Research On Heat Dissipation Characteristics Of Range Extender Motor Controller

In order to solve environmental problems in various countries,new energy vehicles have become the main research and development direction of the development of various countries.Among them,extended-range new energy vehicles are an indispensable part of new energy vehicles.An important component of the range extender is the range extender.Its performance directly affects the working performance of the whole vehicle.As an indispensable part of the range extender,the motor controller plays an irreplaceable role in the range extender.effect.Its performance directly affects the performance of the entire range extender.Traditional motor controllers use air-cooled and forced-air-cooled heat dissipation methods,which cannot meet the requirements of today’s controllers for heat dissipation performance,and require liquid cooling.Aiming at problems such as large heat generation and difficulty in heat dissipation of the motor controller of extended-range electric vehicles,the influence of the structural parameters of the heat dissipation system on the heat dissipation performance is studied,and an optimization method is proposed.The main tasks are:(1)According to the existing motor controller,use SOLIDWORKS 3D software to model the controller,and import the model into SOLIDWORKS FLOW SIMULATION for heat dissipation simulation calculation.In SOLIDWORKS FLOW SIMULATION,the manual grid method is used to set the grid parameters of the controller so that the drawn grid meets the requirements of simulation calculation,and then the boundary conditions are set for it,and finally the solution calculation is performed.According to the different working conditions of the controller,the working conditions of the controller are divided into rated working conditions and overload working conditions,and the heat dissipation of the controller under different working conditions is calculated respectively.Finally,an experimental test platform is established to measure the heat source of the controller.The temperature and the outlet temperature of the controller are calculated to further verify the accuracy of the simulation data by calculating the error between the experimental data and the simulation data.(2)The heat dissipation of the motor controller is mainly completed by the heat dissipation fins.The shape,size,quantity and material of the heat dissipation fins will affect its heat dissipation performance,and its inlet flow rate and cooling medium will also affect the heat dissipation performance.According to these parameters,the simulation calculation is carried out to explore the heat dissipation performance of the controller under different parameters.The study found that the fin structure is different,its fluid-solid contact area is also different,and the flow rate of the cooling medium in the controller is also different,which will eventually affect the heat dissipation performance of the heat source.The number of fins is different,the fluid-solid contact area is different,and the heat source temperature is also different.The inlet flow rate of the controller is different.Although the fluid-solid contact area of the controller is the same,the flow rate of the cooling medium is different,and the temperature of the heat source of the controller is also different.The fin structure,inlet flow,number of fins,cooling medium and fin material all affect the heat dissipation performance of the controller.(3)The water jacket structure and the fins will affect its heat dissipation performance.According to the heat dissipation of the controller,three different controller water jacket structures are proposed to explore the heat dissipation performance of the controller under different water jacket structures.The research found that the controller The water jacket structure is different,the fluid-solid contact area of the controller is also different,and the cooling medium flow rate of the controller is also different,which will eventually lead to different heat source temperatures,indicating that the water jacket structure of the controller affects the heat dissipation performance of the controller.(4)In order to ensure that the structural strength of the controller meets the standard,the simulation data in SOLIDWORKS FLOW SIMULATOM needs to be imported into SIMULATION for stress and strain analysis,and constraints are added to SIMULATION to obtain its stress and strain values under different parameters.Analyzing the simulation data value shows that the strength condition of the controller is satisfied.(5)The motor controller mainly dissipates heat through the controller’s fins.The size of the controller’s fins directly affects the heat dissipation performance of the controller.An optimization method is proposed to optimize the size of the controller’s fins so that the optimized The temperature of the heat source and the pressure drop at the inlet and outlet are reduced.The fin parameters were optimized by establishing a regression model and a regression equation.The study found that the optimized fin parameters reduced the heat source temperature under the condition of ensuring the pressure drop.It shows that it is feasible to establish the regression equation to optimize the fin parameters of the controller.