A 10-kW SiC inverter with a novel printed metal power module with integrated cooling using additive manufacturing

Chinthavali, Madhu; Ayers, C.W.; Campbell, Steven; Wiles, Randy; Ozpineci, Burak

doi:10.1109/wipda.2014.6964622

Cited by 36 publications

(25 citation statements)

References 3 publications

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“…The most significant development and maturity appear in the heat sinks and semi-open fin channels methods. These methods can also be used for power electronics devices, which opens the door for new and novel approaches called integrated electrical machines and drives (IMD) or integrated modular machines and drives (IMMD) [69], [70], [71], [72], and [73]. The main aim of these new approaches is the augmentation of power density and heat extraction.…”

Section: Discussionmentioning

confidence: 99%

Opportunities and Challenges of Utilizing Additive Manufacturing Approaches in Thermal Management of Electrical Machines

et al. 2021

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The additive manufacturing approach is considered a new manufacturing technology method and is evolving dynamically in recent years. It is advancing and achieving as the key enabling technology in a wide range of applications, from medical sciences to the aerospace and automotive industries. This novel approach opens a new path to overcome the conventional manufacturing problems and challenges by providing more design freedom, new ranges of materials, lightweight and complex geometries. According to demands metrics such as lightweight and high power density motors. This offers clear motivation to develop the advanced thermal management method with new materials and a novel additive manufacturing (AM) approach. The paper aims to provide a comprehensive review of all the attempts in various electrical machines' thermal management methods using AM method. It considers the opportunities and challenges that designers are facing while implementing these approaches. Finally, the authors make some comments/forecasts on how the AM could improve the performance and manufacturability of the future thermal management system of electrical machines INDEX TERMS Additive manufacturing (AM), cooling systems, electrical machine, manufacturing techniques, thermal management, three-dimensional (3-D) printing, traction motors.

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Section: Discussionmentioning

confidence: 99%

Opportunities and Challenges of Utilizing Additive Manufacturing Approaches in Thermal Management of Electrical Machines

et al. 2021

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“…Channel matrix and the generated channel dimensions, the copper weight is estimated to be 56.1 502 and the aluminum weight is: 292. 5 7 790 with a total weight of 1292g.…”

Section: B Finite Element Analysis Modelmentioning

confidence: 99%

“…For example, in the matrix in Fig. 9, 15 turns are generated starting from location (1,5), going horizontal first to (1, 10); continuing from (1, 10) and going vertical (down) two points to (3,10). The same process is repeated until the channel reaches the end point (outlet) which is at (80, 5).…”

Section: A First Stage Genetic Algorithm Approachmentioning

confidence: 99%

“…Based on the total heat generation, heat distribution prespecified size, shape, and liquid flow amount, a unique and better performance heat sink can be designed automatically using genetic algorithms (GA). Previous GA applications in power electronics literature have focused on switching time optimization [5][6][7] and in control of power converters [8].…”

Section: Introductionmentioning

confidence: 99%

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Genetic algorithm design of a 3D printed heat sink

Ozpineci

Ayers

2016

2016 IEEE Applied Power Electronics Conference and Exposition (APEC)

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In this paper, a genetic algorithm-(GA-) based approach is discussed for designing heat sinks based on total heat generation and dissipation for a pre-specified size and shape. This approach combines random iteration processes and genetic algorithms with finite element analysis (FEA) to design the optimized heat sink. With an approach that prefers "survival of the fittest", a more powerful heat sink can be designed which can cool power electronics more efficiently. Some of the resulting designs can only be 3D printed due to their complexity. In addition to describing the methodology, this paper also includes comparisons of different cases to evaluate the performance of the newly designed heat sink compared to commercially available heat sinks.

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“…A 40 kW/liter air-cooled three-phase inverter without electromagnetic interference (EMI) filters has been developed in (15). A printed metal power module with integrated cooling using additive manufacturing is developed in (16).…”

Section: Introductionmentioning

confidence: 99%

High Power Density SiC-Based Inverter with a Power Density of 70kW/liter or 50kW/kg

et al. 2019

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This paper presents a high power density silicon carbide (SiC)-based inverter, with a two-level voltage-source structure having forced air cooling, which provides a high volumetric power density of 70 kW/liter or 50 kW/kg in gravimetric terms. In order to achieve a power density greater than that of conventional inverters, the losses must be reduced or the cooling performance must be improved. Small lightweight SiC MOSFET power modules with directly soldered foil fins having good thermal conductivities, are developed in this study. The antiparallel SiC Schottky barrier diodes (SBDs) are removed from the modules to improve the power density. Gate drivers are developed to reduce the switching losses and switching time. A prototype of the proposed high power density inverter, which includes the developed power modules and proposed gate driver, is fabricated. The volume and weight of the prototype inverter are approximately 0.5 liter and 660 g, respectively. Experimental results confirm that the prototype inverter can operate continuously with an output power up to 35 kW. Therefore, the power density of the prototype inverter is approximately 70 kW/liter or 50 kW/kg. The efficiency of the prototype inverter is found to be more than 98%. Hence, the measures undertaken in this study have been verified to improve the power density of the inverters. The proposed high power density inverters can be applied in future aircraft and other electric vehicles.

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A 10-kW SiC inverter with a novel printed metal power module with integrated cooling using additive manufacturing

Cited by 36 publications

References 3 publications

Opportunities and Challenges of Utilizing Additive Manufacturing Approaches in Thermal Management of Electrical Machines

Opportunities and Challenges of Utilizing Additive Manufacturing Approaches in Thermal Management of Electrical Machines

Genetic algorithm design of a 3D printed heat sink

High Power Density SiC-Based Inverter with a Power Density of 70kW/liter or 50kW/kg

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