Rectifier bridge module with current monitoring function
By integrating Hall current sensor and thermistor into the rectifier bridge module, the monitoring complexity and space occupation problems of high-power rectifier bridge module are solved, efficient current and temperature monitoring is achieved, anti-interference ability and consistency are improved, and costs are reduced.
Patent Information
- Application Number
- CN202510547941.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-28
- Publication Date
- 2025-07-22
AI Technical Summary
The temperature and current monitoring of existing high-power rectifier bridge modules requires external sensors, which leads to large space occupation, complex installation and poor anti-interference ability, making it impossible to effectively monitor the core temperature of the device.
The Hall current sensor and thermistor are integrated into the rectifier bridge module, and the current is monitored through the Hall current sensor. The thermistor monitors the temperature in real time. The insulating cover and substrate fixed structure are used to achieve integrated monitoring of current and temperature.
It realizes efficient monitoring of current and temperature, reduces installation complexity and space occupation, improves anti-interference ability and consistency, and reduces costs.
Smart Images
Figure CN120357713A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of rectifier bridge modules, and particularly to a rectifier bridge module with a current monitoring function. Background Art
[0002] A bridge rectifier is a common electronic component used to convert alternating current (AC) into direct current (DC). It consists of four or six diodes and usually adopts a bridge structure, hence the name "rectifier bridge". In power electronics, industrial automation, and other applications that require DC power, the rectifier bridge is a key component. Rectifier bridges are commonly used in power supply devices, chargers, motor drives, signal processing, and many other fields, and are the core components for realizing the conversion between AC and DC.
[0003] The working principle of the rectifier bridge is based on the unidirectional conductivity of the diode. Its main function is to convert the input AC signal into a pulsating DC current. Through the ingenious arrangement and connection of four diodes, the rectifier bridge can provide current to the load during both the positive and negative half-cycles of the AC, thus achieving the rectification of the AC.
[0004] At the AC power input terminal, the AC signal changes periodically, including a positive half-cycle and a negative half-cycle. The rectifier bridge processes it in the following way:
[0005] Positive half-cycle: When the input AC is in the positive half-cycle, two diodes in the rectifier bridge will conduct, and the other two diodes will be in the cut-off state. The current flows from the input terminal through the conducting diodes to the load, and the current at the output terminal is in the DC direction.
[0006] Negative half-cycle: When the input AC is in the negative half-cycle, the rectifier bridge will conduct through the other two diodes to ensure that the current still flows in the same direction to the load, and the direction of the current at the output terminal remains unchanged.
[0007] In this way, the rectifier bridge can utilize both half-cycles of the AC to output a current with a constant direction, forming a pulsating DC. If a smoother DC is required, it can be further processed through a filter circuit.
[0008] The specific composition is as follows:
[0009] Input terminal (AC terminal): Receives the AC input, usually two connecting wires (L and N). These input terminals are connected to the AC power supply through cables.
[0010] Output terminal (DC terminal): The output terminal usually has two connection terminals, one is the positive electrode (+) and the other is the negative electrode (-). These terminals supply DC power to the load.
[0011] Thermal Management Structure: In high-power applications, the diodes in a rectifier bridge may generate significant heat. Therefore, some rectifier bridges are also equipped with heat sinks or thermal management designs to ensure the stability and reliability of the device.
[0012] The above is the industry status of rectifier bridges. However, with the increasing number of high-power devices, more and more rectifier bridge modules with currents above 100A are being used. For such high-power rectifier bridge modules, it is often necessary to monitor their working heat generation and load conditions. To monitor these parameters, external temperature sensors and current transformers must be added. However, external sensors have some disadvantages:
[0013] 1. The temperature sensor is fixed to the device with screws or glue, and the core temperature of the device cannot be measured.
[0014] 2. The external current transformer requires a relatively large space. Conventional current transformers are basically half the size of the rectifier module.
[0015] 3. External sensors increase the installation process, have poor anti-interference ability, and poor consistency. Summary of the Invention
[0016] An object of the present invention is to solve or alleviate the above technical problems.
