Hybrid heat dissipation system of lightweight motor driver and control method

Abstract

The invention discloses a hybrid heat dissipation system of a lightweight motor driver and a control method, and belongs to the technical field of motor heat management and energy-saving heat exchange control, and the hybrid heat dissipation system comprises a data acquisition module, a state estimation module, a threshold value dynamic adjustment module, a state grade determination module and an instruction execution control module. A loss model and a phase change kinetic model are adopted to estimate the melting proportion of the phase change material in each partition in real time, a system task instruction is analyzed to dynamically adjust a judgment threshold value, hierarchical logic comparison is achieved, and a heat dissipation instruction is generated; heat flow distribution is adjusted through space vector pulse width modulation, a boundary layer disturbance device is combined to destroy a fluid boundary layer, and phase change regeneration operation is executed. According to the method, the heat management strategy and the task target can be adaptively coupled, the heat dissipation energy consumption is reduced while high-performance output is ensured, and the continuous working capacity and the overall energy efficiency of the system under high load are improved.

Description

Technical Field

[0001] This invention relates to the field of motor thermal management and energy-saving heat exchange control technology, and in particular to a hybrid heat dissipation system and control method for a lightweight motor driver. Background Technology

[0002] As the core control component for motor operation, the motor driver generates a significant amount of heat during operation due to the power semiconductor devices. To ensure stable system operation under high loads, an efficient cooling system is typically designed to cool the driver.

[0003] In related technologies, Chinese invention patent CN103700638A discloses a phase change material thermal buffer device and method for heat dissipation of high-power devices. It utilizes the constant temperature of phase change material during phase change heat absorption as a cold end for heat conduction, promptly transferring heat dissipated by the hot-end device into the phase change energy storage material. The device consists of a heat sink, a honeycomb structure etched at the bottom of the heat sink, and phase change material filling the honeycomb cavities. Its effectiveness is evaluated or adjusted by the temperature distribution after operating at high power for a certain period.

[0004] Regarding the aforementioned technologies, the inventors believe that while phase change materials (PCMs) can absorb transient heat, existing thermal management methods largely rely on simple temperature threshold triggering or static thermal model evaluation, failing to accurately perceive the melting state within the PCM in real time. This makes it difficult for the heat dissipation system to adaptively couple with upper-level task objectives under complex and variable operating conditions, hindering the optimal balance between pursuing extreme performance, quiet operation, and energy saving, resulting in low overall system energy efficiency and hindering lightweight integrated applications. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides a hybrid heat dissipation system and control method for a lightweight motor driver. This method determines the thermal state level by estimating the real-time melting ratio of the phase change material and dynamically adjusts the determination threshold according to performance priorities, thereby generating graded heat dissipation control commands. This enables refined and adaptive control of the driver's thermal management, effectively balancing system performance, energy efficiency, and reliability.

[0006] To achieve the above objectives, this application adopts the following technical solution:

[0007] In a first aspect, a hybrid heat dissipation control method for a lightweight motor driver is provided, comprising: acquiring real-time electrical parameters and real-time temperature data of power devices and system task instructions from an upper-level control system; estimating the real-time melting ratio of phase change materials in each partition of the driver based on the real-time electrical parameters and real-time temperature data, using a preset power device loss model and phase change dynamics model; parsing the system task instructions to identify the current performance priority, and dynamically adjusting a first threshold and a second threshold in a configuration memory according to the performance priority; determining the current thermal state level by comparing the real-time melting ratio with the adjusted first threshold and second threshold using hierarchical logic; and generating corresponding heat dissipation control instructions according to the determined thermal state level, wherein the heat dissipation control instructions include a cooperative control instruction for delaying temperature rise and a limit heat dissipation instruction for restoring thermal buffer capacity.

[0008] Based on the above technical solution, in the hybrid heat dissipation control method for a lightweight motor driver provided in this application, the method determines the thermal state level by estimating the real-time melting ratio of the phase change material and dynamically adjusts the determination threshold according to the performance priority, thereby generating graded heat dissipation control commands. This enables refined and adaptive control of the driver's thermal management, effectively balancing system performance, energy efficiency, and reliability.

[0009] In conjunction with the first aspect above, in one possible implementation, estimating the real-time melting ratio of the phase change material in each partition within the driver includes: acquiring the real-time electrical parameters of the power device and, in conjunction with the real-time temperature data, calculating the real-time heat flow input of each partition within the driver using a preset power device loss model; inputting the real-time heat flow input and the thermal characteristic parameters of the phase change material into a phase change kinetic model, wherein the thermal characteristic parameters include melting point and latent heat of phase change; and, through calculation using the phase change kinetic model, outputting the real-time melting ratio of the phase change material in each partition, and separately identifying the real-time melting ratio of the partition located upstream of the heat flow path as a weighted reference value for hierarchical logical comparison.

[0010] In conjunction with the first aspect above, in one possible implementation, the hierarchical logical comparison of the real-time melting ratio with the adjusted first threshold and second threshold includes: determining whether the real-time melting ratio of all partitions is lower than the first threshold; if so, determining the thermal state level as standard mode and maintaining the current driving strategy; if the real-time melting ratio of any partition reaches or exceeds the first threshold but is lower than the second threshold, determining the thermal state level as collaborative intervention mode and triggering a collaborative control command; if the real-time melting ratio of any partition reaches or exceeds the second threshold, determining the thermal state level as extreme heat dissipation mode and triggering an extreme heat dissipation command to prevent thermal failure of power devices through external forced cooling.

[0011] In conjunction with the first aspect above, in one possible implementation, the collaborative control command includes: identifying high heat load zones and low heat load zones based on the real-time melting ratio of each zone; dynamically transferring switching losses from the power devices corresponding to the high heat load zones to the power devices corresponding to the low heat load zones by adjusting the control parameters of the space vector pulse width modulation signal; generating a first drive signal and sending it to a boundary layer disturbance integrated in the motor housing; driving the boundary layer disturbance to operate in a preset low-intensity intermittent mode; using mechanical micro-vibration to prematurely disrupt the laminar boundary layer of the fluid outside the motor housing; optimizing convective heat transfer conditions; and delaying the temperature rise of the phase change material.

[0012] In conjunction with the first aspect above, in one possible implementation, the extreme heat dissipation command includes: generating a second driving signal to drive the boundary layer disturbance to operate in a maximum intensity continuous working mode, and simultaneously activating an external active cooling circulation path; monitoring the heat transfer parameters of the active cooling circulation path in real time, and triggering a phase change material regeneration program when the cooling medium flow rate and heat transfer efficiency are confirmed to reach a preset stable threshold; identifying a saturated zone with a real-time melting ratio of 1, and directing the residual heat load of the driving system to the power device corresponding to the saturated zone by adjusting the space vector pulse width modulation parameters, using the active cooling circulation to remove the latent heat of phase change released by the phase change material during solidification, until the real-time melting ratio of the target zone drops below the first threshold.

