With the increased necessity of a high power density and efficient system in aerospace and marine industries, integrated motor drives provide an excellent solution in the modern era. Therefore, a close structural and functional integration of passive components has become a prerequisite task to make a compact overall system. This article reviews the existing motor drives system with integrated passive technologies. To start, the design aspect of the traditional and integrated filter inductors, using the area product approach, is discussed. Subsequently, layouts of traditional and integrated inductors are presented. The available capacitor technologies, suitable for integration, are also discussed with pros and cons of each capacitor type.

This paper presents a validation of the novel motor-shaped rotational inductor. To validate the concept, 12 slots 2 poles rotational inductor is tested at different supply frequencies and rotor speeds. Experimental results have shown that the iron losses reduce as the rotor speed increases to the synchronous speed of the stator supply. The performance of the integrated rotational inductor is also compared with traditional EE core inductor in terms of total losses, synchronous inductance, copper resistance, and total harmonic distortion (THD). The total loss-to inductance ratio of the rotational inductor is reduced by 22.5 when rotor is rotating at 18kRPM and supply frequency is held at 300Hz. A significant reduction in copper resistance-to-inductance is also noticed when supply frequency is varied from 0Hz to 20kHz. Furthermore, the synchronous inductance and voltage and currents THD of rotational inductor is found to be superior to EE core inductor.

In this paper, an innovative method of electro-thermal integration of a drive system is presented. Important challenges of this integration consist of, firstly coupled thermal design of switching power modules and PM electric motor and secondly integration of high frequency switching devices into the motor housing, without compromising the performance of these transistors. To provide a solution to these challenges, an integrated liquid cooling system for both stator windings and transistor modules is designed. On the other hand, a specific module is designed to meet the specific requirements of this packaging technique.

An innovative arrangement for the electro-thermal integration of power electronics and motor in a high power drive systems is presented within this paper with a focus on automotive traction applications. Important challenges which needed to be overcome within this research work consist firstly of the coupling of the thermal design of the switching power modules and of the permanent magnet (PM) electric motor and secondly, the integration of high speed switching devices into the motor housing, without compromising the performance of the transistors. To provide a solution to these challenges, an integrated liquid cooling system for both the stator windings and the power devices has been designed. A bespoke power module has been designed and manufactured in order to meet the specific requirements of this packaging approach. The control structure of the drive system is also highlighted together with initial commissioning results.

Direct substrate jet impingement cooling can eliminate the use of the baseplate and significantly reduce the weight and volume of conventional thermal management solutions. This work demonstrates a cost-effective manufacturing approach based on printed circuit board technology to create impingement cells under a direct bonded copper substrate. Results from both computational fluid dynamics simulations and transient thermal tests verify the good performance of such jet impingement cooling systems under high power density conditions. Further work is ongoing to apply the present cooling and manufacturing technologies for the development of a range of high performance power electronic systems.

The development of new power electronic device and high performance magnetic materials are the main technological factors that have led both industries and research community to focus their attention on high speed electrical drives. Several papers have already outlined the electrical machine and/or converter topology choice for certain high speed application. This choice obviously depends on the applications under study. This paper aims to identify the most important high speed applications. For each of them, the main design challenges are highlighted and an overview of the already available product on the market is presented.

With increased need for high power density, high efficiency and high temperature capabilities in aerospace and automotive applications, integrated motor drives (IMD) offers a potential solution. However, close physical integration of the converter and the machine may also lead to an increase in components temperature. This requires careful mechanical, structural and thermal analysis; and design of the IMD system. This study reviews existing IMD technologies and their thermal effects on the IMD system. The effects of the power electronics position on the IMD system and its respective thermal management concepts are also investigated. The challenges faced in designing and manufacturing of an IMD along with the mechanical and structural impacts of close physical integration is also discussed and potential solutions are provided. Potential converter topologies for an IMD like the matrix converter, two-level bridge, three-level neutral point clamped and multiphase full bridge converters are also reviewed. Wide band gap devices like silicon carbide and gallium nitride and their packaging in power modules for IMDs are also discussed. Power modules components and packaging technologies are also presented.

With increased need for high power density, high efficiency and high temperature capabilities in Aerospace and Automotive applications, Integrated Motor Drives (IMD) offers a potential solution. However, close physical integration of the converter and the machine may also lead to an increase in components temperature. This requires careful mechanical, structural and thermal analysis; and design of the IMD system. This paper reviews existing IMD technologies and their thermal effects on the IMD system. The effects of the power electronics (PE) position on the IMD system and its respective thermal management concepts are also investigated. The challenges faced in designing and manufacturing of an IMD along with the mechanical and structural impacts of close physical integration is also discussed and potential solutions are provided. Potential converter topologies for an IMD like the Matrix converter, 2-level Bridge, 3-level NPC and Multiphase full bridge converters are also reviewed. Wide band gap devices like SiC and GaN and their packaging in power modules for IMDs are also discussed. Power modules components and packaging technologies are also presented.

The space and packaging constraints for various electric transport applications such as for electric and hybrid electric vehicles or mass transit systems ultimately require that electronic and mechanical subsystems become more fully integrated. This paper outlines the current state of art for the power electronic converter technologies which enables greater integration in electric drives. Investigations into the supply options, state of the art devices, switching frequency selection, filtering requirements and system modularity options are explored and future trends are discussed.

Potential benefits of Integrated Motor Drives (IMD) include increase in power density, reliability and efficiency. These benefits are particularly valuable in Aerospace and Automotive applications. However, close physical integration of the drives and the machine may also lead to an increase in component temperature. This requires careful thermal analysis and coupled design of the IMD system. This paper reviews different integration topologies and compares them using FEA based thermal analysis. The effects of the power electronics (PE) position on the IMD system as well as thermal management concepts and cooling systems are also investigated. Thermal models of these IMDs are created using ANSYS and the temperature distributions of these models are analysed.

Electric drives which are deployed in transport applications often have stringent volume/mass constraints requiring that the subsystems of electric drives are incorporated in a tightly packaged mechanical arrangement. As integration of mechanical and electronic subsystems becomes more intricate the thermal management issues relating to dealing with the loss in the converter and actuator in tandem become more complex. This paper presents a review of the state of the art manufacturing techniques and technologies which are enabling ever greater integration in electric drives for transport applications through better thermal management.