An Innovative Additively Manufactured Design Concept of a Dual-Sided Cooling System for SiC Automotive Inverters
Modern Electric Vehicles (EVs) require high power and high efficient powertrains to extend their power range. A key element of the electric powertrain is its drive with an electric motor controlled by a traction inverter. A cooling system dissipates heat generated due to the losses in this inverter...
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| Format: | Article |
| Language: | English |
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IEEE
2024-01-01
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| Series: | IEEE Access |
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| Online Access: | https://ieeexplore.ieee.org/document/10414090/ |
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| author | Ekaterina E. Abramushkina Gamze Egin Martin Atila Sen Shahid Jaman Haaris Rasool Mohamed El Baghdadi Omar Hegazy |
| author_facet | Ekaterina E. Abramushkina Gamze Egin Martin Atila Sen Shahid Jaman Haaris Rasool Mohamed El Baghdadi Omar Hegazy |
| author_sort | Ekaterina E. Abramushkina |
| collection | DOAJ |
| description | Modern Electric Vehicles (EVs) require high power and high efficient powertrains to extend their power range. A key element of the electric powertrain is its drive with an electric motor controlled by a traction inverter. A cooling system dissipates heat generated due to the losses in this inverter and keeps its temperature within limits, i.e. below the operational maximum value. Indirect cooling systems are often the preferred solution due to their easy implementation and robust separation of the electric/electronic parts and the coolant circuit. Indirect cooling comes with additional surface interfaces, hence thermal barriers and increased thermal resistance for the losses’ heat flow path. One way to increase the system’s heat transfer coefficient is by implementing power electronics with dual-sided cooling (DSC) solutions and by enhancing surface structures for the cold plates. Manufacturing complex cold plate solutions with internal surface-enhancing structures by way of classical techniques (e.g. aluminum extrusion with CNC machining) can be difficult, costly, or even not possible. Sealed one-piece solutions are preferred, without the need to weld parts or to use screws, glue, gaskets, etc. 3D metal printing allows to manufacture of a one-unit compact, light, and reliable cold plate. This study shows the advantages and limitations of a 3D metal-printed inverter cold plate by presenting the microchannel design, numerical thermal simulations, and experimental results for the liquid cooled DSC SiC and Si inverters. This work explores the compatible use of 3D metal printing solutions, which will aid the development of modern high-power density EVs. |
| first_indexed | 2024-03-08T03:13:16Z |
| format | Article |
| id | doaj.art-e435a6949ada4dd0a53934daf3826e8b |
| institution | Directory Open Access Journal |
| issn | 2169-3536 |
| language | English |
| last_indexed | 2024-03-08T03:13:16Z |
| publishDate | 2024-01-01 |
| publisher | IEEE |
| record_format | Article |
| series | IEEE Access |
| spelling | doaj.art-e435a6949ada4dd0a53934daf3826e8b2024-02-13T00:01:42ZengIEEEIEEE Access2169-35362024-01-0112204542047010.1109/ACCESS.2024.335868510414090An Innovative Additively Manufactured Design Concept of a Dual-Sided Cooling System for SiC Automotive InvertersEkaterina E. Abramushkina0https://orcid.org/0000-0003-1112-5039Gamze Egin Martin1https://orcid.org/0000-0002-8168-2896Atila Sen2Shahid Jaman3https://orcid.org/0000-0002-8667-6268Haaris Rasool4Mohamed El Baghdadi5https://orcid.org/0000-0002-6090-9609Omar Hegazy6https://orcid.org/0000-0002-8650-7341Department of Electrical Machines and Energy Technology (ETEC), MOBI-Efficient Power Electronics, Powertrain, and Energy Solutions (EPOWERS) Research Group, Vrije Universiteit Brussel (VUB), Brussels, BelgiumDepartment of Electrical Machines and Energy Technology (ETEC), MOBI-Efficient Power Electronics, Powertrain, and Energy Solutions (EPOWERS) Research Group, Vrije Universiteit Brussel (VUB), Brussels, BelgiumDepartment of Electrical