A customers development project involved creating a compact and lightweight intgrated inverter and motor for a high perfomance automotive application. Within the overall fixed casing envelope, compartments were allocated for the electric motor and power converter sections.
This high power density drive required a compact power inverter to be designed. A reliable cooling system for the was critical to meet the power output and reliability criteria.
As a result of the design constraints, several technical challenges arose:
Analysis & Innovation:
ECS’ application knowledge in the automotive sector facilitated a detailed understanding of the product and technical constraints. Following technical workshop with the client, ECS devised a detailed thermal analysis plan consisting of:
As a result of the detailed analyses performed, ECS delivered to the client:
Knowledge of effective liquid cooling techniques allowed ECS to arrive at a highly compact cooler for an integrated drive power converter.
A detailed CFD analysis ensured an optimal design was achieved, ensuring device temperatures remained within limit whilst matching the coolant pressure drop to coolant pump requirements.