Fluid cooled vehicle drive module

• US 6,965,514 B2
• Filed: 12/23/2002
• Issued: 11/15/2005
• Est. Priority Date: 01/16/2002
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Sponsoring Entity: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Kannenberg, Daniel G., Gollhardt, Neil, Radosevich, Lawrence D., Meyer, Andreas A., Beihoff, Bruce C.
• Primary Examiner(s): CHERVINSKY, BORIS LEO
• APPLICATION: US 20030132041A1
• Time in patent office: 1058 Days
• Field of Search: 361/689, 361/698, 361/699, 361/704, 361707-712, 361715-719, 165/80.3, 165/80.4, 363/141, 174/15.1
• US Class Current: 361/699
• CPC Class Codes: B60L 15/007 : Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 2210/20 : AC to AC converters
• CPC Class Codes: H02M 1/44 : Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• CPC Class Codes: H02M 7/003 : Constructional details, e.g. physical layout, assembly, wiring, busbar connections
• CPC Class Codes: H05K 7/20927 : Liquid coolant without phase change
• CPC Class Codes: Y02T 10/645 : Control strategies for dc machines
• CPC Class Codes: Y02T 10/7005 : Batteries
• CPC Class Codes: Y02T 10/7077 : on board the vehicle
• CPC Class Codes: Y02T 10/725 : AC to AC power conversion

Abstract

An electric vehicle drive includes a support may receive one or more power electronic circuits. The support may aid in removing heat from the circuits through fluid circulating through the support. The support, in conjunction with other packaging features may form a shield from both external EM/RFI and from interference generated by operation of the power electronic circuits. Features may be provided to permit and enhance connection of the circuitry to external circuitry, such as improved terminal configurations. Modular units may be assembled that may be coupled to electronic circuitry via plug-in arrangements or through interface with a backplane or similar mounting and interconnecting structures.

Claims

1. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

a thermal support at least partially defining an electric reference plane and configured to receive and circulate a coolant stream for extraction of heat;

a substrate secured to the thermal support and cooled during operation by the coolant stream;

a power electronics circuit directly secured to and cooled by the substrate, the power electronics circuit being configured for generating output signals resulting from power conversion, the power electronic circuit generating heat during operation that is at least partially extracted by the coolant stream via the substrate; and

a driver circuit for applying drive signals to the power electronics circuit, the driver circuit being secured to and cooled by the thermal support.

2. The electric vehicle drive of claim 1, wherein the power electronics circuit is bonded to the substrate.

3. The electric vehicle drive of claim 1, wherein the thermal support is a single-piece support.

4. The electric vehicle drive of claim 1, wherein the thermal support is a multi-piece support.

5. The electric vehicle drive of claim 1, wherein the thermal support includes at least one extension for supporting and cooling additional circuitry.

6. The electric vehicle drive of claim 1, wherein the power electronics circuit forms an inverter.

7. The electric vehicle drive of claim 1, wherein the power electronics circuit forms a matrix converter.

8. The electric vehicle drive of claim 1, further comprising a control circuit secured on and cooled by the thermal support.

9. The electric vehicle drive of claim 1, further comprising line conductors for directing incoming power to the power electronics circuit and load conductors for directing outgoing power from the power electronics circuit.

10. The electric vehicle drive of claim 9, wherein the line conductors are disposed on a first side of the support.

11. The electric vehicle drive of claim 10, comprising a fluid inlet and a fluid outlet for receiving the coolant stream, and wherein the fluid inlet and outlet ports are disposed on a second side of the support.

12. The electric vehicle drive of claim 10, wherein the load conductors are disposed on a second side of the support opposite the line conductors.

13. The electric vehicle drive of claim 1, further comprising an energy storage circuit coupled to the power electronics circuit and secured to and cooled by the thermal support.

14. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

a thermal support for a circuit, the support comprising a substrate having fluid inlet and outlet ports and a circulation path coupled between the inlet and outlet ports, the inlet and outlet ports being configured to transmit a coolant for circulation through the circulation path;

an interface plate configured to support a power electronics circuit, the interface plate being configured for mounting to the support adjacent to the coolant circulation path for extraction of heat from the interface plate during operation;

a power electronics circuit configured for power conversion supported on the interface plate; and

a driver circuit for applying drive signals to the power electronics circuit, the driver circuit being secured to and cooled by the thermal support;

wherein the support at least partially defines an electrical reference plane, a mechanical support, and a thermal extraction path for the power electronics circuit.

