Title: Thermal optimisation study on electrical machine controller for an electric vehicle

Authors: Ping Yang; Ahmad Zhafran Ahmad Mazlan

Addresses: College of Intelligent Manufacturing and Automobile, Chongqing Technology and Business Institute, 401520, Hechuan, Chongqing, China; School of Mechanical Engineering, Engineering Campus, Universiti Sains Malaysia, 14300, Nibong Tebal, Penang, Malaysia ' School of Mechanical Engineering, Engineering Campus, Universiti Sains Malaysia, 14300, Nibong Tebal, Penang, Malaysia

Abstract: In this study, insulated gate bipolar transistor (IGBT) module of a pure electric vehicle motor is investigated through thermal simulation and analysis, experimental verification, and structural optimisation. Based on the temperature rise test, and the comparison of temperature rise and heat dissipation curve using finite element analysis (FEA), it is found that the result can accurately simulates the heat dissipation of the IGBT module, with the temperature error within 2°C and the natural heat dissipation error less than 3°C during forced heat dissipation. This data supports the optimisation of the controller radiator heatsink. Finally, the ANSYS optimisation module was employed to parametrically optimise dimensions and positional parameters such as length, width, and spacing of the heat sink fins, as well as fan-to-heatsink distance. The ideal parameter solution was produced using multi-objective optimisation algorithms and iterative methods, resulting in minimising mass and lowest temperature while meeting the heat dissipation requirements.

Keywords: pure electric vehicles; motor controller; IGBT; insulated gate bipolar transistor; heatsink optimisation; simulation study.

DOI: 10.1504/IJVSMT.2024.140499

International Journal of Vehicle Systems Modelling and Testing, 2024 Vol.18 No.2, pp.175 - 192

Received: 23 Dec 2023
Accepted: 09 May 2024
Published online: 20 Aug 2024 *

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