Modular Power Cell Thermal Management via Recirculated Air
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Solution Overview
Problem
Existing power delivery systems for medium-voltage applications face challenges in reducing size, increasing reliability, and maintaining operation under fault conditions, particularly in modular multilevel power cell systems.
Innovation Solution
A power delivery system comprising removable power cells with water-cooled heat sinks, air and water manifolds, and a heat exchanger, where air and water are recirculated to enhance cooling and thermal management, with self-sealing connections for easy cell replacement, and a back plane to separate cells from the air plenum, facilitating efficient power distribution and fault minimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If power cells are made modular and removable for easier replacement and maintenance, then ease of operation and reliability are improved, but device complexity increases due to the need for standardized interfaces, connection mechanisms, and modular architecture
Solution Approach 1:
The power delivery system is divided into modular power cells that can be independently replaced. Each cell contains complete functional units (power electronics, cooling, capacitors) that can be removed and replaced without affecting other cells, enabling quick maintenance and improved operational ease.
Solution Approach 2:
Standardized interfaces and connection mechanisms are implemented across all power cells, creating universal compatibility. The same mounting rails, electrical connections, and cooling interfaces are used throughout the system, allowing any cell to replace any other cell regardless of position or function.
2Temperature
If air and water are recirculated through heat exchangers for improved thermal management, then temperature control and reliability are improved, but device complexity increases due to additional cooling infrastructure
Solution Approach 1:
The cooling system merges air cooling and water cooling into an integrated thermal management architecture. Air cooling handles capacitor connectors and circuit boards, while water cooling handles power semiconductors, with both systems connected through heat exchangers that recycle thermal energy throughout the system.
Solution Approach 2:
The cooling system operates continuously with recirculating air and water flows. Heat exchangers continuously transfer thermal energy from warm air to cool water, and from warm water back to air, maintaining constant thermal management without interruption or external intervention.
3Temperature
If capacitor connectors and circuit boards are positioned near the air intake for optimal cooling, then temperature control is improved, but manufacturing precision requirements increase due to tighter spatial constraints
Solution Approach 1:
Different cooling strategies are applied to different components based on their thermal requirements. Capacitor connectors and circuit boards receive cooling from the air stream near the intake, while power semiconductors receive dedicated water cooling. Each component is positioned and cooled according to its specific thermal characteristics rather than using a uniform approach.
4Ease of operation
If self-sealing connections are implemented in water manifolds for easy cell replacement, then ease of operation is improved, but device complexity increases due to specialized connection mechanisms
Solution Approach 1:
The water manifold connections are designed to automatically seal when power cells are removed and automatically open when cells are installed. The self-sealing mechanism eliminates the need for manual valve operation or complex connection procedures, allowing operators to simply install or remove cells without additional steps for water flow control.
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 system effectively reduces size, increases reliability, and allows operation under fault conditions by optimizing thermal management and power distribution, enabling efficient recirculation of cooled air and water to maintain performance and extend cell life.
Implementation Method 1
Each power cell includes a water cooled heat sink
Implementation Method 2
The heat exchanger may be positioned to receive the air from the air plenum, cool the air, and recirculate the cooled air
Implementation Method 3
each power cell includes a water cooled heat sink
Data Source
AI summary
A power delivery system includes a group of removable power cells. Each power cell includes a water cooled heat sink, an air intake, and an air output. The system also includes a heat exchanger. The heat exchanger draws air from the cells, cools it, and recirculates the cooled air to the cells via each cell's air intake. The cell may be designed so that components that are not near the heat sink are cooled by air from the intake before that air reaches the heat sink.