Modular Vehicle Power Converter With Integrated Liquid Cooling
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Solution Overview
Problem
Existing electronic power converters for vehicles lack flexibility in controlling electric motors of different sizes, are not compact, and are costly to manufacture.
Innovation Solution
A compact electronic power converter design featuring reversible electric motors, a three-phase AC/DC converter with modular power modules and a cooling system, allowing for adjustable control of electric motors with varying nominal powers, and a clamping system for efficient assembly and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If power modules are piled on top of one another with liquid cooling, then cooling efficiency is improved, but device volume increases
Solution Approach 1:
The patent implements nested cooling channels where cooling passages are integrated within the power module structure itself. The cooling channels are positioned between adjacent power modules, allowing the cooling system to be nested within the existing module arrangement rather than adding external cooling components, thus improving cooling efficiency without increasing overall device volume.
Solution Approach 2:
The patent transitions from traditional external liquid cooling to internal cooling channels embedded within the power module structure. By moving the cooling function into the third dimension (within the module layers), the system achieves efficient heat dissipation without occupying additional external space, effectively resolving the volume-cooling efficiency contradiction.
2Volume of moving object
If power modules are piled on top of one another, then device volume is reduced, but heat dissipation becomes insufficient
Solution Approach 1:
The patent introduces cooling channels as an intermediary medium between adjacent power modules. These channels facilitate heat transfer from the power modules to the cooling liquid, enabling effective heat dissipation in the compact stacked configuration without requiring increased spacing between modules.
Solution Approach 2:
The patent employs liquid cooling through integrated cooling channels, using hydraulic flow to remove heat from the densely packed power modules. The cooling liquid circulates through channels positioned between modules, providing efficient thermal management in the compact vertical arrangement.
3Manufacturing precision
If electronic power converter design is customized for different motor sizes, then control precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the power converter into modular power modules that can be stacked in different configurations. This segmentation allows the system to be adapted to different motor sizes by varying the number and arrangement of modules, while maintaining standardized manufacturing processes for each module type, thus reducing overall manufacturing complexity.
Solution Approach 2:
The patent designs universal power modules with standardized interfaces and cooling channel configurations that can be used across different converter sizes. This multi-functionality allows the same basic module design to serve multiple applications, reducing manufacturing complexity while maintaining control precision through proper module arrangement.
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 solution provides flexible power management for electric motors of different sizes, ensures effective and efficient cooling, and reduces manufacturing complexity and costs, while maintaining a compact design.
Implementation Method 1
an electronic power converter provided with a plurality of power modules piled on top of one another and provided with a liquid cooling
Data Source
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AI summary
An electronic power converter (6) to control at least one electric motor (4) of a vehicle (1) and having at least one group (12) of power modules (11), each designed to power with an alternating current one single phase of the electric motor (4); two lateral plates (20), which are arranged on opposite sides of the group (12) so as to form a pile (17); a hydraulic circuit, which is configured to cause a cooling liquid to circulate inside the plates (20); and a clamping system (25), which applies a clamping force to the pile (17) in order to keep the pile (17) compressed and has elastic elements (26), which are deformed in order to apply a compression force of elastic origin to the pile (17).