Power Cell Coolant Flow Estimation Using Response Surface Modeling
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Solution Overview
Problem
Existing variable frequency drive systems face challenges in accurately determining the internal coolant flow rate, which is crucial for efficient operation and cooling, due to the inaccuracies of direct measurement methods like differential pressure sensors and flow sensors.
Innovation Solution
The system employs a multi-dimensional response surface accessed through computer executable instructions, utilizing computational fluid dynamics simulations to link power input, coolant flow rate, and temperature, enabling the control system to accurately determine the internal coolant flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement methods like differential pressure sensors and flow sensors are used to determine coolant flow rate, then measurement can be performed, but measurement precision deteriorates due to inaccuracies
Solution Approach 1:
The patent introduces temperature as an intermediary parameter to indirectly determine coolant flow rate. Instead of directly measuring flow rate with inaccurate sensors, the system measures temperature changes of the coolant and uses these temperature variations as a mediator to calculate the flow rate, thereby achieving more precise and reliable measurements
Solution Approach 2:
The patent replaces mechanical flow measurement systems (differential pressure sensors and flow sensors) with a thermal-based measurement approach. By substituting mechanical sensing with temperature measurement and computational analysis, the system achieves superior measurement precision while avoiding the inherent inaccuracies of mechanical flow sensors
2Measurement precision
If computational fluid dynamics simulations are used to create response surface, then measurement precision improves for coolant flow rate determination, but device complexity increases
Solution Approach 1:
The patent performs computational fluid dynamics simulations and creates the response surface model in advance, before actual operation. This preliminary action pre-computes the complex relationships between temperature and flow rate under various conditions, storing them in a lookup table that can be quickly queried during operation, thus achieving high precision without adding operational complexity
Solution Approach 2:
The patent transforms the complex multi-dimensional CFD simulation data into a simplified two-dimensional response surface model that relates temperature and flow rate. By reducing the dimensionality and complexity of the data structure while preserving the essential relationships, the system achieves accurate flow rate determination with minimal computational overhead during operation
Data Source
AI summary
A variable frequency drive system includes a power converter (160a) with a plurality of power cells (16a1-16c3) supplying power to one or more output phases, each power cell having multiple switching devices, a plurality of sensors monitoring values of the power converter, and a control system (18) in communication with the power converter and controlling operation of the plurality of power cells, wherein the control system is configured via computer executable instructions to access and utilize a multi-dimensional response surface to obtain an internal coolant flow rate.