Modular Cooling Manifolds for Scalable Power Control Modules
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Solution Overview
Problem
Existing cooling systems for modular power conversion systems face challenges in efficiently routing cooling fluid to multiple modules with different cooling requirements and flow rates, especially as the number of modules increases and customization becomes necessary.
Innovation Solution
A modular cooling system design featuring a plurality of modules with chassis containing first and second manifold segments, forming common manifolds that align to create fluid channels. The system includes module-specific flow paths, an inlet, a first common manifold, a second common manifold, and an outlet, with blocking and orifice plates used to control fluid flow based on module type and configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If different flow paths and dimensions are used for different power electronics, then cooling requirements are met, but system complexity increases
Solution Approach 1:
The cooling system is divided into modular segments where each power electronics module has its own integrated manifold and flow paths. This segmentation allows each module to be independently configured for its specific cooling requirements while maintaining a standardized interface with the common manifold, thus meeting diverse cooling needs without proportionally increasing overall system complexity.
Solution Approach 2:
A common manifold design serves multiple functions: it distributes cooling fluid to all modules, collects return fluid, and provides a standardized interface for modular expansion. This universal component reduces the need for custom routing for each module, simplifying the overall system while accommodating different cooling requirements through modular attachments.
2Quantity of substance
If the number of modules increases, then system capacity increases, but routing difficulty increases
Solution Approach 1:
Each module is designed as a self-contained segment with integrated manifold connections. This segmentation allows modules to be added or removed without redesigning the entire routing system - new modules simply connect to the common manifold at standardized interfaces, making scaling straightforward despite increasing module count.
Solution Approach 2:
The modular architecture allows smaller module units to be nested within the overall system structure, with each module containing its own mini-manifold and flow paths that interface with the larger common manifold. This nested structure enables easy expansion - additional modules can be inserted into the system without disrupting existing routing.
3Adaptability or versatility
If customization of module location and number is allowed, then adaptability increases, but cooling system robustness decreases
Solution Approach 1:
The common manifold is designed as a universal distribution network with standardized interfaces that can accommodate any module configuration. This universal design maintains system robustness by ensuring consistent fluid distribution regardless of how many modules are present or where they are located, while simultaneously enabling full customization of the power electronics system.
Solution Approach 2:
The cooling system is designed with dynamic adaptability - the common manifold can accommodate varying numbers of modules and different configurations through its modular interface design. This dynamic capability allows the system to reconfigure itself as modules are added or removed, maintaining reliable cooling performance across different operational states without requiring a fixed, rigid routing structure.
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
The modular cooling system effectively manages fluid flow to meet the diverse cooling needs of multiple modules, enhancing scalability and customization while maintaining efficient heat transfer and fluid management.
Implementation Method 1
Components of a power conversion system may require cooling during operation. Certain cooling systems use cooling fluid to cool the components of the system via heat transfer.
Data Source
AI summary
A cooling system for a modular power control system (MPCS) is provided. The MPCS comprises modules. Each module has a chassis with a first manifold segment for first common manifold and a second manifold segment for second common manifold. When the modules are mounts to each other, the first manifold segments align to form the first common manifold and the second manifold segments align to form the second common manifold, providing two fluid channels between endcaps. The chassis of at least two modules further have a first opening providing a fluid interface region between the first common manifold and a module specific flow path, and a second opening providing a fluid interface region between the module specific flow path and the second common manifold. The module specific flow path provides at least one fluid branch between the first common manifold and the second common manifold.