Converter Air Cooling with Segmented Partial Flows
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Solution Overview
Problem
Existing air-cooled converter arrangements face inefficiencies in cooling, leading to reduced lifespan of capacitors and limited current carrying capacity due to heat dissipation issues from power electronics modules.
Innovation Solution
The converter arrangement employs a dual cooling air flow system, where a first partial air flow cools the power electronics module and a second, thermally separated partial air flow cools the capacitor, ensuring both components receive cold air, with the air flows merging to cool a second power electronics module, and a direct linear electrical bus bar arrangement for reduced material usage and cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cooling air flow is used for both power electronics module and capacitor, then the cooling system is simple, but the capacitor temperature becomes too high reducing its lifespan
Solution Approach 1:
The single cooling air flow is segmented into two separate partial air flows using a flow separator. The first partial air flow is directed to cool the power electronics module, while the second partial air flow is directed to cool the capacitor. This segmentation allows each component to be cooled by appropriately temperature air flows, preventing the capacitor from being exposed to overheated air and thereby extending its lifespan while maintaining reasonable system complexity.
2Loss of energy
If power electronics module is positioned before capacitor in cooling air flow direction, then cooling air is efficiently used for high-heat component, but capacitor receives heated air reducing its lifespan
Solution Approach 1:
The cooling air flow is segmented into separate paths using a flow separator positioned after the power electronics module. This allows the first partial air flow to cool the power electronics module efficiently, while the second partial air flow bypasses the heated region and is directed to cool the capacitor. The segmentation resolves the contradiction by maintaining cooling efficiency for the high-heat component while protecting the capacitor from exposed heated air.
Solution Approach 2:
A flow separator acts as an intermediary device that divides the cooling air flow into two distinct partial air flows. This intermediary structure enables the system to achieve both efficient cooling of the power electronics module and protected cooling of the capacitor, resolving the spatial arrangement contradiction.
3Device complexity
If standard cooling arrangement is used, then component layout is simple, but current carrying capacity is limited due to heat dissipation issues
Solution Approach 1:
The cooling air flow is segmented into separate partial air flows that can be independently optimized for each component's cooling requirements. This allows the system to handle higher power densities and increased current carrying capacity by ensuring that each component operates within optimal temperature ranges, while the segmented approach maintains manageable layout complexity through systematic air flow distribution.
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 configuration enhances the lifespan of capacitors and increases current carrying capacity while allowing operation at higher ambient temperatures, with significant cost savings from reduced bus bar material and efficient cooling of all components.
Implementation Method 1
a fan (4) for generating a cooling air flow (5)
Implementation Method 2
dissipated heat is created by power electronics modules
Implementation Method 3
A second partial air flow (8) for cooling the at least one capacitor (3) is routed via a first cooling air channel (9) past the first power electronics module (6) such that the second partial air flow (8) is thermally separated from the first power electronics module (6)
Data Source
AI summary
A converter arrangement includes a housing having a first cooling air channel, at least one capacitor disposed in the housing, a fan for generating a cooling air flow, and a first power electronics module disposed in the housing between the at least one capacitor and the fan, as viewed in a direction of the cooling air flow. The first power electronics module is positioned in relation to the fan so as to only be cooled by a first partial air flow. A second partial air flow provided for cooling the at least one capacitor is routed via the first cooling air channel past the first power electronics module such that the second partial air flow is thermally separated from the first power electronics module.