Machines and Energy Technology (ETEC), MOBI-Efficient Power Electronics, Powertrain, and Energy Solutions (EPOWERS) Research Group, Vrije Universiteit Brussel (VUB), Brussels, BelgiumDepartment of Electrical Machines and Energy Technology (ETEC), MOBI-Efficient Power Electronics, Powertrain, and Energy Solutions (EPOWERS) Research Group, Vrije Universiteit Brussel (VUB), Brussels, BelgiumDepartment of Electrical Machines and Energy Technology (ETEC), MOBI-Efficient Power Electronics, Powertrain, and Energy Solutions (EPOWERS) Research Group, Vrije Universiteit Brussel (VUB), Brussels, BelgiumDepartment of Electrical Machines and Energy Technology (ETEC), MOBI-Efficient Power Electronics, Powertrain, and Energy Solutions (EPOWERS) Research Group, Vrije Universiteit Brussel (VUB), Brussels, BelgiumDepartment of Electrical Machines and Energy Technology (ETEC), MOBI-Efficient Power Electronics, Powertrain, and Energy Solutions (EPOWERS) Research Group, Vrije Universiteit Brussel (VUB), Brussels, BelgiumModern Electric Vehicles (EVs) require high power and high efficient powertrains to extend their power range. A key element of the electric powertrain is its drive with an electric motor controlled by a traction inverter. A cooling system dissipates heat generated due to the losses in this inverter and keeps its temperature within limits, i.e. below the operational maximum value. Indirect cooling systems are often the preferred solution due to their easy implementation and robust separation of the electric/electronic parts and the coolant circuit. Indirect cooling comes with additional surface interfaces, hence thermal barriers and increased thermal resistance for the losses’ heat flow path. One way to increase the system’s heat transfer coefficient is by implementing power electronics with dual-sided cooling (DSC) solutions and by enhancing surface structures for the cold plates. Manufacturing complex cold plate solutions with internal surface-enhancing structures by way of classical techniques (e.g. aluminum extrusion with CNC machining) can be difficult, costly, or even not possible. Sealed one-piece solutions are preferred, without the need to weld parts or to use screws, glue, gaskets, etc. 3D metal printing allows to manufacture of a one-unit compact, light, and reliable cold plate. This study shows the advantages and limitations of a 3D metal-printed inverter cold plate by presenting the microchannel design, numerical thermal simulations, and experimental results for the liquid cooled DSC SiC and Si inverters. This work explores the compatible use of 3D metal printing solutions, which will aid the development of modern high-power density EVs.https://ieeexplore.ieee.org/document/10414090/3D printingadditive manufacturingdual-side cooled (DSC) moduleliquid coolingmicrochannelscold plate |
| spellingShingle | Ekaterina E. Abramushkina Gamze Egin Martin Atila Sen Shahid Jaman Haaris Rasool Mohamed El Baghdadi Omar Hegazy An Innovative Additively Manufactured Design Concept of a Dual-Sided Cooling System for SiC Automotive Inverters IEEE Access 3D printing additive manufacturing dual-side cooled (DSC) module liquid cooling microchannels cold plate |
| title | An Innovative Additively Manufactured Design Concept of a Dual-Sided Cooling System for SiC Automotive Inverters |
| title_full | An Innovative Additively Manufactured Design Concept of a Dual-Sided Cooling System for SiC Automotive Inverters |
| title_fullStr | An Innovative Additively Manufactured Design Concept of a Dual-Sided Cooling System for SiC Automotive Inverters |
| title_full_unstemmed | An Innovative Additively Manufactured Design Concept of a Dual-Sided Cooling System for SiC Automotive Inverters |
| title_short | An Innovative Additively Manufactured Design Concept of a Dual-Sided Cooling System for SiC Automotive Inverters |
| title_sort | innovative additively manufactured design concept of a dual sided cooling system for sic automotive inverters |
| topic | 3D printing additive manufacturing dual-side cooled (DSC) module liquid cooling microchannels cold plate |
| url | https://ieeexplore.ieee.org/document/10414090/ |
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