[0017] The means adopted by the present invention is a rectifier bridge module with a current monitoring function, including pins, a carrier board, cross-bridges, a current monitoring cross-bridge, a Hall current sensor, an insulating cover, and six rectifier diodes. The carrier board, cross-bridges, current monitoring cross-bridge, Hall current sensor, and rectifier diodes are all located inside the insulating cover; the pins include a DC positive pin, a DC negative pin, and three AC pins; the carrier board includes a left conductive plate, a right conductive plate, a substrate, a current monitoring conductive plate, and three middle conductive plates; the left conductive plate, the three middle conductive plates, and the right conductive plate are arranged in sequence from left to right, and the three middle conductive plates are arranged in sequence from top to bottom. The current monitoring conductive plate is arranged below the right conductive plate; the left conductive plate, the middle conductive plates, the right conductive plate, and the current monitoring conductive plate are all fixed on the substrate. The substrate has insulation and its cross-section is rectangular; the rectifier diodes include three left diodes and three right diodes. The cathodes of the three left diodes are respectively welded to the left conductive plate, and the cathodes of the three right diodes are respectively welded to the three middle conductive plates; the two ends of the three cross-bridges are respectively welded to the anodes of the left diodes and the middle conductive plates, so that the three cross-bridges are arranged in parallel from top to bottom in sequence; the two ends of the other three cross-bridges are respectively welded to the anodes of the right diodes and the right conductive plate, so that the other three cross-bridges are arranged in parallel from top to bottom in sequence; the two ends of the current monitoring cross-bridge are respectively welded to the bottom end of the right conductive plate and the current monitoring conductive plate; the Hall current sensor is connected with a U-shaped magnetic core and fixed in the middle of the current monitoring cross-bridge, and the U-shaped magnetic core surrounds the middle of the current monitoring cross-bridge.
[0018] The effects achieved by the present invention are as follows: current monitoring can be realized, and the Hall current sensor is arranged inside the insulating cover, with strong anti-interference ability and consistency, small overall volume and fewer installation steps, which is beneficial to cost reduction.
[0019] In a further technical solution, the U-shaped magnetic core is fixed in the middle of the current monitoring cross bridge by high-temperature glue.
[0020] The installation process can be further simplified.
[0021] In a further technical solution, the left upper end of the lowermost middle conductive plate and the right upper end of the middle conductive plate in the middle respectively extend to form L-shaped extension parts, and two of the three AC pins are respectively arranged on the two extension parts.
[0022] The three AC pins can be arranged in a row for easy wiring.
[0023] In a further technical solution, the insulating cover is provided with a power connection hole, and the VCC pole, GND pole, and Vout terminal of the Hall current sensor are respectively exposed from the power connection hole.
[0024] The Hall current sensor can be connected through a pluggable connector, powered, and signals can be obtained, which is convenient for use.
[0025] In a further technical solution, it further includes a thermistor, the thermistor is fixed on the left conductive plate, and the carrier board is a copper-clad ceramic board.
[0026] The internal temperature of the rectifier bridge module with current monitoring function can be monitored in real time.
[0027] In a further technical solution, the thermistor is a glass-encapsulated thermistor, and the thermistor is fixed on the left conductive plate by high-temperature glue.
[0028] In a further technical solution, it further includes a mounting substrate, and the mounting substrate is fixedly connected to the insulating cover and fits with the bottom end of the substrate.
[0029] It is convenient for the installation and use of the rectifier bridge module with current monitoring function. BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Figure 1 is a three-dimensional schematic diagram of the rectifier bridge module with current monitoring function according to an embodiment of the present invention.
[0031] Figure 2 is Figure 1 a schematic diagram after hiding the insulating cover 92.
[0032] Figure 3 is a side view schematic diagram of the rectifier bridge module with current monitoring function according to an embodiment of the present invention; the insulating cover 92 is not drawn.
[0033] Figure 4 is a top view schematic diagram of a rectifier bridge module with a current monitoring function according to an embodiment of the present invention; the insulating cover 92 is not shown.
[0034] Figure 5 is a schematic diagram of cross-section one SEC1; the mounting substrate 91 is not shown.
[0035] Figure 6 is a schematic diagram of cross-section two SEC2.