[0013] In conjunction with the first aspect above, in one possible implementation, dynamically adjusting the first and second thresholds in the configuration memory according to the performance priority includes: parsing the priority configuration identifier in the system task instruction, wherein the priority configuration identifier includes low electromagnetic noise priority, high output performance priority, and long battery life priority; if low electromagnetic noise priority is given, the value of the first threshold is actively lowered to increase the system's sensitivity to heat accumulation and trigger the cooperative control instruction that does not generate aerodynamic noise in advance; if high output performance priority is given, the value of the second threshold is actively raised to authorize the system to fully utilize the entire latent heat capacity of the phase change material, thereby extending the continuous working time of the power device under peak output conditions; if long battery life priority is given, the first and second thresholds are simultaneously lowered to lock the system in a low thermal stress operating range and optimize the total energy efficiency cost of the heat dissipation system.

[0014] In conjunction with the first aspect described above, in one possible implementation, the method further includes calibrating the phase change kinetic model and the power device loss model: controlling the motor driver to operate under a preset reference load spectrum, and simultaneously collecting actual temperature change data of each zone and real-time electrical parameters of the power device; using the real-time electrical parameters to generate a theoretical temperature curve through the uncalibrated loss model and kinetic model, and calculating the deviation data between the actual temperature change data and the theoretical temperature curve; based on the deviation data, iteratively identifying key model parameters in the loss model and kinetic model, generating calibrated key parameters and storing them in a non-volatile memory, wherein the key model parameters include interface thermal resistance and equivalent convective heat transfer coefficient.

[0015] In conjunction with the first aspect described above, in one possible implementation, the method further includes hardware composition optimization based on the calibrated model: performing simulation using the calibrated key parameters and the reference load spectrum, setting the melting point of the phase change material in each partition as an adjustable optimization variable, and optimizing with the goal of minimizing the time variance of the real-time melting ratio of each partition reaching the first threshold; determining a set of ideal melting point values ​​that can synchronize the thermal response of each partition based on the optimization results; comparing the ideal melting point values ​​with the melting point of the phase change material actually used in the current hardware, and generating optimization suggestions containing the adjustment direction of the phase change material composition in each partition, which are used to guide the improvement of the physical structure of the driver.

[0016] Secondly, a hybrid heat dissipation system for a lightweight motor driver is provided, comprising: a data acquisition module for acquiring real-time electrical parameters and real-time temperature data of power devices and system task instructions from an upper-level control system; a state estimation module for estimating the real-time melting ratio of phase change materials in each partition of the driver based on the real-time electrical parameters and real-time temperature data, using a preset power device loss model and phase change dynamics model; a threshold dynamic adjustment module, including a configuration memory, for parsing the system task instructions to identify the current performance priority, and dynamically adjusting a first threshold and a second threshold in the configuration memory according to the performance priority; a state level determination module for determining the current thermal state level by performing a hierarchical logical comparison between the real-time melting ratio and the adjusted first threshold and second threshold; and an instruction execution and control module, communicatively connected to a boundary layer disturbance integrated in the motor housing and the power devices, for generating corresponding heat dissipation control instructions according to the determined thermal state level, wherein the heat dissipation control instructions include a cooperative control instruction for delaying temperature rise and a limit heat dissipation instruction for restoring thermal buffer capacity.

[0017] Compared with the prior art, the present invention has the following advantages:

[0018] This invention achieves deep utilization of the latent heat buffer capacity inside the actuator by accurately estimating and controlling the melting ratio of the phase change material. Compared with traditional control methods that rely on temperature measurement, this method can accurately grasp the heat storage state of the phase change material, avoiding premature or delayed activation of active cooling. This extends the continuous operating time of the actuator under transient high-power output conditions, fully tapping the performance potential of the system.

[0019] This invention proposes an adaptive heat dissipation strategy that is linked to the objectives of higher-level tasks. By analyzing system performance priorities and dynamically adjusting the threshold for determining thermal state, the heat dissipation control behavior can flexibly match whether the current priority is to pursue ultimate performance, focus on battery life and energy efficiency, or require low noise and comfort. This intelligent decision-making mechanism enables the entire motor drive system to have stronger adaptability to different operating conditions, exhibiting optimal overall performance in various application scenarios.

[0020] This invention establishes a hierarchical heat dissipation control system ranging from mild intervention to extreme protection. Cooperative control commands proactively delay heat accumulation through low-energy methods such as loss transfer and enhanced heat transfer via micro-vibration, effectively improving the overall energy efficiency of the system and reducing operating noise. Extreme heat dissipation commands ensure that powerful cooling measures are decisively activated to protect hardware safety when the thermal state is nearing runaway. This tiered response mechanism balances the economy of daily operation with reliability under extreme conditions.

[0021] This invention provides a system-level design and verification method from model calibration to hardware optimization. Through iterative identification of model parameters based on measured data, the long-term accuracy of online state estimation is ensured. Furthermore, simulation optimization using the calibrated high-precision model can guide improvements in hardware design, such as the physical proportions of phase change materials, forming a virtuous cycle between software control and physical design. This provides a data-driven engineering approach for developing motor drive systems with more balanced thermal performance and higher efficiency.

[0022] It should be understood that the descriptions of technical features, technical solutions, beneficial effects, or similar language in this application do not imply that all features and advantages can be achieved in any single embodiment. Rather, it is understood that the description of a feature or beneficial effect means that a specific technical feature, technical solution, or beneficial effect is included in at least one embodiment. Therefore, the descriptions of technical features, technical solutions, or beneficial effects in this specification do not necessarily refer to the same embodiment. Furthermore, the technical features, technical solutions, and beneficial effects described in this embodiment can be combined in any suitable manner. Those skilled in the art will understand that embodiments can be implemented without one or more specific technical features, technical solutions, or beneficial effects of a particular embodiment. In other embodiments, additional technical features and beneficial effects may be identified in specific embodiments that do not embody all embodiments. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 A structural architecture diagram of a hybrid heat dissipation system for a lightweight motor driver provided in an embodiment of this application;

[0025] Figure 2 A schematic flowchart illustrating a hybrid heat dissipation control method for a lightweight motor driver provided in an embodiment of this application;

[0026] Figure 3 This is a graph showing the relationship between the junction temperature of the power device and the melting ratio of the phase change material, provided in an embodiment of this application.

[0027] Figure 4 This is a comparison diagram of the synchronization of partition thermal response before and after hardware configuration optimization provided in the embodiments of this application. Detailed Implementation

[0028] In the description of this application, unless otherwise stated, " / " means "or," for example, A / B can mean A or B. The "and / or" in this document is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, and B alone. Furthermore, "at least one" means one or more, and "multiple" means two or more. The terms "first," "second," etc., do not limit the quantity or order of execution, and "first," "second," etc., do not necessarily imply differences.

[0029] It should be noted that, in this application, the terms "exemplary" or "for example" are used to indicate that something is being described as an example, illustration, or illustration. Any embodiment or design described as "exemplary" or "for example" in this application should not be construed as being more preferred or advantageous than other embodiments or design solutions. Specifically, the use of terms such as "exemplary" or "for example" is intended to present the relevant concepts in a concrete manner.

[0030] The hybrid heat dissipation control method for a lightweight motor driver provided in this application embodiment can be applied to, for example... Figure 1 In the hybrid heat dissipation system 100 of a lightweight motor driver shown, such as Figure 1 As shown, the system includes:

[0031] The data acquisition module is used to acquire real-time electrical parameters and real-time temperature data of power devices, as well as system task instructions from the upper control system.

[0032] The state estimation module is used to estimate the real-time melting ratio of phase change materials in each partition of the driver based on the real-time electrical parameters and real-time temperature data, through a preset power device loss model and phase change kinetics model.

