Annular Electrical Converter Cooling for Redundant Power Modules
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Solution Overview
Problem
Existing electrical converters for aircraft electric motors face challenges in cooling high-redundancy systems while minimizing size and mass, particularly in severe thermal and vibration environments, where traditional cooling methods increase the risk of malfunction and require extensive wiring.
Innovation Solution
An annular-shaped electrical converter with inner and outer cooling baths, a cooling circuit that connects these baths with coolant, and heat sinks with fins to optimize heat transfer, allowing for efficient cooling of power devices while maintaining a compact design and reducing pressure losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of power modules is increased to provide redundancy, then the reliability is improved, but the cooling requirements increase and the size must be increased
Solution Approach 1:
The patent transitions from a planar arrangement of power modules to a three-dimensional configuration by implementing an annular converter with power modules distributed on both inner and outer peripheries. This spatial reorganization allows more power modules to be packed into a compact volume, providing redundancy without proportionally increasing the overall converter size.
Solution Approach 2:
The patent employs a nested structure where the annular converter contains an internal longitudinal passage through which the motor shaft passes. The power modules are arranged concentrically around this central passage, effectively nesting functional components within each other to maximize space utilization and maintain compact dimensions while accommodating multiple power modules for redundancy.
2Reliability
If the number of power modules is increased to provide redundancy, then the reliability is improved, but the cooling requirements become very high
Solution Approach 1:
The patent divides the cooling function into multiple independent cooling circuits, with each circuit dedicated to cooling power modules located on a specific periphery (inner or outer). This segmentation allows for targeted cooling of power module groups, improving cooling efficiency and reducing the thermal load on any single cooling system while supporting a higher total number of power modules for redundancy.
Solution Approach 2:
The patent utilizes the third dimension by implementing cooling baths on both the inner and outer peripheries of the annular converter. This three-dimensional cooling arrangement maximizes the heat exchange surface area within a compact volume, enabling efficient cooling of numerous power modules without requiring excessive cooling capacity or increasing converter dimensions.
3Temperature
If the power modules are positioned on the outer periphery to maximize heat exchanges, then the cooling efficiency is improved, but the length of electrical connections increases
Solution Approach 1:
The patent resolves this contradiction by utilizing both inner and outer peripheries of the annular converter for mounting power modules. This three-dimensional distribution allows power modules to be positioned optimally for heat exchange while maintaining short electrical connections to the annular stator, as modules on both inner and outer peripheries can be electrically connected with minimal wire length due to the annular geometry.
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
The solution enables optimal cooling of a large number of power devices, reducing the risk of electrical faults and maintaining a small size, while minimizing pressure losses and heat zone formation, thus enhancing the reliability and efficiency of the electrical converter.
Implementation Method 1
a cooling circuit configured to supply each inner bath and each outer bath with coolant
Implementation Method 2
heat sinks with fins to optimize heat transfer
Data Source
AI summary
An electrical converter configured to supply an electric machine, in particular for an aircraft, with power, comprising an annular stator and a rotor. The electrical converter comprising a plurality of power inverters, each comprising a plurality of power devices that are configured to be connected to the annular stator so as to supply the electric machine with power, a casing comprising a plurality of inner baths and outer baths, a coolant circuit configured to supply each inner bath and each outer bath with coolant. The power devices being mounted in the inner baths and the outer baths so as to allow all of the power devices to be cooled.