Development of high performance integrated drives with focus on thermals using high temperature components and additive manufacturing

使用高温组件和增材制造开发高性能集成驱动器，重点关注热学

• 批准号: 2611205
• 金额: --
• 依托单位: University of Bristol
• 依托单位国家: 英国
• 项目类别: Studentship
• 财政年份: 2021
• 资助国家: 英国
• 起止时间: 2021 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=studentship-2611205
• 关键词: Development; performance; integrated; drives; focus

The focus of this PhD is the integration of high-power electric motors with their associated power electronics to yield a high-power-density system. A primary research avenue is the computationally efficient thermal modelling of the integrated components. In vehicle applications, both the motor and power electronic controller can produce large quantities of heat during high utilisation (known as losses) which typically requires a bespoke external cooling system to manage the temperature rise. This presents challenges with space, and pipe routing, for liquid cooled solutions, where the motor and controller are usually on the same cooling circuit. Additional complexity and reliability issues can be found through the use of a cooling pump or forced air cooling. Furthermore, with separate controllers and motors, electrical connections, and wire routing introduces extra complexity, and potential points of failure.Integrating the motor and controller into a single unit would allow for simplified thermal management and reduced external connections, potentially leading to improved reliability and reduced cost. A single package, integrated motor-drive would simplify installation of the powertrain into vehicles, and reduce points of failure associated with interconnects. When developing for high power systems, power electronic modularity, size of filters, electrical noise, and thermal management become larger challenges to overcome in the design. This tightly integrated package would allow for the system to have less external connections and reduced mass through a reduction in cable and cooling tube length. This would allow for a design that's able to be more easily integrated into existing systems. With the reduced number of components and increase of standardised, mass manufacturable components, this would reduce the cost of the system allowing for a more accessible motor.This PhD looks to improve the reliability of closely integrated control power electronics through size reduction and the use of higher temperature rated devices, utilising silicon carbide or gallium nitride. These would allow for greater space for electrical noise reduction, and improved reliability with increasing temperatures. This research is expected to have a significant practical basis, through the development of a controller circuit and mechanical housing along with design and results validation. The aim is to demonstrate a representative scale functioning prototype system on a dynamometer along with measuring the resultant efficiency and potential temperatures achieved. A comparison between a system that uses an identical motor and controller but setup in the standard configuration, where the controller is external to the motor can be made. This would allow for comparison of the efficiency with regards to the size reduction to be measured and quantified.Thermal modelling of the heatsinking elements, optimisation of heat distribution and testing different switches for performance at higher temperatures will be performed. As the power electronics are to be mounted near the motor windings, this includes temperatures near the maximum range of the coil's insulation. Further to the design of the heatsink itself, consideration is being made for using additive manufacturing for optimising liquid coolant channels for both the motor and power electronics. Consideration is also being made for using this manufacturing method for internal electrical connections so as to reduce complexity. This project falls within the EPSRC Electrical motors and drives and electromagnetics research area.

本博士的重点是高功率电动机与相关电力电子设备的集成，以产生高功率密度系统。一个主要的研究途径是计算有效的热建模的集成组件。在车辆应用中，电机和电力电子控制器在高利用率期间都会产生大量的热量（称为损耗），这通常需要定制的外部冷却系统来控制温升。这对液冷解决方案的空间和管道布线提出了挑战，其中电机和控制器通常在相同的冷却回路上。通过使用冷却泵或强制空气冷却，可以发现额外的复杂性和可靠性问题。此外，由于单独的控制器和电机，电气连接和电线布线引入了额外的复杂性和潜在的故障点。将电机和控制器集成到一个单元中可以简化热管理，减少外部连接，从而提高可靠性并降低成本。一个单一的封装，集成的电机驱动器将简化动力总成的安装到车辆中，并减少与互连相关的故障点。在开发高功率系统时，电力电子模块化、滤波器尺寸、电气噪声和热管理成为设计中需要克服的更大挑战。这种紧密集成的封装将允许系统减少外部连接，并通过减少电缆和冷却管长度来减少质量。这将使设计能够更容易地集成到现有系统中。随着组件数量的减少和标准化的增加，可大规模制造的组件，这将降低系统的成本，允许更容易获得的电机。该博士希望通过减小尺寸和使用更高额定温度的器件，利用碳化硅或氮化镓来提高紧密集成控制电力电子设备的可靠性。这将为电气降噪提供更大的空间，并在温度升高时提高可靠性。通过控制器电路和机械外壳的开发以及设计和结果验证，预计本研究将具有重要的实践基础。目的是在测功机上演示具有代表性的规模功能原型系统，并测量由此产生的效率和达到的潜在温度。使用相同的电机和控制器但在标准配置中设置的系统之间的比较，其中控制器在电机外部可以进行。这样就可以比较要测量和量化的尺寸减少方面的效率。将对散热元件进行热建模，优化热分布，并测试不同开关在更高温度下的性能。由于电力电子设备要安装在电机绕组附近，这包括线圈绝缘的最大范围附近的温度。除了散热器本身的设计之外，还考虑使用增材制造来优化电机和电力电子设备的液体冷却剂通道。也正在考虑将这种制造方法用于内部电气连接，以减少复杂性。该项目属于EPSRC电机、驱动和电磁学研究领域。