively suppresses the increase in pressure drop. If the fluid input flow rate (i.e., mass flow rate) is low, then a staggered arrangement with a relative spanwise spacing greater than the relative flowwise spacing should be used to ensure efficient heat transfer.

[0118] ② When the application scenario is a high-flow-rate forced convection scenario (such as an industrial cooling system), the fluid velocity in this scenario is high, which will lead to the problem of excessive pressure drop. However, since the heat dissipation efficiency of the inline arrangement is not significantly different from that of the staggered arrangement at different porosities under high flow rates, the inline arrangement with a relative spanwise spacing greater than the relative flow-wise spacing can significantly reduce the pressure drop and is suitable for high-flow-rate scenarios.

[0119] ③ When the application scenario is a balanced performance scenario (such as data center cooling, electric vehicle battery thermal management), it is necessary to consider both heat transfer and pressure drop issues. The inline arrangement has certain advantages in overall performance under any operating conditions and porosity. The inline arrangement with a relative spanwise spacing greater than the relative flow spacing is more suitable for application scenarios that balance heat transfer and energy consumption.

[0120] 5) Since the obtained liquid-cooled plate fin column layout model may have issues such as high heat transfer efficiency but excessive flow resistance, or low heat transfer efficiency but low flow resistance, it is necessary to use comprehensive performance index parameters to verify the multiple liquid-cooled plate fin column layout alternatives in step 4), and obtain the liquid-cooled plate fin column layout design scheme. The specific method is as follows:

[0121] If the comprehensive performance index is ≥1, then the alternative liquid-cooled plate fin column layout scheme shall be adopted as the liquid-cooled plate fin column layout design scheme.

[0122] If the overall performance index is less than 1, then this alternative liquid-cooled plate fin column layout scheme shall not be used as the liquid-cooled plate fin column layout design scheme.

[0123] The expression for the comprehensive performance index is as follows:

[0124]

[0125] In the formula, TP is the comprehensive performance index, and N is the total performance index. u Let N be the Nusselt number. u0 denoted as the baseline Nusselt number corresponding to the baseline model scheme, f is the friction factor, and f0 is the friction factor corresponding to the baseline model scheme.

[0126] In practical applications, the comprehensive performance index of the inline liquid-cooled plate with a porosity of 0.733 and an operating condition of 0.01 kg / s is set to 1, serving as the benchmark model. Other models are compared with this benchmark model. If the final comprehensive performance value (TP) is less than 1, it indicates that the overall performance of this model is lower than the benchmark model, and this model cannot be used as a liquid-cooled plate fin column layout scheme. If the final comprehensive performance value (TP) is greater than 1, it indicates that the overall performance of this model is better than the benchmark model, and this model can be used as a liquid-cooled plate fin column layout scheme.

[0127] It is important to note that in the actual design process, the final liquid-cooled plate fin layout design can be one or more. Furthermore, the liquid-cooled plate fin layout design obtained after comprehensive performance verification can be considered a design with excellent overall thermal-hydraulic performance. However, in the actual production process of liquid-cooled plates, it is often necessary to consider the actual finished product, manufacturing process, and other factors to ultimately determine the most suitable layout.

[0128] The specific implementation of the above steps is as follows:

[0129] 1) Calculate the porosity range based on the geometric dimensions of the liquid cooling plate installation space (such as flow channel height and planar area) and the heat flux generated by the heat source:

[0130] 1-1) In this embodiment, as Figure 2 As shown, the liquid cooling plate has a flow channel height of 6.3 mm and a planar area of ​​0.0084 m². 2 Furthermore, the heat flux generated by the heat source (i.e., IGBT heat source 4) is 1450 KW / m². 2 Furthermore, the total cross-sectional area of ​​the fin column was determined to be 0.002268-0.00105 m². 2 .