[0033] The threshold dynamic adjustment module includes a configuration memory for parsing the system task instructions to identify the current performance priority, and dynamically adjusting the first threshold and the second threshold in the configuration memory according to the performance priority.

[0034] The state level determination module is used to determine the current thermal state level by comparing the real-time melting ratio with the adjusted first threshold and second threshold using hierarchical logic.

[0035] The instruction execution and control module is communicatively connected to the boundary layer disturbance and power devices integrated in the motor housing. It is used to generate corresponding heat dissipation control instructions based on the determined thermal state level. The heat dissipation control instructions include cooperative control instructions for delaying temperature rise and extreme heat dissipation instructions for restoring thermal buffer capacity.

[0036] like Figure 2 As shown in the figure, this application provides a hybrid heat dissipation control method for a lightweight motor driver, including:

[0037] Acquire real-time electrical parameters and temperature data of power devices, as well as system task commands from the upper control system;

[0038] Based on the real-time electrical parameters and real-time temperature data, the real-time melting ratio of phase change materials in each partition of the driver is estimated by using a preset power device loss model and phase change kinetics model.

[0039] The system task instructions are parsed to identify the current performance priority, and the first and second thresholds in the configuration memory are dynamically adjusted according to the performance priority.

[0040] The current thermal state level is determined by comparing the real-time melting ratio with the adjusted first threshold and second threshold using a hierarchical logic.

[0041] Based on the determined thermal state level, a corresponding heat dissipation control command is generated, wherein the heat dissipation control command includes a cooperative control command for delaying temperature rise and a limit heat dissipation command for restoring thermal buffer capacity.

[0042] It should be noted that by collecting electrical and temperature data in real time and inputting them into a preset power device loss model and phase change dynamics model, the key internal state quantity that is physically difficult to measure directly—the real-time melting ratio of the phase change material in each zone—is accurately estimated. Simultaneously, upper-level system task instructions are parsed to identify performance priorities, and based on this, the first and second thresholds used for state determination are dynamically adjusted to ensure that the trigger boundary of the heat dissipation strategy matches the system's macroscopic objectives. Subsequently, by logically comparing the estimated real-time melting ratio with the adjusted grading thresholds, the thermal state of the driver is divided into distinct levels. Finally, based on this thermal state level, hierarchical heat dissipation control instructions are generated and executed, including cooperative control instructions for early, mild intervention and extreme heat dissipation instructions for handling critical states, forming a complete adaptive control loop from perception, estimation, decision-making to execution.

[0043] In one possible implementation of the embodiments of this application, combined with Figure 2 The estimated real-time melting ratio of the phase change material in each partition within the driver includes:

[0044] The real-time electrical parameters of the power device are obtained, and combined with the real-time temperature data, the real-time heat flow input of each partition in the driver is calculated through a preset power device loss model.

[0045] The real-time heat flow input and the thermal characteristic parameters of the phase change material are input into the phase change kinetic model, wherein the thermal characteristic parameters include melting point and latent heat of phase change;

[0046] The phase change kinetics model is used to calculate and output the real-time melting ratio of the phase change material in each partition. The real-time melting ratio of the partition located upstream of the heat flow path is separately identified and used as a weighted reference value for hierarchical logical comparison.

[0047] In some implementations, the real-time heat generation power of the power devices, acting as heat sources, in each zone is precisely calculated, i.e., the real-time heat flow input. Real-time temperature data of the power devices is acquired at high frequency using onboard sensors, such as negative temperature coefficient thermistors (NTCs) integrated into the power module substrate and Hall effect sensors connected in parallel to the phase current output path. And real-time electrical parameters, which typically include DC bus voltage. RMS value of phase current and the switching frequency of space vector pulse width modulation. These data are fed into a pre-defined power device loss model, which, based on semiconductor physics, decomposes the total loss into conduction loss and switching loss. Real-time heat flow input. The calculation is performed using the following formula:

[0048] ;

[0049] in, This represents the thermal power generated by a single power device, measured in watts. For power devices at junction temperature The on-resistance is obtained by consulting a two-dimensional table pre-set in non-volatile memory based on real-time temperature data. This represents the duty cycle of the modulated signal. and These are devices at specific currents. and junction temperature The energy loss during a single turn-on and turn-off is measured in joules, which is also obtained by looking up a table. The current switching frequency is used. This calculation is performed independently for the power devices within each partition of the driver, thus obtaining the real-time heat flow input for each partition. The real-time heat flow input is applied to a phase change kinetics model to simulate and quantify the melting process of the phase change material. The core of this model is a heat balance equation based on energy conservation, with the real-time heat flow input as its input. And the thermal characteristic parameters of the phase change material stored in the configuration memory, mainly including the melting point of the material in each partition. and latent heat of phase change per unit mass The model tracks the accumulation of internal energy by integrating the net heat flux entering the phase change material over time. This process continues until the material reaches its melting point. At this time, the absorbed energy will be mainly used for phase change rather than temperature rise. Real-time melting ratio of phase change materials in each zone. The output is calculated using the following formula:

[0050] ;

[0051] in, It is a dimensionless numerical value, ranging from 0 to 1. This represents the net energy absorbed by the phase change material for phase change after reaching its melting point, which is expressed as net heat flow, i.e., real-time heat flow input. Subtract the heat loss through natural convection and heat conduction Then, over time The result is obtained by integration. The latent heat required for the complete melting of the phase change material in that zone is represented by the mass of the phase change material in that zone. Latent heat of phase change per unit mass of material The product of these values ​​is used. The melting ratios of key zones are labeled to provide a weighted decision basis. Based on a predefined driver thermal topology, zones located upstream of the heat flow path are identified. These zones typically directly carry power devices and are the areas where heat accumulates first. The real-time melting ratios of these zones are then calculated. Individual identification is performed, for example, by setting specific status flags. This identification will give it higher weight in subsequent hierarchical logic comparisons, serving as a weighted reference value for the comparisons and ensuring that the control system has higher sensitivity and faster response priority for the most dangerous hotspot areas. Through the above steps, a set of real-time melting ratio data characterizing the thermal state of the entire driver is finally output, including the melting degree of all zones, and weighted identification of key zone data upstream of the thermal path. This data provides accurate and dynamic decision input for subsequent thermal state level determination and heat dissipation control command generation. Figure 3 The figure shows a schematic diagram illustrating the change in junction temperature of the power device and the real-time melting ratio of the corresponding phase change material over time in an embodiment of this application. The figure demonstrates that as the junction temperature increases with accumulated heat, the real-time melting ratio increases accordingly, and reflects the triggering logic of the first and second thresholds for switching thermal state levels.

[0052] For example, if the real-time electrical parameters of power devices within a certain zone are collected as the effective value of phase current... 300A, DC bus voltage 800V, switching frequency The frequency is 12kHz, and the device junction temperature is measured and calculated by the NTC sensor at this time. for The on-resistance at that junction temperature can be obtained by consulting a two-dimensional table based on these parameters. The Ω is 0.002, and the duty cycle of the modulation signal is... The single activation loss is 0.5. The turn-off loss is 0.004J. The value is 0.003J. Substituting this into the formula: The real-time heat flux input of this partition is calculated. The heat flux was 174 W. This heat flux was then applied to a phase change kinetics model, assuming the partition was filled with 60 g of phase change material, and the latent heat of phase change per unit mass was... If the total latent heat is 220 J / g, then... The value is 13200J. If the net energy absorbed by this region since reaching its melting point is calculated through time integration... The value is 2772J. Substituting this into the formula: The real-time melting ratio of the partition was obtained. The value is 0.21. Since this partition is identified as a priority partition for directly power-carrying devices located upstream of the heat flow path, its status flag is set to a high-priority identifier. This value of 0.21, along with the weight identifier, will be transmitted as a key decision-making basis for triggering the collaborative intervention mode.

