Modular Medium Voltage Drive Cooling System
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Solution Overview
Problem
Conventional medium voltage drive systems are cumbersome, bulky, and expensive due to large DC link capacitors and complex isolation systems, and they lack modularity, leading to high costs, reduced efficiency, and size limitations, especially as voltage and power requirements increase.
Innovation Solution
A modular medium voltage drive system is designed with a cabinet comprising a transformer bay and a power cube bay, featuring a modular two-phase cooling system and a power service bus that allows for easy access and replacement of components, using a combination of fixed and moveable portions to reduce size and weight, and employing a horizontal transformer configuration for improved airflow and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional medium voltage drive systems use large DC link capacitors and complex isolation systems, then voltage and power requirements can be met, but the system becomes cumbersome, bulky, and expensive
Solution Approach 1:
The drive system is divided into modular power cells, each handling a portion of the total power requirement. This segmentation allows the system to meet high voltage and power requirements through parallel connection of multiple smaller, lighter modules rather than requiring a single large, heavy system.
Solution Approach 2:
The power cells are designed with universal interfaces and standardized components that can be configured for different voltage and power levels. This multi-functionality allows the same basic module design to serve multiple applications, reducing the need for custom-heavy designs for each specific power requirement.
2Power
If conventional medium voltage drive systems use large DC link capacitors and complex isolation systems, then voltage and power requirements can be met, but the system becomes cumbersome and bulky
Solution Approach 1:
The drive system is divided into modular power cells, each handling a portion of the total power requirement. This segmentation allows the system to meet high voltage and power requirements through parallel connection of multiple smaller, lighter modules rather than requiring a single large, heavy system.
Solution Approach 2:
The modular power cells are designed to be nested or stacked within a common cabinet structure, with shared components such as cooling systems, control electronics, and structural support. This nesting approach reduces the overall system volume compared to having separate standalone systems for each power cell.
3Reliability
If power cells are provided as fixed enclosed modules customized for a given power and voltage level, then specific applications can be addressed, but the system becomes expensive and lacks modularity
Solution Approach 1:
The power cells are designed with universal interfaces and standardized components that can be configured for different voltage and power levels. This multi-functionality allows the same basic module design to serve multiple applications, reducing the need for custom designs for each specific power requirement while maintaining reliability through proven standardized components.
Solution Approach 2:
The system allows dynamic reconfiguration of power cells through standardized mechanical and electrical interfaces. Modules can be added, removed, or repositioned to adapt to changing application requirements, providing both the reliability of application-specific configurations and the versatility of modularity.
4Productivity
If all system components including transformers, control, and cooling systems are optimized for a specific voltage and power rating, then performance is maximized, but the system lacks modularity and becomes costly
Solution Approach 1:
The drive system is divided into modular power cells, each handling a portion of the total power requirement. This segmentation allows the system to meet high voltage and power requirements through parallel connection of multiple smaller, lighter modules rather than requiring a single large, heavy system.
Solution Approach 2:
The power cells are designed with universal interfaces and standardized components that can be configured for different voltage and power levels. This multi-functionality allows the same basic module design to serve multiple applications, reducing the need for custom designs for each specific power requirement.
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 design reduces the size and weight of the drive system, enhances cooling efficiency, and allows for scalable power and voltage capabilities with reduced costs and improved reliability, enabling efficient operation across a wide range of voltage applications.
Implementation Method 1
a first portion has multiple cube chambers each having a protective enclosure in which to house one of the power cubes, where each cube includes an inlet port to receive a flow of liquid coolant and an outlet port to output a flow of two phase coolant
Implementation Method 2
an outlet port to output a flow of two phase coolant
Data Source
AI summary
In an embodiment, a medium voltage drive system includes a transformer, multiple power cubes each coupled to the transformer, and a manifold assembly. Each power cube includes cold plates each coupled to a corresponding switching device of the cube, an inlet port in communication with a first one of the cold plates and an outlet port in communication with a last one of the cold plates. The manifold assembly can support an inlet conduit and an outlet conduit and further support first and second connection members to enable blind mating of each of the first connection members to the inlet port of one of the power cubes and each of the second connection members to the outlet port of one of the power cubes to enable two phase cooling of the plurality of power cubes.