[0131] 1-2) Using the range of fin density (i.e., the total cross-sectional area of ​​the fins), the range of porosity is obtained as follows:

[0132]

[0133] In the formula, ε is the porosity, S is the total area of ​​the fin array region, and S1 is the total cross-sectional area of ​​the fins. In this embodiment, the total area S of the fin array region is 0.0084 m². 2The total cross-sectional area S1 of the fin column is 0.002268-0.00105m². 2 Therefore, the porosity ε is 0.73-0.87.

[0134] 2) In this embodiment, the maximum output power of the coolant circulation pump is 1.04W, the flow velocity is calculated to be 0.82m / s based on the fluid density, and the converted mass flow rate is 0.14kg / s based on the volumetric flow rate, and this mass flow rate type is high flow rate. The coolant flows from the inlet 1 of the inlet channel 5 through the finned column 3 and finally to the outlet 2 of the outlet channel 6.

[0135] 3) Within the range of porosity ε of 0.73-0.87, select several porosities, and the porosity type corresponding to each porosity is low porosity.

[0136] 4) Based on the target requirements, porosity, mass flow rate, and porosity type, the fin-pillar spacing ratio and fin-pillar array method are obtained, and several alternative liquid-cooled plate fin-pillar layout schemes are generated based on the inherent parameters of the fin-pillars.

[0137] In this embodiment, the target requirement is high heat dissipation and low energy consumption. The porosity type determined in step 1) is low porosity, and the mass flow rate determined in step 2) is high flow rate. Finally, the array mode of the fin column is determined to be a Ly / b>Lx / a inline fin column layout.

[0138] 4) The cross-sectional dimensions of the fin column include the shape of the fin column cross-section and the characteristic dimensions of the fin column. In this embodiment, the fin column cross-section is elliptical, and the ratio of the major axis a to the minor axis b of the ellipse is 1.5:1. To ensure the optimal matching between the flow channel cross-sectional area and the projected area of ​​the needle fin (i.e., the fin column), the fin column height is 92% of the flow channel height. In order to enable the fin column to better transfer heat with the heat source, the fin column roots on the liquid cooling plate are distributed on one side of the heat source, that is, several alternative liquid cooling plate fin column layout schemes are output.

[0139] 5) The obtained alternative liquid-cooled plate fin layout schemes are verified using comprehensive performance indicators, wherein the comprehensive performance indicators are calculated using the following formula:

[0140]

[0141] In the formula, TP is the comprehensive performance index, and N is the total performance index. u Let N be the Nusselt number. u0 denoted as the baseline Nusselt number corresponding to the baseline model scheme, f is the friction factor, and f0 is the friction factor corresponding to the baseline model scheme.

[0142] In this embodiment, the comprehensive performance index is 0.74-1.18. The comprehensive performance index of the inline liquid-cooled plate with a porosity of 0.733 and an operating condition of 0.01 kg / s is set to 1 and used as the benchmark model. The other models are compared with this benchmark model. If the final comprehensive performance TP value is less than 1, it indicates that the comprehensive performance of this model is lower than the benchmark model; if the final comprehensive performance TP value is greater than 1, it indicates that the comprehensive performance of this model is better than the benchmark model. A higher value indicates better performance. In other words, the liquid-cooled plate fin column layout alternatives with a comprehensive performance TP value greater than 1 are output as the design schemes that meet the conditions and have good thermo-hydraulic performance.

[0143] according to Figure 8 It can be seen that the inline fin column layout with Ly / b > Lx / a at a porosity of 0.733 has the best overall performance at the highest operating condition of 0.14 kg / s.

[0144] To further verify the differences in thermo-hydraulic performance between different fin column layout designs, the following embodiments were performed: Figures 5 to 8 Simulation and experiment:

[0145] Example 1: Analysis of coolant flow characteristics under different spacing ratios, the results are as follows Figure 5 As shown in the diagram. Analysis reveals that, under the design condition of Ly / b < Lx / a, a significant increase in the flow spacing of the fins in an inline liquid cooling plate leads to a weakening of the interaction intensity of the vortices behind the fins between rows. Simultaneously, the coolant, after passing through the vortex region behind the fins, diffuses longitudinally, achieving a flow mixing effect similar to that of a staggered liquid cooling plate. This change in hydrodynamic characteristics ultimately results in the heat transfer rate of the inline liquid cooling plate approaching that of the staggered type when the relative spanwise spacing is smaller than the relative flow spacing.

