电动汽车用微小通道液冷电力电子集成模块设计

发布时间：2018-08-28 20:21

【摘要】：我国缺油、少气、多煤,而且汽车尾气排放量已占城市空气污染源的64%,从合理利用能源、控制城市污染的角度,发展电动汽车具有特别重要的意义。以IGBT为代表的电力电子器件是电动汽车的关键元器件。受车辆空间限制和使用环境的约束,车用电机驱动系统对功率器件在散热性能、功率密度、电磁兼容、抗振动与冲击、抗灰尘与雨水等方面的要求比普通电气传动系统更高,目前世界市场范围内的IGBT器件尚不能够完全满足电动汽车制造厂要求。解决上述问题的有效方法之一是借鉴集成电路的思路,针对电动汽车电机驱动系统的特殊运行环境开发电力电子集成模块(Integrated Power Electronic Module, IPEM),将功率芯片、驱动电路、保护电路、控制电路等集成封装在同一个模块里。尚若获得这样的电力电子集成模块,因其体积小,则对其采取电磁屏蔽等各种抗干扰措施、隔振减振等各种抗振动冲击措施就容易的多,效果也好得多；同样,因其体积小,电机控制器和电机之间的距离可以变得很小,甚至可以实现电机驱动系统和电机的一体化,缩短了电力电子装置和电机之间的连线长度,减小了连线的分布电感,相应减小了电磁噪声。模块研发面临的主要技术问题包括热控制问题、模块内部强电元件与弱电元件之间的电磁兼容问题、模块对电动汽车振动环境的适应性问题。基于上述思路,通过查阅资料,分析了电动汽车电机驱动系统、电力电子功率模块的发展现状,明确了电动汽车用功率模块和普通电气传动系统用功率模块的相同与不同之处,分析了电动汽车用电力电子集成模块的设计要求,进行了模块的电路拓扑设计、电路参数设计、结构设计、散热设计,利用PSpice仿真软件对电路设计进行了验证；针对模块运行中的发热与散热问题,建立了电力电子集成模块的热学模型,进行了模块的散热性能仿真。针对电动汽车的特殊需求,对模块功率芯片的动态温度响应进行了专门研究。加大冷却液流量,一方面可以提高冷却效果,另一方面也加大了冷却通道出入口压力差、加大了冷却泵的负荷,为此对冷却液流量进行了优选：针对模块的寄生参数与电磁干扰问题,设计了具有低寄生电感参数的铝线连接结构,并利用Q3D Extractor建立了几何模型提取电感参数,通过仿真验证了低寄生参数设计的有效性。该模块采用微小通道液冷基板、双面布置器件,比单面布置器件散热效果更好；在微小通道液冷基板内部设计了具有双梯形截面的槽道结构,比矩形槽道结构散热效果更加均匀、更容易冲洗、更不易堵塞；所设计的放射状并联铝线连接结构,相比平行并联铝线连接结构而言,具有较低的寄生电感参数,有利于减小因电磁干扰引起的尖峰电压。本论文以电动汽车电机驱动系统为主要应用背景,设计了一种新型的电力电子集成模块,并进行了仿真与分析,为该模块的试制提供了基础。
[Abstract]:Our country is short of oil, less gas, more coal, and the exhaust emissions of automobiles have accounted for 64% of urban air pollution sources. From the point of view of rational utilization of energy and control of urban pollution, it is of special significance to develop electric vehicles. The requirement of traction motor drive system on heat dissipation performance, power density, electromagnetic compatibility, anti-vibration and impact, anti-dust and rain water is higher than that of ordinary electric drive system. At present, IGBT devices in the world market can not fully meet the requirements of electric vehicle manufacturers. One is to develop an integrated power electronic module (IPEM) for the special operating environment of the electric vehicle motor drive system by using the ideas of integrated circuits for reference, and encapsulate the power chip, drive circuit, protection circuit and control circuit in the same module. Module, because of its small size, electromagnetic shielding and other anti-interference measures, vibration isolation and shock absorption and other anti-vibration and shock measures are much easier, the effect is much better; similarly, because of its small size, the distance between motor controller and motor can become very small, and even realize the integration of motor drive system and motor, shorten The main technical problems faced in the module development include thermal control, electromagnetic compatibility between the strong and weak components in the module, and the adaptability of the module to the vibration environment of the electric vehicle. Through consulting the data, this paper analyzes the development status of electric vehicle motor drive system and power electronic power module, clarifies the similarities and differences between electric vehicle power module and ordinary electric drive system power module, analyzes the design requirements of electric vehicle power electronic integrated module, and carries out the module. Circuit topology design, circuit parameters design, structure design, heat dissipation design, the use of PSpice simulation software to verify the circuit design; in view of the module running heat and heat dissipation problems, the thermal model of power electronics integrated module, the module heat dissipation performance simulation. The dynamic temperature response of the rate chip is specially studied. On the one hand, the cooling effect can be improved by increasing the flow rate of the coolant, on the other hand, the pressure difference between the inlet and outlet of the cooling channel can be increased, and the load of the cooling pump can be increased. The aluminum wire connection structure with low parasitic inductance parameters is constructed and the inductance parameters are extracted by Q3D Extractor. The effectiveness of the design with low parasitic parameters is verified by simulation. Considering the slot structure with double trapezoidal cross-section, the heat dissipation effect is more uniform than that of rectangular slot structure, which is easier to wash and clog, and the radial parallel aluminum wire connection structure has lower parasitic inductance parameters than the parallel parallel aluminum wire connection structure, which is conducive to reducing the peak voltage caused by electromagnetic interference. In this paper, a new power electronics integrated module is designed based on the electric vehicle motor drive system, and the simulation and analysis are carried out, which provides the basis for the trial production of the module.
【学位授予单位】：山东大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：U469.72

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