6kW DC/DC Converter Thermal Analysis And Thermal Structure Optimization

With the development of power electronics, the performance of power electronicdevices has been greatly improved, on the other hand, the rate of product replacementis becoming more and more quickly. Electronic devices will develop in the directionof miniaturization, multi-functional and high-performance, which leads heat fluxincreasing within the electronic equipment devices. Thermal analysis as an importantpart of electronics design process, which influence whether the device can achievereasonable cooling during normal operation has an important impact on the design’sreliability and lifetime. So that, with the help of thermal analysis software to optimizethe heat dissipation structure before production has become increasing important. Thethesis mainly researched in the following areas:According to the design parameters we established a6kW boost DC/DCconverter design based on three-phase synchronous rectification technology.According the requirements, we calculated the main parameters and selectedelectrical components; designed the main control board, drive board, sampling circuit,etc. After installation and debugging, the design reached output and efficiencyrequirements.Discussed the principle of power losses in MOSFET, inductor and capacitor,then analyzed and calculated the loss of these electrical components. With the help ofloss calculation, we got data and theoretical basis for next research.With the help of Icepak thermal analysis software, I discussed how differentparameters such as cooling modes, wind tunnel design, the shape of heat sink, theparameters of fans, etc effect cooling result.Completed the optimization of the chassis cooling structure, and with the help ofIcepak thermal simulation we got temperature contours, which proved the thermalperformance had greatly improved than the original design.