逆变器功率密度的极限分析与提升方法

doi:10.19595/j.cnki.1000-6753.tces.242054

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Abstract High power-density inverters are continuously pursued, especially for renewable energy and electrified transportation applications. However, due to the performance bottlenecks of power devices, passive components, and heat sinks, the power density of existing inverters is not high. Some research on high power-density inverters has been explored, mainly focusing on high frequency and thermal management. However, the state-of-the-art power density of the inverter is challenged by unknown theoretical limitations and absent design guidelines. This paper details the theoretical limit, influence law, and improvement method of high power-density inverters, providing basic model and method guidance for designing, optimizing, evaluating, and applying high power-density inverters.
Firstly, by establishing a characterization model of power density, the switching frequency limitation of power devices is characterized by considering the dead time, power dissipation, and thermal runaway issues. Based on the performance analysis of commercial products, the volume-specification principles of DC-link capacitors, filter inductors, and heat sinks are studied. Moreover, according to the interactive coupling among the passive component, heat sink, and power device, the power density limitation of the inverter is revealed. The factors that limit high power-density inverters are quantitatively described, including thermal resistance, maximum junction temperature, ambient temperature, power conversion efficiency, inverter component layout, and switching loss measurement. The power density improvement method of the inverter is proposed from the aspects of power device, circuit topology, thermal management, and structural design.
For the forced air-cooled 50 kW renewable energy inverter, the volume of the filter inductor is the critical limitation of the high power-density inverter. In the 50 kW water-cooled vehicle motor controller, the ripple current-volume performance of the thin film capacitor is the key technical bottleneck that limits the high-power-density vehicle motor controller. Considering the coupling of multiple variables and factors, the influence of each variable on the power density can be regarded as the superposition of these influencing factors. To improve the power density of the inverter, the chip design and package design of power devices can be optimized from the structural, material, and process levels. In terms of circuit topology and thermal management, Si/SiC hybrid circuit, multi-level topology, soft switching circuit, advanced modulation algorithm, and active junction temperature control algorithm are used to reduce the switching loss of the device, improving the switching frequency of the power device and reducing the volume of the heat sink. The DC-link capacitor’s packaging structure and busbar’s structure are optimized.
The following conclusions can be drawn. (1) The volume of the passive component is inversely proportional to the switching frequency, and the volume of the heat sink is proportional to the switching frequency. Therefore, the inverter has an optimal switching frequency, reaching the theoretical limitation of its power density. The power density limitation of the inverter can be further improved with breakthrough technology of power devices, passive components, and heat sinks. (2) The power density of the inverter is related to the maximum junction temperature, the thermal resistance of the package and the heat sink, the ambient temperature, the component layout, and the switching loss. Collaborative optimization of these multiple dimensions can improve the power density of the inverter effectively. (3) High-bandwidth and high-precision measurement techniques like wide-bandgap devices such as SiC, advanced packaging like double-sided cooling, high-heat flux heat-sink like impinging jet cooling, and optical isolation probes can be used to optimize inverter electro-thermal and reduce the volume of passive components and heat sink.

Key words： Inverter high power density theoretical limitation influence principle promotion routine

Received: 15 November 2024

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TM614

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	Niu Fuli
	Zeng Zheng
	Sun Peng
	Zou Mingrui

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Niu Fuli,Zeng Zheng,Sun Peng等. Theoretical Limitation and Promotion Routine of Power Density for Inverter Application[J]. Transactions of China Electrotechnical Society, 2025, 40(16): 5151-5163.

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https://dgjsxb.ces-transaction.com/EN/10.19595/j.cnki.1000-6753.tces.242054 OR https://dgjsxb.ces-transaction.com/EN/Y2025/V40/I16/5151

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