New system integration concept for high power density drives

Current construction technology and design methods of power converters have reached power density limits that can only be surpassed by changing the way we design and build converters. This paper presents a system integration approach that allows for achieving high power densities. The key issues of the approach, namely hybrid integration in the form of integrated power electronics modules (IPEMs) and integrated thermal and spatial design with optimized air flow are presented in the paper. The spatial and thermal concept of a case study 2.2 kW converter for ac drives is presented and the technologies for implementing the IPEMs are listed. The complete system and the experimental results thereof are presented. The converter has a power density of 3.8 kW/1, which is almost four times larger than that of commercially available drives. The approach is not restricted to this application and can be applied to any converter in the medium power range.