An intelligent power module with high accuracy control system and direct liquid cooling for Hybrid system

Abstract

We have developed an intelligent power module (IPM) with high accuracy control system and direct liquid cooling for HEV (Hybrid Electric Vehicle) and PHEV (Plug-in Hybrid Electric Vehicle).The IPM contributes to most efficient fuel consumption of the HEV and PHEV. An Aluminum direct liquid cooling fin structure improves thermal resistance by over 20% compared to the conventional indirect liquid cooling structure. Furthermore a new Sn-Sb solder has been developed to improve thermal cycle capability. The tensile strength and yield strength of this new solder is about 20% higher than conventional Sn-Ag-Cu solder. The highly accurate control system with CPU in the control circuit corrects the error of a temperature sensor on the IGBT chip within +-3 oC. It also controls the buck-boost converter by using a voltage sensor and the accuracy of the output voltage is controlled under +-2%. The system is communicated to the master ECU. The IPM's maximum output power is 400kVA and it is applied in a HEV system to drive 124kW motor output.