Direct-Cooled Inverter With Coolant Sensing for Predictive Maintenance
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Solution Overview
Problem
Existing inverter cooling systems using air cooling require fans, leading to noise, pressure drop, and maintenance needs, while directly cooled components lack effective monitoring for coolant properties and service life prediction.
Innovation Solution
A directly cooled inverter system utilizing a biodegradable cooling fluid with integrated sensors to detect properties spectroscopically, chemically, and physically, coupled with AI for data analysis to predict component failure and optimize maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air cooling is used with fans, then cooling effectiveness is improved, but noise and maintenance requirements increase
Solution Approach 1:
The patent replaces the mechanical fan-based air cooling system with a liquid cooling system that uses a circulation pump to move cooling fluid through heat exchangers directly contact with power electronic components. This substitution eliminates the need for rotating mechanical parts (fans) that generate noise, while maintaining effective cooling through direct thermal contact between the cooling fluid and component surfaces.
2Reliability
If air filters are installed for air cooling, then cooling fluid quality is improved, but pressure drop and maintenance needs increase
Solution Approach 1:
The patent replaces the air filter system with a liquid cooling circulation system that uses a pump and closed-loop fluid circulation. The cooling fluid flows through sealed channels and heat exchangers without requiring filtration elements that create pressure drops. The system maintains fluid quality through the closed-loop design that prevents contamination while eliminating filter-related pressure losses.
3Measurement precision
If sensors are integrated in the cooling circuit, then monitoring capability is improved, but device complexity increases
Solution Approach 1:
The patent integrates multi-functional sensors into the cooling circuit that simultaneously monitor multiple parameters including temperature, fluid flow rate, and coolant properties. These sensors serve multiple purposes: they detect cooling effectiveness, identify potential failures, and provide data for predictive maintenance algorithms. By combining multiple sensing functions into integrated units within the cooling loop, the system achieves comprehensive monitoring without proportionally increasing complexity.
Solution Approach 2:
The patent implements a feedback system where sensor data from the cooling circuit is continuously analyzed by a control unit that adjusts system parameters and provides predictive maintenance alerts. The sensors feed information about coolant temperature, flow conditions, and component thermal states back to the control system, which then optimizes pump operation and cooling fluid circulation to maintain optimal cooling while preventing failures.
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
Enables quiet operation without fans, reduces maintenance, and provides accurate monitoring of coolant properties for predictive maintenance, ensuring uninterrupted operation and extended service life.
Implementation Method 1
the sensor detects the properties of the cooling fluid spectrotopically, chemically and/or physically
Implementation Method 2
the components are cooled directly by an electrically non-conductive fluid... the cooling fluid which at least partially flows through and/or around the components of the inverter and has direct contact with them
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a directly cooled inverter (1) comprising: a cooling circuit (5) for cooling components (2A, 2B, 2C) of the inverter (1); a cooling fluid (7) which at least partially flows through and/or around the components (2A, 2B, 2C) of the inverter (1) and has direct contact with them; at least one sensor (8) which is arranged in the cooling circuit (5), wherein the sensor (8) is designed to detect properties of the cooling fluid (7).