Modular Power Electronics Rack Cooling
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Solution Overview
Problem
Existing motor controller systems face inefficiencies in cooling due to the combination of power conversion, filtering, and thermal management functions within a single unit, where components like transformers and inductors are not adequately cooled by traditional cold plates, necessitating either flooded or spray cooling methods, which do not provide optimum cooling for all components.
Innovation Solution
A modular power electronics rack is designed with separate chambers for power converters, contactors, and magnetic components, utilizing a combination of cold plates and flooded or spray cooling techniques to optimize cooling for each type of component, allowing for modular mounting and parallel summation of power converters to drive larger motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If all power electronic functions (power conversion, filtering, control) are housed within a single unit, then device integration is improved, but cooling effectiveness deteriorates because a single cooling method cannot optimally cool all component types
Solution Approach 1:
The power electronic system is divided into separate modular units, each housing specific functions (power conversion, filtering, control). Each module can be independently cooled according to its thermal requirements, resolving the contradiction between integration and cooling effectiveness.
Solution Approach 2:
Different cooling methods are applied to different modules based on their specific thermal characteristics. Power conversion modules with high heat dissipation use one cooling approach, while filtering modules use another, optimizing cooling effectiveness for each local region.
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
This approach enables efficient cooling of distinct components within a common rack, optimizing thermal management and power handling capabilities by utilizing the best-suited cooling methods for each component, thereby enhancing the performance and flexibility of motor control systems.
Implementation Method 1
A cold plate typically is a heat exchanger that receives a circulating cooling fluid
Implementation Method 2
A pump 15 is shown schematically, and may move cooling fluid from the outlet 17 to the inlet 19
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A power electronics rack comprising a controller (22); power converters (24) including a switch, a storage system, and a gate drive, said gate drive communicating with the controller (22); magnetic components (32, 34, 36); a plurality of contactors (28), said contactors also communicating with said controller, and being operable to be changed by said controller to communicate said power converters to said magnetic components; and said magnetic components communicating with a plurality of motors (38), said controller being operable to change a configuration of said contactors to reconfigure how power is supplied to the magnetic components from said power converters.