Compact vehicle drive module having improved thermal control

• US 6,982,873 B2
• Filed: 12/16/2002
• Issued: 01/03/2006
• Est. Priority Date: 01/16/2002
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Kehl, Dennis L., Kannenberg, Daniel G., Radosevich, Lawrence D., Meyer, Andreas A., Beihoff, Bruce C.
• Primary Examiner(s): CHERVINSKY, BORIS LEO
• Application Number:
  US10/252,466
• Publication Number:
  US 20030133259A1
• Time in Patent Office: 1,114 Days
• Field of Search: 361/689, 361/698, 361/699, 361/711, 361719-721, 174/15.1, 174/16.1, 174/16.3, 165/80.3, 165/80.4, 165/104.33, 363/141
• 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: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 50/50 using propulsion power supplied by batteries or fuel cells
• 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 or busbar connections
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

An electric vehicle drive includes a thermal 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, which may be controlled in a closed-loop manner. Interfacing between circuits, circuit mounting structure, and the support provide for greatly enhanced cooling. The support may form a shield from both external EMI/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 power electronics circuit configured to generate controlled output power; and

an electrical and thermal subassembly to which the power electronics circuit is directly mounted, the subassembly including a fluid diverting means to direct cooling fluid into contact with an interface on which the power electronic circuit is supported and a flow regulating element to provide regulation of temperature of the power electronics circuit in a closed-loop manner.

2. The electric vehicle drive of claim 1, wherein the power electronics circuit includes solid state switches configured to bi-directionally or uni-directionally convert incoming power to controlled outgoing power.

3. The electric vehicle drive of claim 2, wherein a first portion of the power electronics circuit is supported on a first side of the subassembly and a second portion of the power electronics circuit is supported on a second side of the subassembly opposite the first side.

4. The electric vehicle drive of claim 1, wherein the subassembly includes 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.

5. The electric vehicle drive of claim 4, comprising an interface on which the power electronics circuit is secured, the interface contacting cooling fluid flowing through the internal fluid conduit during operation to convectively and conductively remove heat from the power electronics circuit.

6. The electric vehicle drive of claim 5, wherein the interface includes a plate supporting a plurality of solid state switches or power conversion devices directly secured thereto.

7. The electric vehicle drive of claim 6, wherein the solid state switches or power conversion devices are bonded to the plate.

8. The electric vehicle drive of claim 6, wherein the solid state switches or power conversion devices are mechanically mounted to the interface.

9. The electric vehicle drive of claim 5, wherein the interface includes a plurality of heat exchange surfaces extending into the internal fluid conduit.

10. The electric vehicle drive of claim 9, wherein the heat exchange surfaces are generally pin shaped.

11. The electric vehicle drive of claim 5, wherein the fluid diverting means includes a diverter disposed within the internal fluid conduit to control flow of cooling fluid.

12. The electric vehicle drive of claim 5, further comprising a heat exchanging element disposed in the internal fluid conduit.

13. The electric vehicle drive of claim 12, wherein the heat exchanging element is secured to the interface.

14. The electric vehicle drive of claim 5, wherein the interface is removably secured to the subassembly.

15. The electric vehicle drive of claim 1, further comprising a flow control valve for regulating flow of cooling fluid through the internal fluid conduit.

16. The electric vehicle drive of claim 15, further comprising at least one sensor for detecting temperature of a portion of the converter, and wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the internal fluid conduit.

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

a vehicle drive train;

a power converter for driving the drive train, the power electronic circuit being mounted on a support comprising;

a substrate having 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, the substrate being made of a first material;

an interface plate configured to directly support a power electronics circuit and to be secured to the substrate, the interface plate having integral heat dissipation elements extending therefrom configured to extend into the coolant circulation path when the interface plate is mounted to the substrate for extraction of heat from the interface plate during operation, the interface plate being made of a second material different from the first material;

a fluid diverting means to direct cooling fluid into contact with the interface plate;

a flow control valve for regulating flow of cooling fluid through the coolant circulation path; and

at least one sensor for detecting temperature, and wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the coolant circulation path.

18. The electric vehicle drive of claim 17, comprising a plurality of interface plates configured to be secured to the substrate and to contact coolant circulating therethrough during operation.

19. The electric vehicle drive of claim 18, wherein the substrate is configured to receive the interface plates on different sides thereof.

20. The electric vehicle drive of claim 19, wherein the different sides include mutually opposed sides of the substrate.

21. The electric vehicle drive of claim 17, wherein the interface plate supports a plurality of solid state switches bonded thereto.

22. The electric vehicle drive of claim 17, wherein the interface plate includes a plurality of heat exchange surfaces extending into the internal fluid conduit.

23. The electric vehicle drive of claim 22, wherein the heat exchange surfaces are generally pin shaped.

24. The electric vehicle drive of claim 22, wherein the substrate includes a plurality of heat exchange surfaces configured to cooperate with the heat exchange surfaces of the interface plate for heat transfer.

25. The electric vehicle drive of claim 24, wherein the heat exchange surfaces of the interface plate and of the substrate are generally pin shaped.

26. The electric vehicle drive of claim 17, wherein the fluid diverting means includes a diverter disposed within the coolant circulation path to control flow of cooling fluid therethrough.