[0146] Example 2: The heat transfer performance of the liquid-cooled plate was analyzed under two design conditions: Ly / b > Lx / a and Ly / b < Lx / a. The results are as follows: Figure 6As shown in the diagram. Comparative analysis reveals that under the Ly / b < Lx / a design, the heat transfer efficiency of various liquid cooling plates remains highly similar across different porosities (0.73–0.87) and inlet flow rates (0.08–0.14 kg / s), and the maximum temperature difference in all scenarios is only 1.7 K. This indicates that the heat transfer performance under this design condition is less sensitive to the layout. However, the inline liquid cooling plate using the Ly / b > Lx / a design of this invention shows a significant increase in heat transfer efficiency with increasing inlet flow rate and decreasing porosity, eventually reaching the same heat transfer rate as other finned column layouts (such as staggered layouts). Especially when the porosity ε = 0.733 and the mass flow rate m = 0.14 kg / s (i.e., the high flow rate condition in this embodiment), the maximum temperature difference for all finned column layout models under both designs does not exceed 0.4 K. At this point, the heat transfer rate of the liquid cooling plates in all finned column layout designs has become consistent. In summary, the Ly / b > Lx / a design demonstrates potential for heat transfer optimization under high flow rate and low porosity conditions.

[0147] Example 3: Comparative analysis of the hydraulic performance (pressure drop) of the liquid-cooled plate under two design conditions: Ly / b > Lx / a and Ly / b < Lx / a. Figure 7 As shown in the figure, analysis reveals that the hydraulic performance of the liquid-cooled plate under the Ly / b < Lx / a design is significantly lower than that under the Ly / b > Lx / a design, and this performance difference becomes increasingly significant with increasing fin density (i.e., decreasing porosity) and mass flow rate. Taking the highest operating condition (porosity decreasing from 0.873 to 0.733, mass flow rate 0.14 kg / s) as an example, the pressure drop difference of the inline liquid-cooled plate under the Ly / b < Lx / a design increases sharply from 19% to 92.4% compared to the inline liquid-cooled plate under the Ly / b > Lx / a design. In other words, the Ly / b < Lx / a design will generate significant flow resistance losses under high load conditions, which conflicts with the low energy consumption target requirement of this embodiment; while the Ly / b > Lx / a design can effectively control the pressure drop increase and is more suitable for energy-sensitive scenarios such as new energy vehicles and rail transit.

[0148] Example 4: Comparative analysis of the comprehensive performance of liquid cooling plates under two design conditions: Ly / b > Lx / a and Ly / b < Lx / a. Figure 8 As shown in the figure. Analysis reveals that under the Ly / b > Lx / a design, the overall performance of the inline liquid cooling plate is generally better than that of the staggered design, and this advantage gradually increases as the porosity decreases (fin density increases). However, for the Ly / b < Lx / a design, although the inline liquid cooling plate still maintains a certain overall performance advantage, its overall performance difference with the staggered liquid cooling plate is minimal, exhibiting high consistency under various operating conditions. This indicates that under this design condition, it is difficult to achieve significant optimization of overall performance through layout.

[0149] In summary, the design method of this invention can clearly define its applicable scenarios for different design conditions, and optimize the array form and spacing configuration of the fins through specific parameter design basis, providing a practical optimization solution for engineering practice. Furthermore, practical verification shows that the liquid cooling plate designed according to the method of this invention can not only significantly improve heat dissipation efficiency and reduce the maximum operating temperature of electronic devices, thereby effectively extending the service life of the devices, but also significantly reduce fluid flow pressure drop, thereby reducing the pumping power of the circulation system and achieving energy savings.

[0150] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications made to the present invention by those skilled in the art without departing from the spirit of the present invention shall fall within the protection scope of the present invention.

