Accurate Electro-Thermal Computational Model Design and Validation for Inverters of Automotive Electric Drivetrain Applications

Abstract

This paper proposes the fast and accurate electro-thermal model of the existing Simrod three-phase inverter for an electric vehicle (EV) application. The research focuses on analytical and dynamic electro-thermal models of inverters that can be applied for multi-applications. The optimal design approach of passive filters is presented for the DC and AC sides of the inverter. The analytical model has been established, including a mathematical representation of the inverter and induction motor (IM). The high-fidelity electro-thermal simulation model of an inverter with integrated power loss and thermal model is established. The state-space thermal model (for the IRFS4115PbF device) has been created and incorporated into the MATLAB simulation. The simulation model is then validated with the PLECS software-based thermal model to confirm the accuracy. Indirect field-oriented control (IFOC) is designed for squirrel-cage IM at a maximum power rating of 45 kW and implemented on MATLAB/Simulink. The comparative analysis between the real and simulated results is performed to validate the simulation model at a specific speed, torque, and current. Furthermore, the electro-thermal simulation model has been validated with experimental data using efficiency and temperature comparison. The developed simulation model is beneficial for designing, optimizing, and developing advanced technology-based inverters to achieve higher efficiency at a particular operating range of temperature and power quality. The new European driving cycle (NEDC) speed profile simulation results are demonstrated.

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“…Thus, one approach is to adopt a realistic mission profile in order to obtain a reliable assessment of the MOSFET's lifetime. There are daily solar irradiance profiles for photovoltaic systems [3,4], reference speed [5,6] and reference torque [5] profiles for drive motor applications and reference voltage [7] and load mission profiles [8] for electric bus applications.…”

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“…Li et al [1] proposed a method for suppressing the hybrid harmonics of a series-connected 18-pulse rectifier that is expected to be applied in aircraft electrical systems. Rasool et al [2] proposed a dynamic electro-thermal model to accurately demonstrate the characteristics and to improve the efficiency of a three-phase inverter. Wu et al [3] proposed a tripleactive-bridge resonant DC-DC converter with the ability to carry out topology-level power decoupling and multi-phase-shift-based global optimization modulation.…”