27. The electric vehicle drive of claim 17, further comprising a heat exchanging element disposed in the coolant circulation path.

28. The electric vehicle drive of claim 27, wherein the heat exchanging element is secured to the interface plate.

29. The electric vehicle drive of claim 17, wherein the interface plate is removably secured to the substrate.

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

a vehicle drive train;

a plurality of controlled power electronics circuits including solid state switches configured to convert incoming power to controlled outgoing power for driving the drive train;

a fluid cooled support for supporting at least the power electronics circuits, 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 circuits for removal of heat therefrom;

a plurality of interfaces on which the respective power electronics circuits are secured, the interfaces contacting cooling fluid flowing through the internal fluid conduit during operation to convectively remove heat from the power electronics circuit wherein the fluid cooled support includes a fluid diverting means to direct cooling fluid into contact with the interfaces;

a flow control valve coupled to the support for regulating flow of cooling fluid through the internal fluid conduit; and

at least one sensor for detecting temperature of a portion of the converter, and wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the internal fluid conduit.

31. The electric vehicle drive of claim 30, wherein the power electronic circuits are supported on opposing sides of the support.

32. The electric vehicle drive of claim 31, wherein each interface includes a plate supporting a plurality of solid state switches bonded thereto.

33. The electric vehicle drive of claim 31, wherein each interface includes a plurality of heat exchange elements extending into the internal fluid conduit.

34. The electric vehicle drive of claim 33, wherein the heat exchange elements are generally pin shaped.

35. The electric vehicle drive of claim 30, wherein the a fluid diverting means includes diverter disposed within the internal fluid conduit to control flow of cooling fluid therethrough.

36. The electric vehicle drive of claim 30, further comprising a heat exchanging element disposed in the internal fluid conduit.

37. The electric vehicle drive of claim 30, wherein each interface is removably secured to the support.

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

a vehicle drive train;

a power electronics circuit configured to produce output power for driving the drive train;

a substrate having 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, the substrate being made of a first material;

an interface plate supporting the power electronics circuit and to be secured to the substrate, the interface plate having integral heat dissipation elements extending therefrom configured to extend into the coolant circulation path when the interface plate is mounted to the substrate for extraction of heat from the interface plate during operation, the interface plate being made of a second material different from the first material; and

a fluid diverting means to direct cooling fluid into contact with the interface plate;

wherein the substrate includes a plurality of heat exchange surfaces configured to cooperate with the heat exchange surfaces of the interface plate for heat transfer.

39. The electric drive of claim 38, wherein the heat exchange surfaces are generally pin shaped.

40. The electric drive of claim 38, wherein the heat exchange surfaces of the interface plate and of the substrate are generally pin shaped.

41. The electric drive of claim 38, comprising a plurality of interface plates configured to be secured to the substrate and to contact coolant circulating therethrough during operation.

42. The electric drive of claim 41, wherein the substrate is configured to receive the interface plates on different sides thereof.

43. The electric drive of claim 42, wherein the different sides include mutually opposed sides of the substrate.

44. The electric drive of claim 38, wherein the interface plate supports a plurality of solid state switches bonded thereto.

45. The electric drive of claim 38, wherein the fluid diverting means includes a diverter disposed within the coolant circulation path to control flow of cooling fluid therethrough.

46. The electric drive of claim 38, wherein the interface plate is removably secured to the substrate.

47. The electric drive of claim 38, further comprising a flow control valve for regulating flow of cooling fluid through the coolant circulation path.

48. The electric drive of claim 47, further comprising at least one sensor for detecting temperature, and wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the coolant circulation path.

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

a vehicle drive train;

a power converter for driving the drive train, the power electronic circuit being mounted on a support comprising;

a substrate having 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, the substrate being made of a first material;

an interface plate configured to support a power electronics circuit and to be secured to the substrate, the interface plate having integral heat dissipation elements extending therefrom configured to extend into the coolant circulation path when the interface plate is mounted to the substrate for extraction of heat from the interface plate during operation, the interface plate being made of a second material different from the first; and

a fluid diverting means to direct cooling fluid into contact with the interface plate; and

wherein the substrate includes a plurality of heat exchange surfaces configured to cooperate with the heat exchange surfaces of the interface plate for heat transfer.

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

a vehicle drive train;

a power converter for driving the drive train, the power electronic circuit being mounted on a support comprising;

a substrate having 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, the substrate being made of a first material;

an interface plate configured to support a power electronics circuit and to be secured to the substrate, the interface plate having integral heat dissipation elements extending therefrom configured to extend into the coolant circulation path when the interface plate is mounted to the substrate for extraction of heat from the interface plate during operation, the interface plate being made of a second material different from the first material; and

a diverter disposed within the coolant circulation path to control flow of cooling fluid therethrough.

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

a vehicle drive train;

a power converter for driving the drive train, the power electronic circuit being mounted on a support comprising;

a substrate having 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, the substrate being made of a first material; and

an interface plate configured to support a power electronics circuit and to be secured to the substrate, the interface plate having integral heat dissipation elements extending therefrom configured to extend into the coolant circulation path when the interface plate is mounted to the substrate for extraction of heat from the interface plate during operation, the interface plate being made of a second material different from the first material the interface plate being removably secured to the substrate.