[0053] In one possible implementation, combining Figure 2 The hierarchical logical comparison of the real-time melting ratio with the adjusted first threshold and second threshold includes:

[0054] Determine whether the real-time melting ratio of all partitions is lower than the first threshold. If so, determine that the thermal state level is the standard mode and maintain the current driving strategy.

[0055] If the real-time melting ratio of any partition reaches or exceeds the first threshold, but is lower than the second threshold, the thermal state level is determined to be in collaborative intervention mode, and a collaborative control command is triggered.

[0056] If the real-time melting ratio of any partition reaches or exceeds the second threshold, the thermal state level is determined to be the extreme heat dissipation mode, and the extreme heat dissipation command is triggered to prevent thermal failure of power devices through external forced cooling.

[0057] In some implementations, continuously varying real-time melting ratio data is transformed into discrete thermal state levels, providing explicit, hierarchical input for subsequent decision-making. This process is executed within a fixed, high-frequency control cycle, for example, every 100 milliseconds. The inputs are an array of real-time melting ratios for all partitions and a first threshold for the current performance priority. With the second threshold The comparison logic first performs the standard mode check. The controller then iterates through the real-time melting ratios of all partitions. And determine whether all partitions The values ​​are all below the first threshold. First threshold This is the warning line for the thermal buffer capacity of the phase change material. It is a dimensionless parameter, and its value is usually set between 0.2 and 0.4, representing that the thermal buffer still has sufficient margin. If this condition is met, that is, the thermal load inside the actuator is at its lowest, the current thermal state level is determined to be the standard mode. In this mode, it is determined that no additional heat dissipation intervention is required, and the current motor drive strategy and natural heat dissipation are maintained. If the above standard mode determination condition is not met, that is, there is a real-time melting ratio in at least one zone. The first threshold has been reached or exceeded. The system will continue to determine the collaborative intervention mode. The controller will check whether any partition... Reaching or exceeding the first threshold However, at the same time, all partitions All are below the second threshold Second threshold The critical point representing the imminent depletion of the phase change material's thermal buffer capacity is also a dimensionless parameter, typically set between 0.7 and 0.9. If this condition is true, it indicates that the system's thermal load has increased significantly but has not yet reached a critical level; in this case, the thermal state level is determined to be in cooperative intervention mode. This determination immediately triggers a flag and generates a cooperative control command, initiating low-intensity, active heat dissipation measures. If neither of the above two mode determination conditions is met, it means that there must be at least one zone with a real-time melting ratio... The second threshold has been reached or exceeded. This indicates that the phase change material's heat storage capacity in this region is essentially saturated, and the power devices face the risk of overheating and failure. At this point, no further detailed comparisons are made; the thermal state level is directly determined as the extreme heat dissipation mode. This level has the highest priority and will forcibly trigger the extreme heat dissipation command. All available external forced cooling methods will be immediately activated, such as running the boundary layer disturbance at full power and opening the active cooling circulation path, to suppress the power device temperature within the safe operating range as quickly as possible and prevent permanent hardware damage.

[0058] For example, if the current task instruction is "long battery life priority", then a first threshold in the memory will be configured accordingly. Adjusted to 0.40, second threshold. Adjusted to 0.80. Within the current 100-millisecond control cycle, the real-time melting ratio array of the six output partitions is received as follows: The comparison logic first performs a standard mode check, finding the real-time melting ratio of partition 2. It is already greater than of Therefore, the standard mode conditions are not met. Subsequently, the collaborative intervention mode is entered for judgment, and the controller searches and finds the largest melting ratio in the array. The value is 0.45, which satisfies the judgment formula. And the remaining partitions in the array All values ​​are below 0.80, so the logical judgment result is true. Based on this logical operation result, the current thermal state level is immediately determined to be "cooperative intervention mode", and the corresponding flag bit is triggered to generate cooperative control commands. Low-power heat dissipation measures such as discontinuous pulse width modulation to transfer heat load and intermittent operation of boundary layer disturbances are initiated, thereby suppressing temperature rise and balancing system energy efficiency in a forward-looking stage.

[0059] In one possible implementation, combining Figure 2 The coordinated control commands include:

[0060] Based on the real-time melting ratio of each zone, high heat load zone and low heat load zone are identified. By adjusting the control parameters of the space vector pulse width modulation signal, the switching loss is dynamically transferred from the power device corresponding to the high heat load zone to the power device corresponding to the low heat load zone.

[0061] A first drive signal is generated and sent to a boundary layer disturbance integrated into the motor housing, driving the boundary layer disturbance to operate in a preset low-intensity intermittent mode. The mechanical micro-vibration is used to disrupt the laminar boundary layer of the fluid outside the motor housing in advance, optimizing the convective heat transfer conditions and delaying the temperature rise of the phase change material.

[0062] In some implementations, the purpose of the coordinated control command is to delay the melting process of the phase change material through two low-energy, low-intrusion active intervention methods, without significantly affecting motor performance or generating noticeable noise, thereby extending the safe operating time of the actuator under high heat loads. This command includes two parallel control actions. The first control action achieves heat load balancing within the actuator through electronic control. This is initially based on the real-time melting ratio of each zone. It identifies high heat load zones and low heat load zones. The controller will... Zones exceeding the first threshold are marked as high heat load zones, while... The partitions with values ​​significantly below the first threshold or the lowest values ​​among all partitions are marked as low-heat-load partitions. Subsequently, the control parameters of the space vector pulse width modulation (SVPWM) signal are dynamically adjusted, with the core being the change in modulation strategy to transfer switching losses. In standard operating mode, continuous pulse width modulation (SVPWM) may be used, with its switching losses relatively evenly distributed across the power devices in the three-phase bridge arms. Upon entering the cooperative intervention mode, the controller switches to a discontinuous pulse width modulation (DPWM) strategy. Discontinuous pulse width modulation eliminates the switching losses of the power devices in a phase by continuously conducting one of the upper or lower bridge arms of a specific phase within a specific sector of each fundamental cycle, thereby stopping its switching operation within that interval. Based on the phase corresponding to the high-heat-load partition, a precise DPWM scheme, such as DPWM_MAX or DPWM_MIN, is selected to clamp the power devices associated with that partition, reducing their switching losses to zero. This heat load is then dynamically transferred to the power devices in other phases corresponding to the low-heat-load partition that are still switching normally. This process is completed within the motor controller at microsecond speeds, having minimal impact on external motor characteristics such as the smoothness of output torque. The second control action is to actively enhance the convective heat transfer capability of the drive housing to the external environment. A first drive signal is generated and sent to a boundary layer disturbance integrated on the surface of the motor housing. The boundary layer disturbance is a miniature vibration actuator, typically a piezoelectric ceramic plate or a small eccentric rotor motor, which generates high-frequency, low-amplitude mechanical micro-vibrations on the housing surface. The first drive signal is a preset low-intensity intermittent mode drive signal, such as a pulse width modulation (PWM) signal with a frequency of 50 to 200 Hz and a duty cycle of 10% to 30%, and this PWM signal is output intermittently with a longer period, such as 1 second of operation followed by 5 seconds of pause. This micro-vibration can effectively disrupt the high thermal resistance laminar boundary layer of air attached to the outside of the motor housing, inducing it to transform into a turbulent state. In engineering, the more intense fluid mixing within the turbulent boundary layer can significantly improve the convective heat transfer coefficient between the housing surface and the surrounding air, with an increase of 30% to 50%. In this way, the external heat dissipation path is optimized in advance with extremely low energy consumption, effectively removing more heat and thus directly slowing down the temperature rise rate and melting process of the internal phase change material.

