Optimization of Multi-Phase Motor Drive System Design through Thermal Analysis and Experimental Validation of Heat Dissipation

Abstract

In power semiconductor systems such as inverters, managing losses is critical for optimizing performance. Inverters, which convert DC to AC for applications such as renewable energy systems, motor drives, and power supplies, are significantly affected by the thermal performance of components such as metal-oxide-semiconductor field-effect transistors (MOSFETs). Efficient thermal management is critical for the longevity and performance of power electronic systems, especially in high-power applications. Designing effective thermal management strategies for inverters reduces losses, increases efficiency, and improves performance while considering space constraints and complex component interactions. In this study, power electronics simulations and computational fluid dynamics (CFD) thermal analysis were integrated to design the inverter. Using an integrated simulation, a thermal analysis was performed based on the inverter losses per module. A power electronics simulation was used to verify the validity of the loss values in the inverter design, and the CFD thermal analysis facilitated the visual analysis of the variables to be considered. The validity of the design was evaluated through experimental verification of the inverter system. A temperature saturation of 63.9 ℃ at 60Arms was recorded in the simulation, and a temperature saturation of 45 ℃ or less at 59Arms to 60Arms was obtained for each phase in the actual test. Considering the ambient temperature difference, it showed a difference of approximately 9.9 ℃. This conclusion allows us to reduce the high probability of risk derived by considering a small margin of safety for each variable in the design. This solution can be used to compactly design real inverters and solve complex thermal problems in power semiconductor-based systems. Finally, this study analyzes the similarities and differences between CFD simulations, power electronics simulations, and real-world experimental validation, highlighting the importance of thermal management in improving the efficiency of power electronic systems, particularly inverters.