AC/DC Converter Thermal Management via Fixing Means
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Solution Overview
Problem
The existing AC-DC converters in rotating electrical machines face challenges in effectively dissipating heat generated by the control card, which is often located far from the cooling device due to space constraints, leading to potential component deterioration and reduced operational efficiency.
Innovation Solution
The integration of a fixing means that securely attaches the power modules to the cooling device and establishes a thermal connection between the control card and the cooling device using high-strength, high-thermal-conductivity materials, such as 7075-T6 aluminum screws, to facilitate heat transfer without additional cooling devices, ensuring efficient heat dissipation and reduced size requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the control card is placed far from the cooling device due to space constraints, then the connection between control card and cooling device is simplified, but the heat dissipation efficiency of the control card deteriorates
Solution Approach 1:
The fixing means integrates two functions: mechanically fixing the power module to the cooling device, and thermally connecting the control card to the cooling device. By merging the fixing function and thermal conduction function into a single component, the control card can be positioned away from the cooling device structurally while maintaining thermal connection, thus simplifying the overall connection structure while preserving heat dissipation efficiency.
Solution Approach 2:
The fixing means acts as an intermediary element between the control card and the cooling device. It provides a thermal conduction path that allows heat to transfer from the control card to the cooling device even when they are not in direct contact, effectively mediating the thermal connection while allowing spatial separation.
2Temperature
If an additional cooling device is added for the control card, then the heat dissipation of the control card is improved, but the device size and complexity increase
Solution Approach 1:
The fixing means is designed to perform multiple functions simultaneously: it mechanically secures the power module to the cooling device, provides structural support, and conducts heat from the control card to the cooling device. This multi-functionality eliminates the need for separate cooling components for the control card, maintaining effective heat dissipation while avoiding increased device complexity.
Solution Approach 2:
The existing fixing structure is made to serve an additional thermal conduction function. Instead of adding a dedicated cooling mechanism for the control card, the patent modifies the fixing means to inherently provide thermal connection, allowing the system to use its existing structural components for dual purposes.
3Volume of moving object
If the cooling device size is reduced, then the overall converter size is reduced, but the heat dissipation capacity deteriorates
Solution Approach 1:
The fixing means concentrates thermal conduction capability at the local interface between the control card and the cooling device. By enhancing the thermal properties of the fixing means itself rather than increasing the overall cooling device size, the system achieves effective heat dissipation from the control card while maintaining a compact overall structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively dissipates heat from the control card, reducing the size of the cooling device and the entire AC-DC converter while maintaining component integrity and operational efficiency, without interfering with existing components.
Implementation Method 1
the control module rests on the at least one fixing means so as to transfer the heat generated by at least a part of the control module to the cooling device
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
An AC/DC converter (100) intended to be incorporated into a rotating electric machine, comprising: at least one power module (12), a control module for controlling the at least one power module (12), a cooling device (14), in which the at least one power module (12) is attached to the cooling device (14) via at least one attachment means (23), and the control module rests on the at least one attachment means (23) in such a way as to transfer the heat generated by at least one part of the control module to the cooling device (14).