ABSTRACT This paper introduces a promising approach for developing an integrated traction motor drive based on the Integrated Modular Motor Drive (IMMD) concept. The IMMD concept strives to meet aggressive power density and performance targets by modularizing both the machine and power electronics and then integrating them into a single combined machine-plus-drive structure. Physical integration of the power electronics inside the machine makes it highly desirable to increase the power electronics operating temperature including higher power semiconductor junction temperatures and improved device packaging. Recent progress towards implementing the IMMD concept in an integrated traction motor drive is summarized in this paper. Several candidate permanent magnet (PM) machine configurations with different numbers of phases between 3 and 6 are analyzed to compare their performance characteristics and key application features. A 6-phase, 10- pole PM machine topology has been selected as the mostpromising configuration for meeting the major requirements in the areas of power density, efficiency, and module count. A parallel investigation of fault-tolerant distributed control configurations for the IMMD traction drive has led to selection of a heterarchical controller configuration that requires each phase module to be equipped with its own independent microcontroller operating as a peer with all of the other phase module controllers. The potential of silicon (Si) insulated gate bipolar transistors (IGBTs) operating at junction temperatures up to 200°C has been evaluated using a hardware testbed in terms of device losses and thermal issues. Based on these study results, a 10 kW phase-leg package design using Si IGBTs has been investigated including die selection, material selection, layout design, parasitic extraction and thermal characterization. Thermal performance characterization has been conducted for different packaging structures, operating conditions and coolant selections. The proposed packaging design and cooling approach can maintain the Si IGBT junction Development of Integrated Modular Motor Drive for Traction Applications2011-01-0344 Published 04/12/2011 Gilsu Choi Univ. of Wisconsin - Madison Zhuxian Xu and Ming Li Univ. of Tennessee - Knoxville Shiv Gupta and Thomas Jahns Univ. of Wisconsin - Madison Fred Wang Univ. of Tennessee and ORNL Neil A. Duffie Univ. of Wisconsin - Madison Laura Marlino Oak Ridge National Laboratory Copyright © 2011 SAE International doi:10.4271/2011-01-0344 SAE Int. J. Fuels Lubr. | Volume 4 | Issue 1 286Downloaded from SAE International by Univ of Nottingham - Kings Meadow Campus, Monday, September 10, 2018temperature below 200°C with an ambient temperature of 150°C. INTRODUCTION Today's hybrid electric vehicle (HEV) traction drives cannot meet the aggressive power density and cost targets for 2015 and 2020 because the electric machine and drive electronics are packaged as separate components, each with its own housing and thermal management system. The connectors and cables needed to interconnect the machine and drive add to the weight and cost. The integration of motor and drive offers a number of attractive features such as reduced drive volume and the elimination of power transmission cables. Radiated electromagnetic interference and voltage transients due to power transmission over long cable distances are also reduced. Motor and drive integration can also offer fault- tolerant features not possible with conventional drives [ 1,2]. However, there are many challenges associated with achieving the physical integration of the motor drive inside the machine housing. Designing power electronics to operate in the hostile thermal and vibrational environment inside an electrical motor is a challenging task. In addition, the desire to minimize the added volume and weight associated with the motor drive electronics while simultaneously minimizing cost generates requirement