Double-Side Cooled Power Module Thermal Fault Detection
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Solution Overview
Problem
In power systems utilizing paralleled double-side cooled (DSC) power modules, existing technologies fail to effectively detect and respond to cooling pipe blockages, which can lead to increased temperatures and potential system malfunctions due to inadequate thermal dissipation.
Innovation Solution
A method that monitors the temperature difference between two DSC power modules thermally coupled to the same cooling channel, comparing this difference with a threshold to detect blockages, and subsequently disables gate driver circuits or operates the power modules in a low-power mode to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If DSC power modules are used to increase power density, then power output is improved, but thermal management complexity increases
Solution Approach 1:
The system segments thermal monitoring by assigning dedicated temperature sensors to specific cooling channels (first cooling channel and second cooling channel) of the DSC power modules. This segmentation allows independent monitoring of different thermal zones, enabling targeted fault detection without requiring complex system-wide thermal management.
Solution Approach 2:
The control circuit continuously receives temperature information from sensors and compares it against reference values or thresholds. When abnormal temperature differences are detected between parallel DSC modules sharing the same cooling channel, the system provides feedback by generating alarm signals or adjusting operational parameters, creating a closed-loop thermal management system.
2Reliability
If multiple temperature sensors are deployed to monitor cooling effectiveness, then fault detection capability is improved, but system cost increases
Solution Approach 1:
Temperature sensors serve multiple functions: they monitor absolute temperature levels, detect temperature differences between parallel modules, identify cooling channel blockages, and provide data for control decisions. This multi-functionality maximizes the value of each sensor investment, improving reliability without proportionally increasing cost.
Solution Approach 2:
The system detects faults by monitoring changes in temperature parameters, specifically temperature differences between parallel DSC modules that share cooling channels. By focusing on parameter changes (delta T) rather than absolute values alone, the system achieves sensitive fault detection with standard temperature sensors.
3Loss of energy
If cooling pipe blockage occurs, then thermal dissipation efficiency deteriorates, but early detection enables preventive action
Solution Approach 1:
The system performs preliminary detection of cooling pipe blockages by continuously monitoring temperature differences before they lead to overheating or damage. When abnormal temperature patterns are detected, the control circuit can trigger alarm signals or adjust operational parameters in advance, preventing catastrophic failures.
Solution Approach 2:
The temperature difference caused by cooling pipe blockage, which represents a harmful thermal condition, is converted into a useful detection signal. The control circuit uses this abnormal temperature pattern as information to identify the blockage and trigger preventive actions, turning a symptom of failure into a diagnostic opportunity.
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 approach enables early detection of cooling pipe blockages, preventing overheating and system failures by reducing power consumption and allowing for safe operation even in the presence of partial or total blockages.
Implementation Method 1
Each DSC power module has a top surface and a bottom surface, which are each thermally coupled with one or more cooling channels of a cooling pipe system. The two DSC power modules are thermally coupled with a same cooling channel of the one or more cooling channels.
Implementation Method 2
Each DSC power module has a top surface and a bottom surface, which are each thermally coupled with one or more cooling channels of a cooling pipe system.
Implementation Method 3
cooling pipe system including a plurality of cooling channels
Data Source
AI summary
In accordance with an embodiment, a method includes: monitoring a temperature difference between two double-side cooled (DSC) power modules of a plurality of DSC power modules arranged in stacks of DSC power modules; comparing the temperature difference with a first temperature threshold; detecting a cooling pipe system blockage when the temperature difference is above the first temperature threshold; and after detecting the cooling pipe system blockage, disabling gate driver circuits coupled to the plurality of DSC power modules or operating the DSC power modules in a low-power mode. Each stack includes a plurality of DSC power modules. Each DSC power module has a top surface and a bottom surface, which are each thermally coupled with one or more cooling channels of a cooling pipe system. The two DSC power modules are thermally coupled with a same cooling channel of the one or more cooling channels.