[0063] For example, if the current thermal state level is determined to be in collaborative intervention mode, the real-time melting ratio of partition 2 is first identified. The value is 0.45, exceeding the first threshold of 0.40, classifying it as a high heat load zone, while zone 3... A value of 0.08 indicates a low heat load zone. For the A-phase power devices corresponding to zone 2, the original continuous SVPWM modulation with uniformly distributed switching losses is switched to a discontinuous pulse width modulation (DPWM_MAX) strategy. By keeping the upper bridge arm continuously conducting within the peak current sector of phase A, the switching frequency of the power device is reduced from 12,000 times per second to 0 times per second, thus reducing the switching losses according to the loss formula. When the total switching loss is 0.007J, the 84W switching heat load generated per second by the device is directly eliminated and dynamically transferred to the power device corresponding to partition 3, which is in a low-temperature state. Simultaneously, a first drive signal with a frequency of 150Hz and a duty cycle of 20% is sent to the piezoelectric ceramic disturbance integrated on the surface of the motor housing, and the device operates in an intermittent mode of 1 second operation followed by 5 seconds pause. The resulting mechanical micro-vibration disrupts the surface laminar boundary layer, causing the convective heat transfer coefficient to decrease from the reference value. Upgraded to The efficiency is increased by 40%, thereby achieving synergistic intervention of balanced internal heat distribution and enhanced external heat exchange efficiency with extremely low power consumption, effectively delaying the phase change material from entering the saturation state.

[0064] In one possible implementation, combining Figure 2 The extreme heat dissipation command includes:

[0065] A second driving signal is generated to drive the boundary layer disturbance to operate in a continuous working mode with maximum intensity, and the external active cooling circulation path is started simultaneously.

[0066] The heat exchange parameters of the active cooling circulation path are monitored in real time. When the cooling medium flow rate and heat exchange efficiency are confirmed to reach the preset stable threshold, the phase change material regeneration program is triggered.

[0067] The saturated zone with a real-time melting ratio of 1 is identified. By adjusting the space vector pulse width modulation parameter, the residual heat load of the drive system is directed to the power device corresponding to the saturated zone. The active cooling cycle is used to remove the latent heat of phase change released by the phase change material during solidification until the real-time melting ratio of the target zone drops below the first threshold.

[0068] In some implementations, the purpose of the extreme cooling command is to first suppress the temperature of power devices to the maximum extent possible to prevent damage from overheating, and then actively restore the thermal buffer capacity of the phase change material to prepare for subsequent high-performance operation. First, the most efficient cooling method is activated. A second drive signal is generated and drives the boundary layer disturbance integrated into the motor housing. This second drive signal is a maximum intensity continuous operating mode signal, such as a 100% duty cycle DC signal, causing the disturbance to operate continuously at its rated maximum power, generating the strongest mechanical micro-vibrations to maximize the convective heat transfer coefficient. Simultaneously, a command is issued to activate the external active cooling circulation path, for example, opening the solenoid valve of the coolant circulation line and starting the water pump, allowing the cooling medium to flow through the cooling jackets of the driver and motor at maximum flow rate. After the forced cooling is activated, the regeneration process is prepared. It is confirmed that the cooling system has reached an effective operating state to avoid performing regeneration operations under ineffective cooling conditions. The heat transfer parameters of the active cooling circulation path are monitored in real time. Key parameters include the flow rate of the cooling medium, usually monitored by a flow meter, and the heat transfer efficiency, which is usually indirectly assessed by monitoring the temperature difference between the cooling medium at the inlet and outlet of the driver. When the cooling medium flow rate reaches a preset stable threshold, such as greater than 1.5 liters per minute, and the heat exchange efficiency is stable, indicating that the external cooling system has established a strong heat removal capacity, the phase change material regeneration process will be triggered. The phase change material regeneration process utilizes the established strong external cooling capacity to actively guide and accelerate the solidification process of the liquid phase change material to restore its latent heat storage function. First, based on real-time melting ratio data, all real-time melting ratios are identified. The system is divided into saturation zones of 1. Subsequently, the controller adjusts the space vector pulse width modulation parameters to orient a portion of the residual heat load of the drive system towards the power devices corresponding to these saturation zones. Specifically, a discontinuous pulse width modulation strategy is selectively applied, but the goal is to apply controllable, low switching or conduction losses to the power devices in the target phase, making them a weak "heat-holding" source. The essence of this operation is to maintain the temperature of the passively cooled power devices at slightly above or equal to the melting point of the phase change material, thereby establishing a stable and efficient heat conduction path between the power devices and the solidifying phase change material. This ensures that the large amount of latent heat of phase change released by the phase change material during solidification can be smoothly conducted through the power device substrate to the external active cooling circulation path and rapidly removed. This process continues until the real-time melting ratio of the target zone is monitored to drop to the first threshold. The following values, for example, below 0.2, indicate that the hot buffer capacity of the partition has been effectively restored.

[0069] For example, if the real-time melting ratio of partition 1 is monitored... Upon reaching 0.82 and exceeding the second threshold of 0.80, the system is immediately identified as operating in extreme heat dissipation mode and an extreme heat dissipation command is issued. First, the piezoelectric boundary layer disturbance integrated into the motor housing is driven to operate in maximum intensity continuous mode with a 100% duty cycle. Simultaneously, the water pump is activated to circulate the coolant at a flow rate of 2.0 liters / minute, exceeding the preset stable threshold of 1.5 liters / minute. At this point, monitoring the temperature difference between the coolant inlet and outlet confirms stable heat dissipation capability and triggers the phase change material regeneration program. (Regarding the real-time melting ratio...) For the saturation zone approaching 1, a controllable 30W residual heat load is applied to the power device corresponding to this zone by fine-tuning the space vector pulse width modulation parameters. This maintains the junction temperature slightly above the phase change melting point, allowing the phase change material in zone 1, which was originally in a liquid state, to release a huge amount of latent heat during solidification, such as the total latent heat capacity. The 13200J heat can be smoothly transferred to the active cooling cycle. When the latent heat released by the zone 1 is detected to reduce its real-time melting ratio to 0.28, which is lower than the first threshold of 0.40, it is determined that the thermal buffer capacity of the zone has been effectively restored and the regeneration process is exited. Thus, the rapid charging and energy efficiency optimization of the thermal management system "battery" are achieved through this active solidification method.

[0070] In one possible implementation, combining Figure 2 The dynamic adjustment of the first and second thresholds in the configuration memory based on the performance priority includes:

[0071] Parse the priority configuration identifier in the system task instruction. The priority configuration identifier includes priority for low electromagnetic noise, priority for high output performance, and priority for long battery life.

