IGBT(晶闸管)用水冷散热器(水冷板)的工艺与设计-钻孔式-压管式-密封圈式-搅拌摩擦焊-真空电子

allforyou,allforinverterEAGTOP水冷散热器EAGTOP水冷散热器生产制造工艺PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz运用领域（电力电子）•电力输送高压直流输电、柔性直流输电、SVG等。高压直流输电、柔性直流输电、SVG等。•新能源风力发电、光伏发电等。•交通运输电力机车、动车、电驱舰艇、电动汽车等。•其他工业变频、信号处理、UPS、医疗、激光等。PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverter•水冷板在水冷系统中的作用（水冷变流器）水冷板水冷板PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverter•从成品到使用PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverter•以液体作为冷却介质的散热器z定义以液体作为冷却介质的散热器•原理：藉由结构上紧凑且比较薄的板状、条状金属，内部布置流体通道，使流体与水冷板之间产生对流换热，从而散去水冷板表面高功率电子元器件的热功耗。•优点：与风冷相比具有体积小、安静、散热性能好、干净、对环境依赖小等等优点。PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)水冷板工艺产品定位真空钎焊搅拌摩擦焊&真空钎焊密封圈式搅拌摩擦焊真空电子束焊钻孔式压管式工艺门槛PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺与分类•钻孔式•钻孔式工艺：CNC钻孔或型材拉槽—CNC钻孔或型材拉槽—用堵头加焊接将部分区域密封—CNC外型加工特点：工艺简单—工艺简单—低成本—性能低下PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺与分类•压管式•压管式工艺：CNC铣槽或型材拉槽—CNC铣槽或型材拉槽—将折弯铜管或焊、压、粘入槽腔—CNC外型加工特点：工艺简单—工艺简单—较低成本—性能较低PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺与分类密封式•密封圈式工艺：—CNC或压铸加工水腔与外型与外盖—用螺丝与密封圈或胶水压合密封特点：—工艺简单—低成本—性能较低—可靠性值得验证PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺与分类搅拌摩擦焊&真空电子束•搅拌摩擦焊&真空电子束工艺：—CNC单独加工水腔与外盖—摩擦焊（电子束）做密封焊接—CNC成品加工特点：—有工艺门槛设计结构较灵活—设计结构较灵活—性能较好—可靠性高成本偏高—成本偏高PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺与分类搅拌摩擦焊式•搅拌摩擦焊式PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺与分类真空电子束式•真空电子束式—搅拌摩擦焊升级替代工艺优点：焊接线性速度快焊缝强度高批量生产成本较低缺点：对铝合金材质有一定要求PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺与分类真空钎焊式•真空钎焊式工艺：CNC或其他方式加工水腔—CNC或其他方式加工水腔—真空钎焊做面密封—CNC成品加工特点：—工艺门槛更高（面焊接）设计结构更灵活—设计结构更灵活—性能更好（双面热源）—可靠性高成本偏高—成本偏高PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺与分类PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺与分类灵活的产品设计•灵活的产品设计PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)冷板工艺分类冷板技术优点缺点冷板技术优点缺点钻孔•工艺简单•成本低•性能低下•表面温度不均匀•重量轻•不能双面安装热源压管•重量轻•低压降•成本低•不能双面安装热源•对加工工艺要求高•管伸出冷板外，体积大O圈组装•成本相对较低•依靠O形圈密封，存在泄漏隐患O圈组装•不适应高频振动环境摩擦（电子束）焊•性能较好•可靠性高•设计灵活•成本偏高•工艺门槛高•设计灵活真空钎焊•双面冷却•性能好•表面温度均匀•成本高•工艺门槛高•设计灵活PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)产品设计-设计步骤1.客户提供设计输入参数—散热器尺寸、温升型号发热量—IGBT型号、发热量—水路流量、压降—其它要求等2.建模及工艺路线选定—设计主要水路结构、选择IGBT下流道串并联及扰流方式—选定适合的制造工艺制图及建模型—制图及建3D模型3.热仿真验证4.型式实验验证PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverter产品参数LCPParametersz产品设计-输入参数尺寸Sizerequirement长度（Lengh）*宽度（Width）*厚度(Thickness)：1000*1000*50mmIGBT数量及发热量Heatdissipation__________KW排布简图outlines接头方式及位置Connectorpattern水度内丝□外丝□快速接头□其他(Others)_____ 进水温度（℃）Inlettemperature-30℃---60℃冷却剂Coolant纯水或者水与乙二醇的混合液流量（LPM）Volumeflowrate80L/minVolumeflowrate液冷板表面温升（℃）Temperaturerise30℃昀大工作压力（kPa）Maxoperatingpressure0.8Mpa---2.0MPaIGBT数量及发热量30kWHeatdissipation30kW热阻Thermalresistance4℃/kw(根据热源分布而定)压降Pressuredrop表面处理清洗阳极(Black镀镍(Nickel镀铬(Chrome其他()PassivePowerElectronicsComponentsIntegratedSolution表面处理Superficialtreatment清洗(Wash)□阳极(Blackanodized)□镀镍(Nickelplating)□镀铬(Chromeplating)□其他(Others)_____allforyou,allforinverterz鹰峰(EAGTOP)产品设计-流道设计•根据经验及客户要求初步确定几种不同的水路分布方案串并联混合槽道串联槽道PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)产品设计-理论计算•运用理论公式初步计算每种方案的压降及温升理论计算PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)产品设计-热仿真温度分布•温度分布•压降进口出口PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)产品设计-型式试验验证流量流阻Tin(℃)Tout(℃)T1(℃)T2(℃)T3(℃)T4(℃)功率温升热阻（k/w）（l/min）（bar）Tin(℃)Tout(℃)T1(℃)T2(℃)T3(℃)T4(℃)（W）(℃)（k/w）150.1515.520.532.335.437.137.9564522.40.00397180.3014.61930.733.735.235.9575821.30.0037PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz产品设计-图纸PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)水冷板生产能力水冷板生产车间真空钎焊炉水冷板生产车间真空钎焊炉真空电子束焊机真空电子束焊机PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz鹰峰(EAGTOP)型式试验验证实验项目实验项目—气密性测试—流阻型式试验—热阻型式试验—结构强度—盐雾实验—高低温导电性—导电性PassivePowerElectronicsComponentsIntegratedSolutionallforyou,allforinverterz我们服务的客户