SIMULATION IN THERMAL DESIGN FOR ELECTRONIC CONTROL UNIT OF ELECTRONIC UNIT PUMP

The high working junction temperature of power component is the most common reason of its failure. So the thermal design is of vital importance in electronic control unit （ECU） design. By means of circuit simulation, the thermal design of ECU for electronic unit pump （EUP） fuel system is applied. The power dissipation model of each power component in the ECU is created and simulated. According to the analyses of simulation results, the factors which affect the power dissipation of components are analyzed. Then the ways for reducing the power dissipation of power components are carried out. The power dissipation of power components at different engine state is calculated and analyzed. The maximal power dissipation of each power component in all possible engine state is also carried out based on these simulations. A cooling system is designed based on these studies. The tests show that the maximum total power dissipation of ECU drops from 43.2 W to 33.84 W after these simulations and optimizations. These applications of simulations in thermal design of ECU can greatly increase the quality of the design, save the design cost and shorten design time

Analysis of Temperature Rise in High-Speed Permanent Magnet Synchronous Traction Motors by Coupling the Equivalent Thermal Circuit Method and Computational Fluid Dynamics

To solve the problem of temperature rise caused by the high power density of high-speed permanent magnet synchronous traction motors,the temperature rise of various components in the motor is analyzed by coupling the equivalent thermal circuit method and computational fluid dynamics.Also,a cooling strategy is proposed to solve the problem of temperature rise,which is expected to prolong the service life of these devices.First,the theoretical bases of the approaches used to study heat transfer and fluid mechanics are discussed,then the fluid flow for the considered motor is analyzed,and the equivalent thermal circuit method is introduced for the calculation of the temperature rise.Finally,the stator,rotor loss,motor temperature rise,and the proposed cooling method are also explored through experiments.According to the results,the stator temperature at 50,000 r/min and 60,000 r/min at no-load operation is 68℃ and 76℃,respectively.By monitoring the temperature of the air outlets inside and outside the motor at different speeds,it is also found that the motor reaches a stable temperature rise after 65 min of operation.Coupling of the thermal circuit method and computational fluid dynamics is a strategy that can provide the average temperature rise of each component and can also comprehensively calculate the temperature of each local point.We conclude that a hybrid cooling strategy based on axial air cooling of the inner air duct of the motor and water cooling of the stator can meet the design requirements for the ventilation and cooling of this type of motors.

Coupler Loss Analysis of Magnetically Coupled Resonant Wireless Power Transfer System

The demand for electric vehicles has increased over the past few years.Wireless power transfer for electric vehicles provides more flexibility than traditional plug-in charging technology.Charging couplers are critical components in wireless power transfer systems.The thermal effect produced by the magnetic coupler in work will cause the temperature of the device to rise rapidly,affecting the work efficiency,transfer power,operation reliability,and service life.This paper modeled and analyzed each component's temperature distribution characteristics and thermal behavior.Firstly,the magnetic coupler's mutual inductance and magnetic circuit model are established,and the thermal model of the magnetic coupler analyzes the heat generation process.The thermal models of the coupler under three different magnetic core distributions are established,and the temperature rise of each component is obtained.The temperature rise of different parts of the coupler is verified by the temperature rise test structure of the experiment.

Thermal Property Measurements of a Large Prismatic Lithium-ion Battery for Electric Vehicles

Because of the high cost of measuring the specific heat capacity and the difficulty in measuring the thermal conductivity of prismatic lithium-ion batteries,two devices with a sandwiched core of the sample-electric heating film-sample were designed and developed to measure the thermal properties of the batteries based on Fourier's thermal equation.Similar to electrical circuit modeling,two equivalent thermal circuits were constructed to model the heat loss of the self-made devices,one thermal-resistance steady circuit for the purpose of measuring the thermal conductivity,the other thermal-resistance-capacitance dynamic circuit for the purpose of measuring the specific heat capacity.Using the analytic method and recursive least squares,the lumped model parameters of these two thermal circuits were extracted to estimate the heat loss and correct the measured values of the self-made devices.Compared to the standard values of the reference samples of the glass and steel plates,the measured values were corrected to improve the measurement accuracies beyond 95% through steady thermal-circuit modeling.Compared to the measured value of the specific heat capacity of the battery sample at 50% state of charge using the calorimeter,the measured value using the self-made device was corrected in order to elevate the measurement accuracy by about 90% through dynamic thermal-circuit modeling.As verified through the experiments,it was reliable,convenient,and low cost for the proposed methodology to measure the thermal properties of prismatic lithium-ion batteries.