Pulse Inverter Cooling Channel Layout for Power Module Heat Control
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Solution Overview
Problem
Existing pulse inverters face inefficiencies in cooling, particularly for power modules, which can lead to overheating due to ohmic resistance, and existing cooling methods may not provide sufficient cooling for these modules, potentially requiring increased energy consumption or inadequate cooling if all components are cooled uniformly.
Innovation Solution
A pulse inverter with a cooling device utilizing an electrically insulating cooling fluid that flows through a fluid-tight housing and a cooling channel, where the power module is thermally connected to the channel's outer surface, ensuring cold fluid directly cools the power module before heating up and contacting other components, thereby achieving efficient and targeted cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If all components are cooled uniformly by flooding the housing, then all components receive cooling, but the power module cannot be cooled sufficiently and energy consumption increases
Solution Approach 1:
The cooling system implements local quality by directing relatively cold cooling fluid specifically to the power module through the cooling channel first, before the fluid enters the housing to cool other components. This ensures that the component with the highest cooling requirement (power module) receives the most effective cooling at the local level, rather than treating all components uniformly.
Solution Approach 2:
The cooling system is segmented into two distinct paths: a cooling channel dedicated to the power module and a housing for other components. The cooling fluid flows through the cooling channel first, then enters the housing. This segmentation allows different cooling strategies to be applied to different components, optimizing overall cooling efficiency.
2Temperature
If cooling fluid temperature is reduced or flow rate increased to ensure sufficient cooling, then power module cooling improves, but energy consumption of cooling system increases
Solution Approach 1:
The system performs preliminary cooling by directing the relatively cold cooling fluid through the cooling channel to the power module before the fluid enters the housing. This preliminary action ensures that the power module receives optimal cooling conditions first, preventing overheating without requiring the entire system to operate at maximum capacity.
Solution Approach 2:
The system utilizes parameter changes by allowing the cooling fluid temperature to vary along its flow path. The fluid enters the cooling channel at a lower temperature to maximize power module cooling, then absorbs heat in the housing, and is subsequently cooled again by the pump before re-entering the cooling channel. This dynamic parameter management optimizes cooling efficiency while controlling energy consumption.
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 design provides particularly efficient cooling for power modules while ensuring sufficient cooling for other components, reducing the risk of overheating and energy consumption by directing cold fluid specifically to the modules with the highest cooling requirements.
Implementation Method 1
the power module being in thermal contact with a cooling channel, wherein the cooling channel has an outlet, the outlet opening into the housing
Implementation Method 2
the cooling fluid flowing through the cooling device first flowing through the cooling channel and then through the housing
Data Source
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AI summary
The invention relates to a pulse inverter (3) for operating an electric motor vehicle, wherein the pulse inverter has a power module (4) for converting direct current supplied by a motor vehicle battery (1) into alternating current, wherein the pulse inverter (3) has a cooling device for cooling components of the pulse inverter (3) by means of an electrically insulating cooling fluid flowing through the cooling device, wherein the cooling device has a fluid-tight housing, wherein the cooling fluid flowing through the fluid-tight housing is in direct contact with at least one of the components to be cooled, wherein the cooling device has a cooling channel (10), wherein the power module (4) is thermally connected to an outer surface of the cooling channel (10), wherein the cooling channel (10) has an outlet (11), wherein the outlet (11) opens into the fluid-tight housing.so that the cooling fluid flowing through the cooling device first flows through the cooling channel (10) and then through the fluid-tight housing.