Electro-Thermal-Control Co-Design of An All Silicon Carbide 2250 kW Dual-Inverter for Heavy-Duty Traction Applications

This work presents the design and demonstration of an all silicon carbide (SiC) 2250 kW dual-inverter for heavy-duty traction applications. Through the use of a formal electro-thermal-control co-design approach, the maximum power density of the proposed inverter system is 60 kW/L, which is accomplished by. More specifically, to analyze the thermal performance of the inverter, a lumped thermal model is developed based on the characteristics of the power modules and the cold plate. To analyze the complicated interaction between the power losses and module junction temperatures, a closed-loop iterative estimation scheme is proposed to estimate the inverter power loss and module junction temperature. Based on the proposed thermal model and estimation scheme, a detailed optimization procedure on the selection of switching frequency and dc-link capacitor is presented to maximize power density. Furthermore, design optimization of the busbar was conducted to minimize the stray inductance, thus reducing the voltage overshoot during switching transients. Comprehensive experimental studies were performed on a physical converter prototype built based on the optimization results, which validate both the effectiveness of the presented design approach.