Vehicle Inverter Modular Power Module Stacking
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Solution Overview
Problem
Conventional inverters face challenges in accommodating diverse motor output specifications due to size and weight limitations, requiring multiple motors and complex cooling systems, which increases development time and cost, and makes it difficult to maintain a consistent structure as the number of power modules increases.
Innovation Solution
The inverter structure features a power module assembly with power modules stacked in three columns and coolers alternately stacked for horizontal contact, allowing for adjustable power module configurations without altering the cooler configuration, enabling efficient heat transfer and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of power modules is increased to achieve higher output, then the motor output capability is improved, but the housing and cooling path configuration must be changed, increasing device complexity and development cost
Solution Approach 1:
The inverter is divided into modular power module units that can be independently stacked. Each power module is a self-contained unit with standardized interfaces, allowing the system to achieve higher output by simply adding more modules rather than redesigning the entire housing and cooling system. This segmentation enables scalable power output while maintaining consistent structural configuration.
2Power
If multiple power modules are used to achieve high output, then the power conversion capability is improved, but the development time and cost increase due to the need for new housing and cooling path designs
Solution Approach 1:
A universal housing and cooling path configuration is designed that can accommodate any number of power modules. The standardized interfaces and modular architecture allow the same housing design to serve multiple power output levels (e.g., 100kW, 200kW, 300kW) by simply varying the number of stacked modules, eliminating the need for separate development cycles for each power level.
3Ease of manufacture
If conventional inverter design is used with planar structure, then the manufacturing process is simple, but the cooling path must be redesigned when power module quantity changes, reducing adaptability
Solution Approach 1:
The inverter transitions from a planar two-dimensional layout to a three-dimensional stacked configuration. Power modules are arranged vertically in layers, allowing the system to scale power output by adding height rather than expanding footprint. This vertical stacking maintains manufacturing simplicity while providing adaptability to different power requirements through variable module quantities.
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 design allows for varying motor outputs while maintaining a consistent shape and reducing the inverter's volume, improving cost-effectiveness and ease of manufacturing by enabling the common use of parts and simplifying the manufacturing process.
Implementation Method 1
coolers of a plurality of coolers are alternately stacked one above another such that each cooler of the plurality of coolers comes into contact at upper and lower surfaces thereof with adjacent power modules of the plurality of power modules for heat transfer therebetween
Data Source
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AI summary
An inverter structure for a vehicle is provided. The inverter includes a capacitor for receiving direct current supplied from a battery, a power module assembly including a plurality of power modules and a plurality of coolers, and an output bus-bar connected to the plurality of power modules to output three-phase alternating current to a motor. In particular, inside of the power module, power modules of a plurality of power modules are connected to the capacitor to convert the direct current into the three-phase alternating current, and coolers of a plurality of coolers are alternately stacked one above another such that each cooler comes into contact at its upper and lower surfaces with adjacent power modules to enable heat transfer.