[0072] If low electromagnetic noise is prioritized, the value of the first threshold is actively lowered to increase the system's sensitivity to heat accumulation and trigger the cooperative control command that does not generate aerodynamic noise in advance.

[0073] If high output performance is prioritized, the value of the second threshold is actively increased, and the authorized system makes full use of the full latent heat capacity of the phase change material, thereby extending the continuous working time of the power device under peak output conditions.

[0074] If long battery life is the priority, the first threshold and the second threshold are lowered simultaneously to lock the system in a low thermal stress operating range and optimize the total energy efficiency cost of the heat dissipation system.

[0075] In some implementations, the engineering objective of this process is to align the thermal control strategy with the macroscopic task objectives of the upper-level system. This is achieved by adjusting the trigger boundaries of the thermal state level to determine behavioral preferences under different operating conditions. This function first parses system task instructions received from the upper-level control system, such as the vehicle controller. These instructions contain explicit priority configuration identifiers, which are predefined enumeration values ​​or codes used to specify the current performance priority, specifically including low electromagnetic noise priority, high output performance priority, and long range priority. When the parsed priority is low electromagnetic noise priority, forced cooling methods that generate significant aerodynamic noise, such as high-power boundary layer disturbances or cooling fans, are avoided as much as possible. To this end, a first threshold stored in the configuration memory is actively lowered. The value is adjusted, for example, from a baseline of 0.4 to 0.25. This adjustment increases the sensitivity to heat buildup, allowing the cooperative intervention mode to be triggered earlier. Since the loss transfer and low-intensity vibration mechanisms included in the cooperative control commands produce almost no perceptible noise, activating these silencing measures earlier can more effectively delay temperature rise, thereby reducing or avoiding the probability of entering a powerful but noisy extreme cooling mode. When the resolved priority is high output performance priority, the system's thermal capacity is maximized, allowing the motor driver to operate continuously for longer periods under peak output conditions. To this end, the second threshold will be actively increased. The value, for example, is increased from a base value of 0.8 to 0.95. The second threshold is the boundary for triggering the extreme cooling mode, which is typically accompanied by potential power limiting to protect the hardware. By increasing this threshold, the licensee can more fully utilize the latent heat capacity of the phase change material, delaying the triggering of protective derating or intensive cooling, thus providing greater performance margin for short sprints or high-intensity load tasks. When the resolved priority is long battery life, the total energy efficiency cost of the entire drive and cooling system is minimized to extend battery range. To this end, the first threshold will be simultaneously decreased. With the second threshold The value, for example, is The value was lowered from 0.4 to 0.2, and... The value has been reduced from 0.8 to 0.6. This move lowers the overall thermal operating range, locking it within a low thermal stress operating zone. Earlier activation of low-energy-consumption synergistic intervention and earlier restriction of entering high-heat states can prevent efficiency degradation of power devices due to high temperatures, while also avoiding the additional energy consumption associated with activating high-power extreme cooling devices, thus optimizing overall energy efficiency over long operating cycles.

[0076] For example, if the priority configuration identifier received from the upper-level vehicle controller is "low electromagnetic noise priority", the first threshold in the configuration memory will be configured after parsing. From the benchmark value Lowered to the adjusted value At this point, if the output partition melting ratio... The value is 0.26, which satisfies the judgment formula in the baseline mode. It is judged as the standard mode, but under the current mode, it meets the requirements. By triggering the collaborative intervention mode in advance, a near-noise-free heat transfer strategy is used to slow down the temperature rise, thereby avoiding or delaying the entry into the extreme cooling mode that requires the activation of high-noise equipment such as forced fans. Conversely, if the identifier is switched to "high output performance priority," the second threshold will be... From the benchmark value Upgraded to the adjusted value Through formula With a net heat production rate of 150W and a total latent heat of 13200J, it is theoretically possible to gain an additional peak performance duration of about 13.2 seconds, thereby maximizing the utilization of the phase change material's heat capacity to match the demands of instantaneous high-load tasks.

[0077] In one possible implementation, combining Figure 2 The method further includes calibrating the phase transition dynamics model and the power device loss model:

[0078] The motor driver is controlled to operate under a preset reference load spectrum, and the actual temperature change data of each zone and the real-time electrical parameters of the power device are collected synchronously.

[0079] The theoretical temperature curve is generated using the real-time electrical parameters through an uncalibrated loss model and a kinetic model, and the deviation between the actual temperature change data and the theoretical temperature curve is calculated.

[0080] Based on the deviation data, the key model parameters in the loss model and the kinetic model are iteratively identified to generate calibrated key parameters and store them in a non-volatile memory. The key model parameters include interfacial thermal resistance and equivalent convective heat transfer coefficient.

[0081] In some implementations, the overall engineering objective of this process is to improve the accuracy of online real-time melting ratio estimation by correcting the discrepancies between the theoretical model and the actual hardware through a one-time offline calibration experiment. This calibration process is typically performed during product development or routine maintenance on a test bench equipped with a dynamometer and a high-precision data acquisition system. The calibration process begins with performing a controlled experiment and simultaneously acquiring data. A set of high-fidelity system thermal response data that can serve as a reference is obtained. The motor driver is controlled to operate under a preset reference load spectrum. This reference load spectrum is a series of precisely defined speed and torque command sequences, such as simulating a period of urban traffic congestion or a continuous high-torque ramp-up, to ensure that the dynamic characteristics of the thermal input are representative and reproducible. During operation, the controller simultaneously acquires actual temperature change data measured by temperature sensors installed in each zone at a high sampling rate, such as 10 Hz. At a higher sampling rate, such as 10 kHz, real-time electrical parameters of the power devices, including DC bus voltage, phase current, and switching frequency, are simultaneously acquired. This data is recorded with a unified timestamp, forming the basic dataset required for calibration. Model simulation and deviation calculations are performed to quantify the difference between the current uncalibrated model and the actual physical behavior. The acquired real-time electrical parameters are used as input to feed into the uncalibrated power device loss model and phase transition dynamics model. These uncalibrated models use initial parameters from theoretical calculations or the initial design phase. After model computation, a theoretical temperature curve is generated. This represents the temperature change over time predicted by the model under the same electrical excitation. Subsequently, the actual temperature change data is calculated. Comparison with theoretical temperature curve Deviation data between Quantization is usually performed using the root mean square error, calculated as follows:

[0082] ;

[0083] in, This represents the total deviation. At a certain point in time The actual temperature collected, It is the theoretical temperature output by the model at the same point in time. This refers to the total number of data points. Finally, iterative identification and storage of key model parameters are performed. Through optimization algorithms, the model parameters are systematically adjusted to make the model output infinitely close to the actual measurement results. The calculated deviation data is then used... As the objective function, key model parameters in the loss model and kinetic model are iteratively identified. These key model parameters mainly include interfacial thermal resistance. and equivalent convective heat transfer coefficient Interfacial thermal resistance represents the thermal resistance between the power device chip and the phase change material due to imperfect contact, and it significantly affects the temperature rise rate. The equivalent convective heat transfer coefficient is a lumped parameter representing the overall heat dissipation capacity between the entire driver housing and the environment. An optimization algorithm, such as gradient descent or particle swarm optimization, is employed to minimize the deviation. To achieve the goal, we repeatedly adjusted. and The values ​​were then recalculated and the simulation was repeated until the deviation was found. The algorithm converges to a sufficiently small, acceptable threshold. Once converged, a set of optimal values ​​is obtained. and These values ​​are the key parameters after calibration. These parameters are written into a non-volatile memory within the controller, such as an EEPROM, for later retrieval during actual operation, thus ensuring the long-term accuracy of the thermal state estimation.

