Compact Motor Power Converter With Stacked Liquid-Cooled Modules
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Solution Overview
Problem
Existing electronic power converters for vehicles lack flexibility in controlling electric motors of different sizes, are not compact, and are costly to manufacture.
Innovation Solution
A compact electronic power converter design featuring reversible electric motors with a three-phase AC/DC inverter, comprising six power modules arranged in two groups with a cooling system and a clamping system using elastic elements, allowing for adjustable power output to control electric motors with varying nominal powers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If power modules are piled on top of one another with liquid cooling, then cooling efficiency is improved, but device volume increases
Solution Approach 1:
The patent embeds cooling channels directly within the power module structure itself, nesting the cooling function inside the power-generating components. This eliminates the need for separate external cooling systems and reduces overall converter volume while maintaining effective heat dissipation through integrated thermal management pathways.
Solution Approach 2:
The patent combines the power module and cooling system into a single integrated unit, merging previously separate functions (power conversion and thermal management) into one compact structure. This integration reduces the total volume by eliminating interfaces and spacing between separate cooling systems and power modules.
2Power
If power modules are piled on top of one another, then power density is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the power converter into modular power modules that can be independently manufactured and then stacked. Each module is a self-contained unit with standardized interfaces, allowing complex high-power density functionality to be achieved through simple repetition of standardized segments rather than complex integrated design.
Solution Approach 2:
The patent designs universal power modules with standardized interfaces and configurations that can be used in various converter arrangements. The same basic module design serves multiple functions and can be piled in different configurations to achieve different power densities, reducing manufacturing complexity through standardization.
3Volume of moving object
If power modules are piled on top of one another, then compactness is improved, but adaptability to different motor sizes decreases
Solution Approach 1:
The patent employs a dynamic configuration system where power modules can be selectively added or removed from the stack based on the specific motor application requirements. The modular architecture allows the converter to be dynamically adapted to different motor sizes and power requirements while maintaining a compact footprint through efficient use of vertical stacking space.
Solution Approach 2:
The patent segments the power converter into discrete, interchangeable power modules that can be configured in different quantities and arrangements. This segmentation enables the same basic compact module design to be adapted to various motor sizes by simply changing the number of modules stacked, providing versatility without sacrificing compactness.
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 provides flexibility in powering single or dual electric motors with adjustable nominal power, efficient cooling, and reduced manufacturing complexity and costs, while maintaining a compact design.
Implementation Method 1
designed to be cooled by a liquid cooling system
Implementation Method 2
The pile is provided with a clamping system which applies a clamping force to the pile by means of elastic elements
Data Source
AI summary
An electronic power converter to control at least one electric motor of a vehicle and having at least one group of power modules, each designed to power with an alternating current one single phase of the electric motor; two lateral plates, which are arranged on opposite sides of the group so as to form a pile; a hydraulic circuit, which is configured to cause a cooling liquid to circulate inside the plates; and a clamping system, which applies a clamping force to the pile in order to keep the pile compressed and has elastic elements, which are deformed in order to apply a compression force of elastic origin to the pile.