Design and Performance Analysis of a Novel Cooling Device for IGBT Modules in Wind Power Converters

Overheating failure is one of the common causes of motor converter failure, so it is very important to improve the heat dissipation of the converter. In response to the inefficiency of traditional converter heat dissipation devices, we propose a novel heat dissipation device. The device combines micro-heat pipe arrays (MHPAs) and interleaved fins, and the MHPAs were initially applied in the converter. The device leverages the exceptional thermal conductivity of the MHPA to rapidly transfer heat from the heat source to various parts of the fins, ultimately achieving efficient heat dissipation and lowering the temperature. This study investigates the thermal resistance, heat dissipation performance, and overall temperature distribution of both the new and traditional heat dissipation devices using theoretical modeling, multi-condition experimental comparisons, and numerical simulation analysis. The experimental results demonstrate that the new heat dissipation device exhibits lower thermal resistance, higher heat dissipation, and greater convective heat transfer intensity compared to the conventional device. In a scenario with 6.3 kW power and 4.3 m/s wind speed, the new heat dissipation device decreases thermal resistance by 15 times, boosts heat dissipation by 30%, enhances convective heat transfer by 12.5%, and lowers the heatsink object temperature by 30%. As power and wind speed increase, the heat dissipation performance of the new heat dissipation device can be further improved. Additionally, the new heat dissipation device exhibits a characteristic where the temperature of the fins is higher on the outside and lower on the inside. Increasing the length of the fins helps improve the device’s heat dissipation performance. The feasibility of the MHPA being applied in converter heat dissipation systems is validated in this study. This device significantly enhances converter heat dissipation efficiency and is crucial for advancing the high-power capabilities of motors.