The Design And Optimization Of Radiator In Electric Vehicle Motor Controller System

This paper takes the miniature pure electric vehicles controller as the research object,aims at the design of the radiator with a view of the heat transferring and optimization of thestructure of radiator. A reasonable radiator is finally designed successfully which can meet thecooling requirements of the controller.The high-power electronic devices, such as power MOSFET and IGBT module, are themain heat source of motor controller. The mini electric car’s climbing heat loss is calculatedwhen the controller current reached a maximum value and the effects of elevating temperatureon heat loss is considered. Through the rational use of thermal equivalent circuit and somecalculation, the required heat sink thermal resistance is derived. According to the calculatedMOSFET power loss, the cooling form of radiator is determined reasonably, and themechanism of heat and heat pathway of controller cooling system is also analyzed. Theadvantages and disadvantages of cooling effect about the Al and Cu radiator are analyzedtheoretically, and their differences in machining process are compared. Based on this, theradiator material is determined by means of calculation, including the radiator’s specific size,and the shape. The resistance calculated can meet the cooling requirements.On the basis of the above work, first of all, the cooling performance of the designedcontroller radiator is simulated by using professional thermal analysis software ICEPAK, andthe results are analyzed, and then a comparison analysis between this radiator and the originalone with a cooling fan is carried out. Finally, the conclusion is obtained that an optimizationspace exists for the cooling fan’s structure. In order to further confirm the analysis results ofICEPAK and the reliability of the new radiator’s performance, some laboratory tests andfurther outdoor experiments in site environment have also been conducted.After above theoretical analysis and practical experiments, the product is released intomarket ultimately, and its outputs is gradually increasing. The research results have not onlysolved the cooling problem of the company’s existing controller, but also provide a referencefor the study of other controller radiators.