Next Generation Integrated Drive, NGID: A Novel Approach to Thermal and Electrical Integration of High Power Density Drives in Automotive Applications

An innovative arrangement for the electrothermal integration of power electronics and motor in a high power drive systems is presented within this paper with a focus on automotive traction applications. Important challenges which needed to be overcome within this research work consist firstly of the coupling of the thermal design of the switching power modules and of the permanent magnet (PM) electric motor and secondly, the integration of high speed switching devices into the motor housing, without compromising the performance of the transistors. To provide a solution to these challenges, an integrated liquid cooling system for both the stator windings and the power devices has been designed. A bespoke power module has been designed and manufactured in order to meet the specific requirements of this packaging approach. The control structure of the drive system is also highlighted together with initial commissioning results.