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Liquid-Cooled Cold Plate for Automotive Power Electronics with Shark-Inspired Flow Guides
技术
- 分析与建模 - 数字孪生/模拟
- 分析与建模 - Generative AI
- 功能应用 - 产品生命周期管理系统 (PLM)
适用行业
- 航天
- 汽车
- 消费品
适用功能
- 产品研发
- 质量保证
用例
- 添加剂制造
- 数字孪生
- 质量预测分析
服务
- 软件设计与工程服务
- 系统集成
挑战
The engineers of Puntozero faced the challenge of redesigning the cold plate of the power electronics in Dynamis PRC’s electric race car for additive manufacturing. The primary issues identified were the non-uniform flow near the curvatures of the duct and the insufficient heat transfer surface area. These problems needed to be addressed to optimize the cooling efficiency and overall performance of the race car's power electronics. The team aimed to create a more efficient cooling system that could handle the high-performance demands of the Formula SAE Electric competition.
关于客户
Dynamis PRC is the Formula Student team of Politecnico di Milano, a prestigious technical university in Italy. The team participates in the Formula SAE Electric competition, which serves as a platform for testing and showcasing innovations in drivetrain technology and fuel efficiency in a high-performance setting. Puntozero, a company specializing in advanced engineering solutions, partnered with Dynamis PRC to tackle the challenge of optimizing the cooling system for the race car's power electronics. The collaboration aimed to leverage additive manufacturing and advanced design techniques to achieve significant improvements in cooling efficiency and weight reduction.
解决方案
Puntozero engineers drew inspiration from the structure of shark scales to create a directional lamellar geometry that conforms to the duct of the cold plate. This design stirs the flow around the channel corners, enhancing the heat transfer surface area by 300%. The flow guides are based on a gyroid lattice, warped using advanced Field-Driven Design techniques. For the main structure of the heatsink, a diamond TPMS lattice with progressively decreasing thickness was selected. This external lattice reduced the weight and production cost of the component, improved its manufacturability, and increased the contact surface area with the power electronics to promote heat transfer. The cold plate prototype was additively manufactured in a powder alloy with a consistency close to pure aluminum. Computational tomography (CT) scanning was used to ensure the channel was free from powder and that the part was manufactured within specification and without imperfections.
运营影响
数量效益
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