Expandable Coolant Manifold for Modular AC Switch Cooling
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Solution Overview
Problem
Conventional electric motor systems face challenges in efficiently cooling high voltage components like IGBTs and MOSFETs within inverters, requiring complex and costly cooling systems that are not easily adaptable for rapid maintenance or design changes.
Innovation Solution
An electric machine system with an integrated switching mechanism and an expandable coolant manifold that allows for detachable switch modules and individual cooling circuits, enabling flexible and rapid repair or redesign without complete system replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling systems are used for high voltage components, then cooling function is provided, but system complexity and cost increase
Solution Approach 1:
The coolant manifold is integrated directly into the switch assembly housing, merging the cooling system with the electrical switching system. This eliminates the need for separate external cooling components and reduces overall system complexity while maintaining effective cooling of high voltage components.
Solution Approach 2:
The switch assembly housing serves multiple functions: it houses the high voltage switching components (IGBTs, MOSFETs) and simultaneously acts as the coolant manifold for thermal management. This multi-functionality reduces the number of separate components needed in the system.
2Device complexity
If integrated cooling system is used, then system compactness is improved, but adaptability for maintenance and design changes decreases
Solution Approach 1:
The switch assembly is divided into modular sections with individual coolant channels for each switching component. This segmentation allows specific modules to be removed or replaced for maintenance without affecting the entire cooling system, improving adaptability while maintaining integration.
Solution Approach 2:
The cooling system is designed with flexible adaptability, allowing the manifold configuration to be modified or expanded as switching components are added or removed. This dynamic design enables easy maintenance and design changes without requiring complete system replacement.
3Ease of repair
If separate cooling systems are used for each switch module, then maintenance flexibility is improved, but device complexity increases
Solution Approach 1:
Multiple coolant channels for individual switch modules are merged into a single integrated manifold structure. This provides separate cooling paths for each module (enabling individual maintenance) while using a unified manifold design (reducing overall structural complexity).
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 solution provides efficient cooling for high voltage components, allows for easy replacement and addition of switch modules, and facilitates rapid design changes without costly rebuilding, enhancing maintenance and adaptability.
Implementation Method 1
Cooling systems for inverters include a fluid coolant such as oil, water, air or other media that can absorb and retain heat
Data Source
AI summary
An electric machine system including an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing, and a rotor rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. The switch assembly includes a switch module having a switch member. The switch module is configured and disposed to be detachably mounted in the switch portion of the machine housing. A cooling system that includes an expandable coolant manifold is arranged in the switch portion of the machine housing. The expandable coolant manifold is fluidly connected to the switch module.