IGBT based Inverter Design for Vehicle Application

Abstract:
Vehicle applications and the related environmental conditions create challenges to meet the requirements for the power electronic conversion. Technically most demanding are wide ambient temperatures ranges, a high number of thermal cycles with wide temperature steps, strong demand to minimize weight and space consumption, high resistance to shock and vibration as well as rugged design to protect against environmental impact by dust or liquids. This paper describes properties of a newly developed 250kVA, IGBT based inverter for the use in commercial hybrid and electric vehicles. The integrated liquid cooling combines low thermal impedance with low pressure loss. This allows high power densities up to 20 kVA/liter and power weights up to 16 kVA/kg. Particular care has been taken on thermal optimization, ruggedness against vibration and shock as well as the stringent EMI requirements of the vehicle environment. Built-in EMI filters attenuate electromagnetic emission. Together with use of shielded cables and suitable electric machines compliance with common EMI standards as the European council directive 72/245/EEC is feasible.