Study On Water Cooled Heat Dissipation Characteristics Of Motor Controller Of Pure Electric Vehicle

When IGBT is running, it will generate a lot of heat loss. If the heat couldn't be timely emitted, it would cause irreversible damage to IGBT and a serious threat to the security and stability of the pure electric vehicles, therefore the design of heat radiator with more excellent performance become an imminent question.In this paper, the related theoretical bases of thermal analysis were elaborated, including heat transfer theory, fluid mechanics, fluid dynamics theory, as well as the traditional method of heat dissipation design, thermal analysis of the type of knowledge. At the same time, the thermal resistance and power consumption of the motor controller IGBT are calculated, which provides a basis for the design and thermal analysis of the heat sink.According to the actual situation of IGBT, the three-dimensional model of the radiator is designed and built. Because of the limited space inside the electric vehicle, a water cooling radiator with two layers of water is designed, which can save space and increase the heat dissipation efficiency as well. The 3D model of water-cooling radiator is put into FLUENT software, which is a part of ANASYS platform, to conduct thermal simulation analysis and the effect of flow on the heat transfer performance and pressure drop. Finally, the optimal flow rate is 8L/min. Then the radiator was used to optimize the structure, according to the design of radiator is divided into two parts waterway characteristics, optimization is from two aspects:in the up-waterway and down-waterway, the radiator is arrange spoiler arranged needle cylinder respectively. After the comparison, the optimal layout for heat dissipation structure is determined, which arranges 610 pin column in the down-waterway.In order to verify the use of ANASYS software for thermal analysis is consistent with the actual situation, boundary conditions and parameter settings in the software to meet the actual situation, several groups of Engineering test are performed. The radiator with optimized structure is made out, then with the help of using water cooled experimental platform, according to the simulation boundary conditions, several experiments are conducted and experimental results are obtained. The structure and the simulation results were compared, and the error analysis prove that the simulation results are in good agreement with the actual situation.