[0084] For example, on the experimental platform, the driver is controlled to operate under a reference load spectrum simulating a high torque ramp, and the actual temperature change data of partition 1 within 300 seconds is collected by a high-precision sensor. At the same time, the initial interface thermal resistance is set by inputting synchronously acquired electrical parameters such as current and voltage into the uncalibrated model. The equivalent convective heat transfer coefficient is 0.5 K / W. The theoretical temperature curve is generated at a value of 150 W / (m²·K). Then, using the formula: Calculate the deviation, if substituted Initial root mean square error after sampling points for This triggers the optimization algorithm to perform iterative identification. After multiple iterations and adjustments using the particle swarm optimization algorithm, when... Corrected to 0.62K / W and When corrected to 135 W / (m²·K), the deviation is calculated. convergence to The minimum value is then calculated. Finally, this set of calibrated key parameters is written into the EEPROM memory, enabling subsequent operation to output accurate real-time melting ratios based on more realistic physical parameters, thus eliminating thermal model errors caused by assembly tolerances.

[0085] In one possible implementation, combining Figure 2 The method also includes hardware configuration optimization based on the calibrated model:

[0086] Simulations were performed using the calibrated key parameters and the reference load spectrum. The melting point of the phase change material in each partition was set as an adjustable optimization variable, and optimization was performed with the goal of minimizing the time variance of the real-time melting ratio of each partition reaching the first threshold.

[0087] Based on the optimization results, a set of ideal melting point values ​​that can synchronize the thermal response of each zone is determined.

[0088] The ideal melting point value is compared with the melting point of the phase change material actually used in the current hardware to generate optimization suggestions that include the adjustment direction of the phase change material composition of each partition, which are used to guide the improvement of the physical structure of the driver.

[0089] In some implementations, the overall engineering objective of this process is to proactively optimize the thermal management system of the actuator from a physical design perspective, using a validated and accurate simulation model, particularly regarding the selection and configuration of phase change materials, to achieve a more balanced and efficient thermal response. This process is typically used as a virtual design verification method during design iteration or product upgrade planning. The process begins by setting up simulation and optimization tasks, establishing an optimization problem aimed at synchronizing the thermal response. It then calls upon calibrated key parameters stored in non-volatile memory, including precise interfacial thermal resistance. and equivalent convective heat transfer coefficient The heat input is determined by combining a preset reference load spectrum with the heat input. In the calibrated phase transition kinetic model, the melting point of the phase transition material in each partition is used. Set as an adjustable optimization variable, where This represents the partition number. The objective function for optimization is set to minimize the real-time melting ratio of each partition. Reaching the first threshold Time required The variance is calculated as follows:

[0090] ;

[0091] in, This represents variance calculation. For the first Real-time melting ratio of each zone Starting from zero, it grows until it reaches the first threshold for the first time. The time elapsed. Let be the total number of partitions within the drive. The objective function aims to find a set of melting point configurations such that, under typical operating conditions, the phase change materials in all partitions can enter the effective phase change thermal storage stage almost simultaneously, avoiding the "bottleneck effect" where some areas saturate prematurely while the thermal storage capacity of other areas remains unutilized. An optimization simulation is performed to determine the ideal melting point, and the optimal solution that minimizes the objective function is found through calculation. In a simulation environment, a global optimization algorithm, such as a genetic algorithm or simulated annealing algorithm, is used to determine the melting point of each partition. Within a pre-defined feasible range, such as 40 to 90 degrees Celsius, optimization is performed. In each iteration, the optimization algorithm generates a new set of melting point combinations. Using this set of melting points and a calibrated model, a complete thermal simulation under the reference load spectrum is performed to calculate the time variance for that melting point combination. The algorithm continuously adjusts the melting point combinations based on the calculation results until it finds a set of ideal melting point values ​​that minimizes the time variance. This set of values ​​represents the theoretically optimal melting point configuration for phase change materials that achieves the most synchronized thermal response under current hardware structure and load conditions. Hardware optimization suggestions are generated, transforming the theoretically optimal solution obtained from simulation into feasible guidance for improving actual physical hardware. The optimized ideal melting point values ​​are then used... Melting points of phase change materials used in current hardware designs for each partition A point-by-point comparison is performed. By analyzing the differences between the two, a specific optimization recommendation report can be generated, including the direction of adjustment for the phase change material composition of each partition. For example, if the simulation shows that the ideal melting point of a certain partition is 65 degrees Celsius, but the material used in practice is 60 degrees Celsius, the recommendation report will indicate that the formula for that partition should be changed or adjusted to obtain a phase change material with a higher melting point. This report provides clear, data-driven design improvement directions for subsequent hardware prototyping or product upgrades, aiming to fundamentally improve the overall thermal management performance of the driver. Figure 4 The figure shows a bar chart comparing the trigger time of phase change material entering the phase change stage in each partition before and after optimization in the embodiments of this application. The figure clearly shows that after optimizing the melting point of each partition, the time variance of the real-time melting ratio of each partition reaching the first threshold is significantly reduced, reflecting the synchronization effect of thermal response.

[0092] For example, the calibrated interface thermal resistance stored in non-volatile memory is invoked. and equivalent convective heat transfer coefficient The melting points of the phase change materials in the six partitions were determined in the simulation environment. Set as the variable to be optimized. The goal is to minimize the real-time melting ratio of each partition. Reaching the first threshold Time required to set to 0.20 The variance is the objective function, which can be expressed using the formula: Execute a genetic algorithm to find the optimal solution. If the melting point actually used in the current hardware is... The time series of each partition reaching the threshold were measured in the benchmark load spectrum simulation. The original variance was calculated to be approximately 350; through multiple rounds of simulation iterations, the algorithm found a set of ideal melting point combinations. If the melting point of the upstream heat flux zone is increased to 68°C and that of the downstream zone is decreased to 55°C, the time series after simulation will be optimized as follows: At this point, the minimum variance obtained from the calculation formula decreased to 0.97. Subsequently, this ideal melting point combination was compared with the actual melting points, and optimization suggestions were output, explicitly indicating that the phase change material ratios in partitions 1 and 3 should be adjusted to increase their melting points respectively. and downgrade This allows for the synchronization of thermal response across all zones through precise matching of physical parameters, fundamentally eliminating the "weakest link" effect in the heat dissipation system.

[0093] It should be noted that the electrical connections between the various units described above do not necessarily represent direct or indirect connections. Any indirect connection method can be applied to the embodiments of the present invention as long as it achieves the purpose of the present invention. The above descriptions are merely exemplary embodiments of the present invention and should not be construed as limiting the scope of the present invention.

[0094] All equivalent changes and modifications made in accordance with the teachings of this invention are still within the scope of this invention. Those skilled in the art will readily conceive of other embodiments of this invention upon considering the specification and the disclosure of practical truth. This application is intended to cover any variations, uses, or adaptations of this invention that follow the general principles of this invention and include common knowledge or conventional techniques in the art not described herein.

