Develop and optimize a thermal management system for power electronics in electric vehicle chargers. The solution addresses the challenge of directly measuring hotspot temperatures by leveraging advanced thermal modeling, balancing safety requirements with efficiency. By minimizing the need for large safety margins, the approach enhances onboard charger performance while maintaining reliability.

Technology Features:

VTS Position: 10 thermal sensor in the MOSFETs (8 for DC/DC and 2 for AC/DC).

Accuracy: real sensor estimation versus virtual sensor difference of maximum ±5 ˚C both in steady-state and transient

Model size: < 40 kB as target for memory footprint

Runtime: < 200 us of execution time for the virtual sensors, suitable for the 10 ms task implementation in the TI C2000.

Thermal Management of Power Electronics

Measuring & Monitoring Temperature Accurately

Efficient Power Flow & Control Optimization

Reducing Computational Complexity for Real-Time Execution

Bridging the Gap Between Simulation & Real Performance

Higher performance: accuracy within ±5°C, reducing safety margins and improving performance.

Better thermal stability: calibration tests ensured error remained <5°C across all operating conditions.

More accurate real-time control: execution time ~170 µs.

Optimized power efficiency: 16 thermocouples installed for thermal measurements, and 10+ different load conditions and 4 fluid flow rates analyzed.