Custom Liquid Cooling Test System for Power Module Thermal Management at the China Academy of Railway Sciences

The China Academy of Railway Sciences (CARS) is China’s leading national research institution for railway technology, supporting the development of high-speed rail systems, intelligent transportation, power electronics, traction equipment, and advanced railway infrastructure.

As modern railway systems continue to adopt higher-power semiconductor devices, effective thermal management has become increasingly critical to equipment reliability and performance. Components such as IGBTs, SiC power modules, converters, and traction inverters generate substantial heat during operation and require precise thermal testing to validate performance under real-world operating conditions.

To support advanced power electronics research, Beijing Generalway developed a custom liquid cooling test system specifically designed for power module thermal testing. The system provides highly accurate coolant temperature control, stable flow regulation, and intelligent automation, creating a reliable testing environment for next-generation railway power electronics.

The Challenge

Power semiconductor devices are extremely sensitive to temperature. Excessive heat or unstable cooling conditions can affect electrical performance, accelerate component aging, and reduce long-term reliability.

Thermal validation laboratories require cooling systems capable of accurately reproducing operating conditions while maintaining exceptional control over coolant temperature and flow rate.

For the China Academy of Railway Sciences, the cooling system needed to:

* Provide stable coolant temperatures throughout thermal testing

* Maintain precise coolant flow for power module evaluation

* Support long-duration reliability testing

* Deliver continuous operation with minimal maintenance

* Provide automated monitoring and intelligent control

* Accommodate different power module sizes and testing conditions

* Ensure highly repeatable laboratory testing results

The project required a purpose-built thermal management platform capable of supporting advanced power electronics development and validation.

Our Solution

To meet these demanding requirements, Beijing Generalway designed and manufactured a custom liquid cooling test system specifically engineered for high-power semiconductor testing.

The system combines high-efficiency plate heat exchangers, precision circulation pumps, intelligent temperature control, and automated flow regulation into a fully integrated thermal management platform.

An intelligent control system continuously monitors coolant temperature, flow rate, and operating conditions, automatically adjusting system performance to maintain stable test environments throughout the entire testing cycle. The system achieves temperature control accuracy of ±0.5°C, ensuring highly repeatable thermal conditions for power module characterization and reliability testing.

The modular cooling architecture allows researchers to evaluate a wide range of power electronic devices, including IGBT modules, silicon carbide (SiC) power modules, traction converters, inverter assemblies, and other high-power semiconductor components.

Designed for continuous laboratory operation, the cooling platform features remote monitoring, automated fault diagnostics, and comprehensive safety protection, enabling unattended testing while improving laboratory efficiency and equipment reliability.

Equipment Supplied

* Application: Power Module Liquid Cooling Test System

* Product Supplied: Custom Liquid Cooling Platform

* Cooling Technology: High-Efficiency Plate Heat Exchanger

* Temperature Control Accuracy: ±0.5°C

* Applications: IGBT Modules, SiC Power Modules, Traction Inverters, Railway Power Electronics

* Control Features: Intelligent Temperature & Flow Control

* Monitoring: Remote Monitoring and Automated Fault Diagnostics

* Operation: Continuous Laboratory Testing

Results

Following installation, the liquid cooling system significantly improved the laboratory’s thermal testing capabilities for advanced power electronic devices.

Project benefits include:

* Precision coolant temperature control within ±0.5°C

* Stable coolant flow throughout thermal testing

* Improved repeatability of power module performance evaluation

* Reliable long-duration testing capability

* Enhanced laboratory automation through intelligent controls

* Reduced operator workload via remote monitoring

* Improved equipment reliability and testing efficiency

* Flexible testing platform supporting multiple power electronics applications

The completed system now provides the China Academy of Railway Sciences with a dependable thermal management platform that supports the development and validation of high-performance railway power electronics.

Why This Project Matters

As electrification accelerates across rail transportation, electric vehicles, renewable energy, industrial automation, and energy storage, thermal management has become one of the most important factors affecting power electronics reliability and performance.

Testing these devices under accurately controlled thermal conditions is essential for validating product performance, extending service life, and improving system safety.

The China Academy of Railway Sciences project demonstrates how a custom liquid cooling platform can deliver the precision, stability, and automation required for advanced power module testing. By combining intelligent control with efficient heat transfer, the system provides a flexible solution for laboratories developing next-generation semiconductor devices and high-power electronic systems.

The project serves as an excellent reference for research institutes, EV manufacturers, railway equipment suppliers, semiconductor companies, inverter manufacturers, and engineering laboratories seeking advanced liquid cooling solutions for power electronics testing.