IGBT Heat Dissipation Design And Optimization

Motor controller is the core component of electric vehicle to drive in a safe way,IGBT module is the key to ensure that the motor controller work in a safe and reliable state,it’s crucial to ensure that the highest temperature is under the junction temperature of IGBT,designing a reasonable cooling system is particularly important.First,the IGBT module power loss is analyzed,the corresponding on-state power loss,switch power loss and the IGBT module total power loss are calculated.The heat resistance distribution inside the radiator are analyzed.By using the relevant heat transfer theory and hydrodynamics formula,the thermal resistances are calculated.The equivalent model of power loss and thermal resistance is established to calculate the junction temperature of IGBT module,which lays a solid foundation for the subsequent simulation.Secondly,the initial air-cooled radiator of the IGBT module and the water-cooled radiator models with three different flow channels,named rectangular series pipeline,parallel pipeline and series pipeline,are established.The radiator is divided by a hexa unstructured grid,and then the corresponding boundary conditions are set up.Finally,fin structure parameters of the air-cooled radiator is respectively simulated with the ANSYS ICEPAK,including fin height,fin thick,fin gap and fin angle.They are analyzed with temperature field,pressure field and velocity field,and the heat transfer coefficient and pressure loss,the nusselt and friction factor.Then turbulent kinetic energy and turbulent dissipation rate are read on ICEPAK for analysis.The influence of different flow rates of the radiator is also analyzed,and the optimal heat dissipation scheme is obtained.Then the three different flow channel structures of the water cooling radiator are simulated and the corresponding calculation and analysis are carried out to get the optimal scheme.The cooling system of electric vehicle motor controller is designed through theoretical analysis,calculation and simulation,which provides a reference for the cooling design of this type of controller.