Thermal Design and Modeling of off Board chargers

: Cabinet proposal for Level 3 charging station

Abstract

This thesis aims to present a complementary approach to the one provided by the MATLAB simulation tool, where the environment is a platform with a quasi-perfect laboratory scenario. The problem to asses will be related to a well-known phenomenon perceived almost every day in every electronic device, called thermal-throttling. In essence, it is a behavior that the electric components may have when the temperature rises in response to the power losses present in the transistors or active components, which impacts the passive components, such as capacitors and coils. Every industry intends to prevent it as it is complex and costly to solve. However, companies such as Samsung 2022 are exposed due to their manipulation of benchmark applications, programming their processors to run at their maximum capacity while making a bench mark, and limiting the CPU capacity to maintain an acceptable temperature for the user with most of the apps. Nevertheless, one may face this primary design problem in de vices such as phones, computers, printers, blenders, and all components supplied by any energy, where EV charging stations are the principal objective of this project.
This work may begin with the concept of the charging station and its topology, followed by deductive reasoning. In other words, one goes through the whole station, giving particular attention to the present problems related to power electronics and thermal management, with a representation as closest as possible to the thermal and electronic environment. One converges all the solutions in a reliable prototype.
Thermal management is achievable by defining the primary sources of heat and the reasons behind this phenomenon. The importance of the causes for the electronic components to heat up may directly impact the final design of every component in every field of the entire electronics. Mainly in what is the desire to be achieved today in the renewables market, as their goal is to be as efficient as possible.
The thermal flow simulation management and performance were developed in one of the most common 3D Modelling tools: SOLIDWORKS, a (Software as a service) SaaS local and cloud-based platform where one can lead a project within a wide variety of domains. The main reasons behind the choice of the software are, in principle, related to the cost efficiency rate, the reliability, support, and lastly, accessibility for students. A well-structured distribution of components in electronic devices may impact the size, output power, reliability, efficiency, manufacturability, and last but not least, the perception by the market and the final users. Within this layout, one may say that the better the design, the higher the revenue perceived and the reputation of the brand. In other words, EV production in this particular case and its parts must be as cheap as possible to make it accessible for the people who depend on the mobility sector. Thus, the hypothesis to demonstrate with this work will be how an efficient cooling system will improve the converter efficiency and in consequence depict that high power charging stations can be installed in a safety working environment.

Date of Award	1 Jul 2022
Original language	English