UPS Hybrid Cooling System for High Power Density Heat Management
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Solution Overview
Problem
Existing UPS systems face challenges in maintaining a balanced heat management due to high power density, which can lead to overheating issues, especially in compact designs.
Innovation Solution
A hybrid cooling system that combines air cooling with a closed coolant circuit, where the blower draws air through a heat exchanger and a coolant pump circulates coolant through the motor/generator and power output stages, enhancing heat removal and distribution within the machine cabinet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a compact UPS system design with high power density is implemented, then the space efficiency and power output per unit volume are improved, but the heat management becomes difficult and overheating issues occur
Solution Approach 1:
The cooling system is segmented into multiple independent cooling circuits, each dedicated to specific components (power output stages, motor/generator, inductors). This segmentation allows targeted cooling of high-heat-generating components without compromising the overall heat balance of the compact system.
Solution Approach 2:
A heat exchanger is introduced as an intermediary component between the cooling medium and the power electronic components. The heat exchanger enables efficient heat transfer from the compact power components to the cooling fluid, solving the heat management challenge in the high-density design.
2Device complexity
If air cooling is used for simplicity, then the cooling system complexity is reduced, but the cooling efficiency is insufficient for high power density components
Solution Approach 1:
The system transitions from simple air cooling to a hydraulic cooling system using liquid coolant circulating through dedicated cooling circuits. This hydraulic approach provides superior cooling efficiency for high-power components while maintaining acceptable system complexity through standardized cooling pump and heat exchanger components.
3Temperature
If cooling air is drawn directly into the machine cabinet, then the cooling effectiveness is improved, but contamination of the interior occurs
Solution Approach 1:
Air filters are positioned at the air intake paths to act as intermediaries that remove contaminants from the cooling air before it enters the machine cabinet. This allows effective cooling with ambient air while preventing dust and particulate contamination of sensitive power electronic components.
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 solution allows for increased power density without overheating issues by effectively cooling critical components, such as the motor/generator and power output stages, while preventing contamination through air filtration and minimizing the risk of spark overs.
Implementation Method 1
a heat exchanger, together with a coolant pump, coolant channels through the motor/generator and cooling to bodies for the power output stages
Implementation Method 2
a blower which draws air out of the surroundings of the machine cabinet through an air filter into the machine cabinet, blows the air within the machine cabinet through a heat exchanger
Implementation Method 3
a coolant pump, coolant channels through the motor/generator and cooling to bodies for the power output stages
Data Source
AI summary
In an UPS system, following components are arranged in a machine cabinet: an AC-to-DC converter connected to a DC voltage link on its output side, a DC-to-AC converter connected to the DC voltage link on its input side; a motor/generator electrically connected to the DC voltage link and having a flywheel coupled to its rotor; a bypass to the AC-to-DC converter and the DC-to-AC converter connected in series, a bypass switch being arranged in the bypass; a controller; and a blower which draws air out of the surroundings through air filters, blows the air in the machine cabinet through a heat exchanger, and ejects the air again. The heat exchanger is arranged in a coolant circuit together with a coolant pump, cooling bodies for the power output stages, and coolant channels which include stator channels running through a stator of the motor/generator.