15. The electric vehicle drive of claim 14, wherein the power electronics circuit is bonded to the interface plate.

16. The electric vehicle drive of claim 14, wherein the thermal support is a single-piece support.

17. The electric vehicle drive of claim 14, wherein the thermal support is a multi-piece support.

18. The electric vehicle drive of claim 14, wherein the thermal support includes at least one extension for supporting and cooling additional circuitry.

19. The electric vehicle drive of claim 14, wherein the power electronics circuit forms an inverter.

20. The electric vehicle drive of claim 14, wherein the power electronics circuit forms a matrix converter.

21. The electric vehicle drive of claim 14, further comprising a control circuit secured on and cooled by the thermal support.

22. The electric vehicle drive of claim 14, further comprising line conductors for directing incoming power to the power electronics circuit and load conductors for directing outgoing power from the power electronics circuit.

23. The electric vehicle drive of claim 22, wherein the line conductors are disposed on a first side of the support.

24. The electric vehicle drive of claim 23, wherein the fluid inlet and outlet ports are disposed on a second side of the support.

25. The electric vehicle drive of claim 23, wherein the load conductors are disposed on a second side of the support opposite the line conductors.

26. The electric vehicle drive of claim 14, further comprising an energy storage circuit coupled to the power electronics circuit and secured to the thermal support.

27. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

a controlled power electronics circuit including solid state switches configured to convert incoming power to controlled outgoing power;

a control circuit coupled to the power electronics circuit and configured to generate control signals for control of the solid state switches;

a fluid cooled support at least partially defining an electrical reference plane and on which at least the power electronics circuit is directly secured, the fluid cooled support including inlet and outlet ports for a cooling fluid and an internal fluid conduit for directing flow of cooling fluid adjacent to the power electronics circuit for removal of heat therefrom; and

a driver circuit for applying drive signals to the power electronics circuit, the driver circuit being secured to and cooled by the support.

28. The electric vehicle drive of claim 27, wherein the power electronics circuit is bonded to an interface plate mounted to the support.

29. The electric vehicle drive of claim 27, wherein the support is a single-piece support.

30. The electric vehicle drive of claim 27, wherein the support is a multi-piece support.

31. The electric vehicle drive of claim 27, wherein the support includes at least one extension for supporting and cooling additional circuitry.

32. The electric vehicle drive of claim 27, wherein the power electronics circuit forms an inverter.

33. The electric vehicle drive of claim 27, wherein the power electronics circuit forms a matrix converter.

34. The electric vehicle drive of claim 27, wherein the control circuit is secured on and cooled by the fluid cooled support.

35. The electric vehicle drive of claim 27, further comprising line conductors for directing incoming power to the switches and load conductors for directing outgoing power from the switches.

36. The electric vehicle drive of claim 35, wherein the line conductors are disposed on a first side of the support.

37. The electric vehicle drive of claim 36, wherein the fluid inlet and outlet ports are disposed on a second side of the support.

38. The electric vehicle drive of claim 36, wherein the load conductors are disposed on a second side of the support opposite the line conductors.

39. The electric vehicle drive of claim 27, further comprising an energy storage circuit coupled to the power electronics circuit and secured to the support.

40. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

a thermal support at least partially defining an electric reference plane and configured to receive and circulate a coolant stream for extraction of heat;

a substrate secured to the thermal support and cooled during operation by the coolant stream;

a power electronics circuit directly secured to and cooled by the substrate, the power electronics circuit being configured for generating output signals resulting from power conversion, the power electronic circuit generating heat during operation that is at least partially extracted by the coolant stream via the substrate; and

a control circuit secured on and cooled by the thermal support.

41. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

a thermal support for a circuit, the support comprising a substrate having fluid inlet and outlet ports and a circulation path coupled between the inlet and outlet ports, the inlet and outlet ports being configured to transmit a coolant for circulation through the circulation path;

an interface plate configured to support a power electronics circuit, the interface plate being configured for mounting to the support adjacent to the coolant circulation path for extraction of heat from the interface plate during operation;

a power electronics circuit configured for power conversion supported on the interface plate; and

a control circuit secured on and cooled by the thermal support;

wherein the support at least partially defines an electrical reference plane, a mechanical support, and a thermal extraction path for the power electronics circuit.

42. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

a controlled power electronics circuit including solid state switches configured to convert incoming power to controlled outgoing power;

a control circuit coupled to the power electronics circuit and configured to generate control signals for control of the solid state switches; and

a fluid cooled support at least partially defining an electrical reference plane and on which at least the power electronics circuit is directly secured, the fluid cooled support including inlet and outlet ports for a cooling fluid and an internal fluid conduit for directing flow of cooling fluid adjacent to the power electronics circuit for removal of heat therefrom, wherein the control circuit is secured on and cooled by the fluid cooled support.