Claims

1. A hybrid heat dissipation control method for a lightweight motor driver, characterized in that, The method includes: Acquire real-time electrical parameters and temperature data of power devices, as well as system task commands from the upper control system; Based on the real-time electrical parameters and real-time temperature data, the real-time melting ratio of phase change materials in each partition of the driver is estimated by using a preset power device loss model and phase change kinetics model. The system task instructions are parsed to identify the current performance priority, and the first and second thresholds in the configuration memory are dynamically adjusted according to the performance priority. The current thermal state level is determined by comparing the real-time melting ratio with the adjusted first threshold and second threshold using a hierarchical logic. Based on the determined thermal state level, a corresponding heat dissipation control command is generated, wherein the heat dissipation control command includes a cooperative control command for delaying temperature rise and a limit heat dissipation command for restoring thermal buffer capacity.

2. The hybrid heat dissipation control method for a lightweight motor driver according to claim 1, characterized in that, The estimated real-time melting ratio of phase change material in each partition of the driver includes: The real-time electrical parameters of the power device are obtained, and combined with the real-time temperature data, the real-time heat flow input of each partition in the driver is calculated through a preset power device loss model. The real-time heat flow input and the thermal characteristic parameters of the phase change material are input into the phase change kinetic model, wherein the thermal characteristic parameters include melting point and latent heat of phase change; The phase change kinetics model is used to calculate and output the real-time melting ratio of the phase change material in each partition. The real-time melting ratio of the partition located upstream of the heat flow path is separately identified and used as a weighted reference value for hierarchical logical comparison.

3. The hybrid heat dissipation control method for a lightweight motor driver according to claim 1, characterized in that, The hierarchical logical comparison of the real-time melting ratio with the adjusted first and second thresholds includes: Determine whether the real-time melting ratio of all partitions is lower than the first threshold. If so, determine that the thermal state level is the standard mode and maintain the current driving strategy. If the real-time melting ratio of any partition reaches or exceeds the first threshold, but is lower than the second threshold, the thermal state level is determined to be in collaborative intervention mode, and a collaborative control command is triggered. If the real-time melting ratio of any partition reaches or exceeds the second threshold, the thermal state level is determined to be the extreme heat dissipation mode, and the extreme heat dissipation command is triggered to prevent thermal failure of power devices through external forced cooling.

4. The hybrid heat dissipation control method for a lightweight motor driver according to claim 3, characterized in that, The coordinated control commands include: Based on the real-time melting ratio of each zone, high heat load zone and low heat load zone are identified. By adjusting the control parameters of the space vector pulse width modulation signal, the switching loss is dynamically transferred from the power device corresponding to the high heat load zone to the power device corresponding to the low heat load zone. A first drive signal is generated and sent to a boundary layer disturbance integrated into the motor housing, driving the boundary layer disturbance to operate in a preset low-intensity intermittent mode. The mechanical micro-vibration is used to disrupt the laminar boundary layer of the fluid outside the motor housing in advance, optimizing the convective heat transfer conditions and delaying the temperature rise of the phase change material.

5. The hybrid heat dissipation control method for a lightweight motor driver according to claim 4, characterized in that, The extreme heat dissipation command includes: A second driving signal is generated to drive the boundary layer disturbance to operate in a continuous working mode with maximum intensity, and the external active cooling circulation path is started simultaneously. The heat exchange parameters of the active cooling circulation path are monitored in real time. When the cooling medium flow rate and heat exchange efficiency are confirmed to reach the preset stable threshold, the phase change material regeneration program is triggered. The saturated zone with a real-time melting ratio of 1 is identified. By adjusting the space vector pulse width modulation parameter, the residual heat load of the drive system is directed to the power device corresponding to the saturated zone. The active cooling cycle is used to remove the latent heat of phase change released by the phase change material during solidification until the real-time melting ratio of the target zone drops below the first threshold.

6. The hybrid heat dissipation control method for a lightweight motor driver according to claim 1, characterized in that, Dynamically adjusting the first and second thresholds in the configuration memory based on the performance priority includes: Parse the priority configuration identifier in the system task instruction. The priority configuration identifier includes priority for low electromagnetic noise, priority for high output performance, and priority for long battery life. If low electromagnetic noise is prioritized, the value of the first threshold is actively lowered to increase the system's sensitivity to heat accumulation and trigger the cooperative control command that does not generate aerodynamic noise in advance. If high output performance is prioritized, the value of the second threshold is actively increased, and the authorized system makes full use of the full latent heat capacity of the phase change material, thereby extending the continuous working time of the power device under peak output conditions. If long battery life is prioritized, the first and second thresholds are lowered simultaneously to lock the system in a low thermal stress operating range and optimize the total energy efficiency cost of the cooling system.

7. The hybrid heat dissipation control method for a lightweight motor driver according to claim 2, characterized in that, The method further includes calibrating the phase transition dynamics model and the power device loss model: The motor driver is controlled to operate under a preset reference load spectrum, and the actual temperature change data of each zone and the real-time electrical parameters of the power device are collected synchronously. The theoretical temperature curve is generated using the real-time electrical parameters through an uncalibrated loss model and a kinetic model, and the deviation between the actual temperature change data and the theoretical temperature curve is calculated. Based on the deviation data, the key model parameters in the loss model and the kinetic model are iteratively identified to generate calibrated key parameters and store them in a non-volatile memory. The key model parameters include interfacial thermal resistance and equivalent convective heat transfer coefficient.

8. The hybrid heat dissipation control method for a lightweight motor driver according to claim 7, characterized in that, The method also includes hardware configuration optimization based on the calibrated model: Simulations were performed using the calibrated key parameters and the reference load spectrum. The melting point of the phase change material in each partition was set as an adjustable optimization variable, and optimization was performed with the goal of minimizing the time variance of the real-time melting ratio of each partition reaching the first threshold. Based on the optimization results, a set of ideal melting point values ​​that can synchronize the thermal response of each zone is determined. The ideal melting point value is compared with the melting point of the phase change material actually used in the current hardware to generate optimization suggestions that include the adjustment direction of the phase change material composition of each partition, which are used to guide the improvement of the physical structure of the driver.

9. A hybrid heat dissipation system for a lightweight motor driver, characterized in that, The system is used in a hybrid heat dissipation control method for a lightweight motor driver as described in any one of claims 1-8, the system comprising: The data acquisition module is used to acquire real-time electrical parameters and real-time temperature data of power devices, as well as system task instructions from the upper control system. The state estimation module is used to estimate the real-time melting ratio of phase change materials in each partition of the driver based on the real-time electrical parameters and real-time temperature data, through a preset power device loss model and phase change kinetics model. The threshold dynamic adjustment module includes a configuration memory for parsing the system task instructions to identify the current performance priority, and dynamically adjusting the first threshold and the second threshold in the configuration memory according to the performance priority. The state level determination module is used to determine the current thermal state level by comparing the real-time melting ratio with the adjusted first threshold and second threshold using hierarchical logic. The instruction execution and control module is communicatively connected to the boundary layer disturbance and power devices integrated in the motor housing. It is used to generate corresponding heat dissipation control instructions based on the determined thermal state level. The heat dissipation control instructions include cooperative control instructions for delaying temperature rise and extreme heat dissipation instructions for restoring thermal buffer capacity.

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