Compared with the traditional single-sided cooling (SSC) power module, owing to the decreased thermal resistance and packaging parasitics, the double-sided cooling (DSC) power module is a promising solution of the motor drive for electric vehicle (EV) implementation. However, the lack of the model to characterize the thermo-mechanical interaction mechanism in the DSC power module challenges the co-design methodology of the power module from the respective of multi-physics. In this paper, aiming at reliability improvement, to balance the tradeoff between thermal resistance and mechanical stress, a multi-objective-coordinated automated design methodology is proposed for the DSC power module. To characterize the influences of material properties and structure sizes, the mathematical models for the thermal and mechanical features of the DSC power module are proposed. These models are also examined by using the finite element analysis (FEA) tool. Besides, to promote the specifications of DSC power module, a multi-objective optimization model is proposed to coordinate thermo-mechanical metrics in multi-physics. The non-dominated sorting genetic algorithm II (NSGA-II) is implemented to automatically achieve the Pareto solutions of the proposed multi-objective optimization model with respect to thermal resistance and mechanical stress. Considering the influences of material properties, optimal structure sizes of the DSC power module are comprehensively presented. The proposed multi-objective-oriented optimization methodology provides a new routine to reshape the thermo-mechanical performance of the next-generation DSC power module toward more reliable EV implementation.

中文翻译：

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面向可靠性的双面冷却功率模块自动化设计：一种热机协同多目标优化方法

与传统的单面冷却 (SSC) 功率模块相比，由于降低了热阻和封装寄生效应，双面冷却 (DSC) 功率模块是电动汽车 (EV) 电机驱动的一种很有前景的解决方案。然而，由于缺乏表征 DSC 功率模块中热-机械相互作用机制的模型，从多物理场各自的角度对功率模块的协同设计方法提出了挑战。在本文中，针对可靠性提高，平衡热阻和机械应力之间的权衡，本文提出了一种多目标协调的 DSC 功率模块自动化设计方法。为了表征材料特性和结构尺寸的影响，提出了 DSC 功率模块的热和机械特性的数学模型。还使用有限元分析 (FEA) 工具检查这些模型。此外，为了提升DSC功率模块的规格，提出了多目标优化模型来协调多物理场中的热机械指标。实施非支配排序遗传算法 II (NSGA-II) 以自动实现所提出的多目标优化模型在热阻和机械应力方面的帕累托解。综合考虑材料特性的影响，综合给出了DSC功率模块的最佳结构尺寸。