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Inverters with constant full load capability for electric drives
Overheating components significantly limit the performance of drivetrains in electric vehicles. Inverters in particular are subject to a high thermal load, which is why they have to be actively cooled. In the Dauerpower project, Fraunhofer IZM is working with project partners from the automotive industry to develop an electric inverter that can work at a lower operating temperature thanks to optimized cooling management, resulting in a lower power loss. In addition to longer full-load utilization, the required semiconductor area can also be reduced as a result, which can further decrease the costs of the electric mobility transition.
In cooperation with Porsche and Bosch, Fraunhofer IZM is now developing a compact three-phase drive inverter with a high continuous output of 720 kilowatts or 979 horsepower and a rated current of 900 amperes. To prevent the passive components of an inverter, such as capacitors and copper elements, from being damaged by heat build-up, conventional systems throttle their maximum output in continuous operation. Compared to CNC milling processes, 3D printing allows a great deal of freedom with regard to the design of the cooling channel and, in turn, optimum utilization of the limited installation space.
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