IGBT liquid cooling application case
The Growing Need for Efficient Cooling in Metro Systems
As cities expand and green transportation initiatives accelerate, metro systems face rising thermal challenges due to:
High passenger density generating excess body heat
Underground confinement limiting natural airflow
Heat from trains, equipment, and geological retention
Peak cabin temperatures exceeding 24°C (15°C+ above outdoor lows)
Traditional air-based cooling (fans, HVAC) struggles with inefficiency, high energy costs, and inadequate heat dissipation. IGBT (Insulated Gate Bipolar Transistor) modules, critical for rail power systems, are particularly vulnerable to overheating—leading to reliability issues, energy waste, and increased maintenance costs.
Why Liquid Cooling Outperforms Air Cooling
| Cooling Method | Heat Transfer Efficiency | Energy Consumption | Noise Levels |
|---|---|---|---|
| Air Cooling | Low (50-100 W/m²·K) | High (fans run continuously) | Loud (65+ dB) |
| Liquid Cooling | Extremely High (5,000-15,000 W/m²·K) | 40-60% Lower | Near-Silent |
Liquid cooling plates offer 25x better heat transfer, ensuring stable IGBT temperatures while reducing energy waste.
Case Study: Liquid Cooling for Metro IGBT Power Modules
Challenge: Overheating in High-Density Rail Systems
IGBT modules in metro traction systems reach 85°C+, risking thermal runaway
Air cooling fails to maintain safe operating temperatures
High energy costs from continuous fan operation
Solution: Custom Liquid Cooling Plates
✔ Microchannel cold plates directly attached to IGBTs
✔ Water-glycol coolant for efficient heat extraction
✔ AI-driven flow control optimizing cooling per load
Results
✅ 30°C lower IGBT temperatures (preventing failures)
✅ 50% less energy used vs. traditional air cooling
✅ Near-silent operation (reducing noise pollution)
✅ Extended component lifespan (fewer replacements)
Future of Rail Cooling: Smart & Sustainable Solutions
1. AI-Optimized Liquid Cooling
Predictive algorithms adjust cooling in real time
Dynamic load balancing for energy efficiency
2. Phase-Change Cooling for High Heat Flux
Boiling/condensation cycles for 50% better efficiency
Tested in next-gen metro power systems
3. Nanofluid-Enhanced Heat Transfer
Graphene-doped coolants improve conductivity 3x
Reduces pump power needs
Why Liquid Cooling is the Future for Rail Transit
✔ Prevents IGBT failures (critical for metro reliability)
✔ Cuts energy costs by 50% (supports green transit goals)
✔ Silent & compact (ideal for urban environments)
✔ Scalable for high-power trains & smart grids
Case customer: A rail transit customer in Hunan
▶Customer design requirements
Water flow rate: 20L/min
Water inlet temperature: 25°C/45°C
Fluid composition: pure water/50% ethylene glycol A
Ambient temperature: 45°C
▶Simulation Report
▶Product Presentation
Water flow rate: 20L/min
Water inlet temperature: 25°C/45°C
Fluid composition: pure water/50% ethylene glycol A
Ambient temperature: 45°C
