Modular Drive Cooling via Two-Phase Liquid
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional medium voltage drive systems are cumbersome, bulky, and expensive due to large DC link capacitors and complex customized isolation systems, which are not easily scalable or modular, leading to high costs and reduced efficiency.
Innovation Solution
A modular drive system with a cabinet design that includes a power cube bay for housing power cubes with liquid coolant and a transformer bay with a heat exchanger, allowing for two-phase cooling and improved airflow, enabling a scalable and efficient power conversion solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional medium voltage drive systems use large DC link capacitors and complex customized 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 achieve high voltage and power capabilities through parallel connection of multiple standardized modules, avoiding the need for single large capacitors and isolation systems in conventional designs.
Solution Approach 2:
The patent changes the electrical parameters by using series connection of modular power cells to achieve medium voltage levels. Each module operates at lower voltage with standardized components, and the series configuration multiplies the voltage while maintaining modularity, thus reducing weight and size compared to conventional single-stage high voltage designs.
2Power
If power cells are customized for specific voltage and power levels, then performance requirements are met, but the system becomes expensive and not easily scalable
Solution Approach 1:
The patent creates a universal modular power cell design that can be configured for different voltage and power levels by simply changing the number of series-connected modules. This standardized universal module serves multiple applications from low to medium voltage, eliminating the need for custom-designed power cells for each specific rating and significantly reducing manufacturing costs and improving scalability.
Solution Approach 2:
The system allows dynamic configuration by adding or removing modular power cells in series to adapt to different voltage and power requirements. This dynamic scalability enables the same basic module design to serve multiple power levels without customization, making the system easily adaptable to changing application requirements.
3Temperature
If conventional cooling systems are used, then cooling function is provided, but the system suffers from high costs, reduced efficiency, and size limitations
Solution Approach 1:
The cooling system is merged with the modular power cell structure, with each power cell containing its own integrated cooling channels and thermal management components. This integration eliminates the need for separate complex external cooling systems and reduces overall system complexity while improving cooling efficiency through direct thermal coupling with power electronic components.
Solution Approach 2:
The patent employs liquid coolant circulation through integrated cooling channels within each modular power cell. This hydraulic cooling system provides efficient heat removal from power electronic components, replacing less efficient air-based or complex water-cooled systems while reducing overall system size and cost.
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 size and weight, enhances cooling efficiency, and allows for a wide range of voltage applications with improved power density and reduced costs, while maintaining reliability and ease of maintenance.
Implementation Method 1
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
Implementation Method 3
a heat exchanger to enable heat exchange with the flow of liquid coolant
Data Source
AI summary
In an embodiment, a drive system includes a transformer enclosed in an enclosure including a heat exchanger to cool a fluid medium. In addition, the system includes a plurality of power cubes each including a rectifier, a DC-link, and an inverter. Each power cube may include a plurality of cold plates each coupled to a corresponding switching device of the inverter, an inlet port in communication with a first one of the plurality of cold plates and an outlet port in communication with a last one of the plurality of cold plates. In turn, a manifold assembly is to couple at least the power cubes to enable two phase cooling of the power cubes and the transformer via one or more heat exchangers.