Variable Airflow Cooling for IGBT Inverter Heat Dissipation

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Solution Overview

Problem

The power handling capability of insulated gate bipolar transistor (IGBT) inverters in traction vehicles is limited by the heat dissipation capacity of IGBTs, necessitating improved temperature modeling and monitoring techniques to enhance cooling efficiency.

Innovation Solution

A system comprising a heatsink, dual IGBTs, a temperature sensor, and a cooling unit with a variable airflow rate, controlled by a controller to optimize cooling based on temperature readings, is implemented to improve heat dissipation and power handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the power handling capability of IGBT inverters is increased, then more electrical power can be supplied to traction motors, but the heat dissipation capacity of IGBTs becomes insufficient

Engineering Contradiction:

Improvepower handling capabilityVSAvoidheat dissipation capacity

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The cooling system transitions from a static fixed airflow design to a dynamic variable airflow system. The controller adjusts the airflow rate through the heatsink based on real-time temperature readings from temperature sensors, allowing the cooling capacity to adapt dynamically to the thermal load generated by IGBTs during different power handling conditions

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements a closed-loop feedback control mechanism where temperature sensors continuously monitor the temperature of IGBTs and heatsink, send signals to the controller, which then adjusts the airflow rate accordingly. This feedback loop ensures that cooling is optimized based on actual thermal conditions, preventing overheating while maximizing power handling capability

Inventive Principle:

Principle #23Feedback

2Device complexity

If a fixed airflow cooling system is used, then the cooling structure is simple, but the cooling efficiency cannot be optimized based on temperature variations

Engineering Contradiction:

Improvecooling structure simplicityVSAvoidcooling efficiency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The airflow rate parameter is changed from a fixed value to a variable parameter that can be adjusted based on temperature conditions. The controller modifies the airflow rate in response to temperature sensor inputs, optimizing the cooling efficiency for different thermal loads and operational scenarios

Inventive Principle:

Principle #35Parameter changes

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 effectively models and monitors IGBT temperatures, enhancing the power handling capacity of IGBT inverters by optimizing cooling, thereby improving the operational efficiency of traction vehicles.

Implementation Method 1

a heatsink, a first dual IGBT coupled to the heatsink... The power handling capability of the inverter is limited, at least in part, by the ability of the IGBTs to dissipate the heat generated by the current in the IGBTs

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a cooling unit comprising a plenum and a variable source of air flow... an air flow rate provided by the cooling unit is determined based on the desired level of cooling

Methodology Applied

Scientific EffectForced convection: Forced Convection

Data Source

PatentUS8625283B2System and methods for improving power handling of an electronic device

Publication Date: 2014.01.07 GENERAL ELECTRIC CO

AI summary

There is provided an electronic device that includes a heatsink, a first dual IGBT coupled to the heatsink and configured to provide electrical power to a field exciter, a second dual IGBT coupled to the heatsink and configured to provide electrical power to a battery, a third dual IGBT coupled to the heatsink and common to the field exciter and the battery. The electronic device also includes a temperature sensor disposed in the heatsink, a cooling unit comprising a plenum and a variable source of air flow, and a controller. The controller is configured to receive a temperature reading from the temperature sensor and, based on the temperature reading, determine a desired level of cooling for at least one of the dual IGBTs, wherein an air flow rate provided by the cooling unit is determined based on the desired level of cooling.