Research On Key Technologies Of Power Density For Electric Vehicle Motor Controller

With the increasingly high re quirements of environme ntal protection and we are also faced with multiple constraints on energy security,environmental pollution and urban transport,it's an inevitable trend to develop new energy vehicles.At the same time,ne w e nergy vehicles will be mo ving in the direction of electrification,intelligence and light weight.As we kno w,motor controller is the key component of ne w energy vehicles,but China's motor controller meets the problems of lo w po wer density,high cost and poor reliability.The current challenges to solve these problems are cooling technology of high po wer electronic components,and ho w to achie ve the maximum performance,life time of IGBT and DC-Link capacitor(thin film)under typic al vehicle mission profile.The main task of this paper is to solve the problems of heat dissipatio n and performance impro veme nt of key de vices through the research of cooling technologies,the design and selection of IGBT and DC-Link capacitor,and the research of software algorithms,so as to impro ve the power density,reduce the cost and improve the reliability of the motor controller.Heat dissipatio n technology research mainly by analyzing IGBT and film capacitor thermal road mo del,choose different pac kaging of IGBT and thin film capacitors,according to the manufacturer to pro vide material parameters to establish the simulatio n model,comparing the results of simulation and scheme optimization,choose the optimal cooling solutions.IGBT and thin-film c apacitors of key components in the motor controller need to be selected according to the s ystem electrical topology,software PWM wave strategy and product s pecification.By selecting the voltage and current le vel of IGBT,then the total loss of IGBT was calculated,and IGBT temperature rise was evaluate d to determine the rationality of IGBT selection.Is the design of the thin film capacitors,according to the product specification and software control performance re quirements of the thorough analysis to determine the capacitance capacity value,ripple c urrent and key indic ators such as structure size,an d capacitor manufacturer cooperation together for capacitance mo nomer solution design.Software algorithm research is thro ugh the software algorithm to identify motor controller running environment condition and operation condition,without affecting the vehicle under the condition of s afe and reliable performance and reduce the loss of IGBT and e nhance the capacity of IGBT o utput strategy,raise the controller output capacity.Finally the cooling technology,the principle of design model selection of IGBT and film c apacitor and the software of the IGBT junction temperature estimating algorithm research is applie d to product de velopme nt,on the de velo ped product verify the validity of the research point and the accuracy.