Claims

1. A design method for a liquid-cooled plate fin column layout of a motor controller, characterized in that, Includes the following steps: 1) Determine the range of porosity based on the geometric parameters of the liquid cooling plate installation space and the heat flux parameters generated by the heat source; 2) Based on the maximum output power of the coolant circulation pump, obtain the maximum flow velocity at the coolant inlet, and based on the maximum flow velocity at the coolant inlet, obtain the mass flow rate; 3) Within the range of porosity determined in step 1), select several porosities and determine the porosity type of the corresponding porosity; 4) Based on the target requirements, porosity, mass flow rate, and porosity type, the fin-pillar spacing ratio and fin-pillar array method are obtained, and several alternative liquid-cooled plate fin-pillar layout schemes are generated based on the inherent parameters of the fin-pillars. 5) Using comprehensive performance indicators, the multiple liquid-cooled plate fin column layout alternatives in step 4) are verified to obtain the liquid-cooled plate fin column layout design scheme.

2. The design method according to claim 1, characterized in that, In step 4), the fin spacing ratio is the ratio of the spanwise spacing of the fins to the flowwise spacing of the fins, and the spanwise spacing of the fins is greater than the flowwise spacing of the fins.

3. The design method according to claim 1, characterized in that, In step 3), the specific method for determining the array configuration of the fins based on the target requirements, porosity, and mass flow rate is as follows: 4-1) If the porosity type is low porosity and the mass flow rate is high, then the array method of the fin columns is determined to be an inline array. 4-2) If the porosity type is low porosity and the mass flow rate is low, then the array configuration of the fins should be determined based on the target requirements: ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array. ②If the target requirements are low energy consumption and comprehensive performance, then the array configuration of the fins is a straight-line array; 4-3) If the porosity type is high porosity and the mass flow rate is high, then the array configuration of the fins should be determined according to the target requirements: ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array. ②If the target requirements are low energy consumption and comprehensive performance, then the array configuration of the fins is a straight-line array; 4-4) If the porosity type is high porosity and the mass flow rate is low, then the array configuration of the fins should be determined based on the target requirements: ①If the target requirement is high heat dissipation, then the fin array should be an interleaved array. ②If the target requirements are low energy consumption and comprehensive performance, then the array method of the fins is a straight array.

4. The design method according to claim 3, characterized in that, When the porosity is ≤0.733, the porosity type is low porosity; when the porosity is >0.733, the porosity type is high porosity.

5. The design method according to claim 3, characterized in that, When the mass flow rate is ≥0.12kg / s, the mass flow rate type is high flow rate; when the mass flow rate is <0.12kg / s, the mass flow rate type is low flow rate.

6. The design method according to claim 1, characterized in that, In step 5), the several alternative liquid-cooled plate fin layout schemes are verified using comprehensive performance indicators, and the liquid-cooled plate fin layout design scheme is obtained as follows: If the comprehensive performance index is ≥1, then the alternative liquid-cooled plate fin column layout scheme shall be adopted as the liquid-cooled plate fin column layout design scheme. If the overall performance index is less than 1, then this alternative liquid-cooled plate fin column layout scheme shall not be used as the liquid-cooled plate fin column layout design scheme.

7. The design method according to claim 6, characterized in that, The expression for the comprehensive performance index is as follows: In the formula, TP is the comprehensive performance index, and N is the total performance index. u Let N be the Nusselt number. u0 denoted as the baseline Nusselt number corresponding to the baseline model scheme, f is the friction factor, and f0 is the friction factor corresponding to the baseline model scheme.

8. The design method according to claim 1, characterized in that, The inherent parameters of the fin column include the fin column cross-sectional dimensions, fin column height, and fin column position.

9. The design method according to claim 1, characterized in that, Step 1), the steps for obtaining the porosity range include: 1-1) Determine the fin density range of the liquid cooling plate based on the geometric dimensions of the installation space and the amount of heat flux generated by the heat source; 1-2) Using the density range of the fins, the porosity range is obtained as follows: In the formula, ε is the porosity, S is the total area of ​​the fin array region, and S1 is the total cross-sectional area of ​​the fin.

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