[0036] Figure 7 is a circuit diagram of a rectifier bridge module with a current monitoring function according to an embodiment of the present invention.
[0037] The specification drawings that best illustrate the technical features of the present invention are Figure 2 .
[0038] Cross-section one SEC1; cross-section two SEC2; pin 1; AC pin 11; DC positive pin 12; DC negative pin 13; pin notch 19; carrier board 2; left conductive plate 21; middle conductive plate 22; extension 221; right conductive plate 23; substrate 29; rectifier diode 3; left diode 31; right diode 32; cross-bridge 4; Hall current sensor 5; U-shaped magnetic core 51; current monitoring conductive plate 52; current monitoring cross-bridge 53; thermistor 6; power connection hole 7; mounting substrate 91; insulating cover 92. Detailed implementation manners
[0039] The following will describe the detailed implementation manners of the present invention with reference to the specification drawings.
[0040] As a specific embodiment, a rectifier bridge module with a current monitoring function according to an embodiment of the present invention includes pin 1, carrier board 2, cross-bridge 4, current monitoring cross-bridge 53, Hall current sensor 5, insulating cover 92, and six rectifier diodes 3. The carrier board 2, cross-bridge 4, current monitoring cross-bridge 53, Hall current sensor 5, and rectifier diodes 3 are all located inside the insulating cover 92. The insulating cover 92 can be an outer cover such as plastic, or an outer cover formed by curing epoxy plastic for semiconductor packaging.
[0041] Pin 1 includes a DC positive pin 12, a DC negative pin 13, and three AC pins 11. It is easy to understand that pin 1, cross-bridge 4, and current monitoring cross-bridge 53 are all made of conductive materials and have conductivity; the three AC pins 11 in pin 1 are respectively used to connect the three phase poles of three-phase alternating current, and the DC positive pin 12 and the DC negative pin 13 are respectively used as the positive output and negative output of direct current.
[0042] The carrier board 2 includes a left conductive plate 21, a right conductive plate 23, a substrate 29, a current monitoring conductive plate 52, and three middle conductive plates 22.
[0043] As Figure 5 shown, the left conductive plate 21, the three middle conductive plates 22, and the right conductive plate 23 are arranged in sequence from left to right, and the three middle conductive plates 22 are arranged in sequence from top to bottom. The current monitoring conductive plate 52 is arranged below the right conductive plate 23. It should be noted that the pin 1 is provided with a pin notch 19; although Figure 5 both ends of the DC positive pin 12 are shown to span the left conductive plate 21 and the lowermost middle conductive plate 22, due to the existence of the pin notch 19, the right end of the DC positive pin 12 does not contact the lowermost middle conductive plate 22; the same is true for the DC negative pin 13.
[0044] The left conductive plate 21, the middle conductive plates 22, the right conductive plate 23, and the current monitoring conductive plate 52 are all fixed on the substrate 29. The substrate 29 has insulation and its cross-section is rectangular. It is easy to understand that the left conductive plate 21, the middle conductive plates 22, the right conductive plate 23, and the current monitoring conductive plate 52 are arranged as a whole within the rectangle of the substrate 29 and are rectangular as a whole.
[0045] The rectifier diode 3 includes three left diodes 31 and three right diodes 32. The cathodes of the three left diodes 31 are respectively welded to the left conductive plate 21, and the cathodes of the three right diodes 32 are respectively welded to the three middle conductive plates 22.
[0046] Both ends of the three cross bridges 4 are respectively welded to the anodes of the left diodes 31 and the middle conductive plates 22, so that the three cross bridges 4 are arranged in parallel from top to bottom in sequence.
[0047] Both ends of the other three cross bridges 4 are respectively welded to the anodes of the right diodes 32 and the right conductive plate 23, so that the other three cross bridges 4 are arranged in parallel from top to bottom in sequence.
[0048] Usually, the carrier board 2 is a copper-clad ceramic board. The ceramic board in the copper-clad ceramic board corresponds to the copper-clad parts of the conductive plates such as the substrate 29, the left conductive plate 21, the right conductive plate 23, the substrate 29, and the three middle conductive plates 22.
[0049] Both ends of the current monitoring cross bridge 53 are respectively welded to the bottom end of the right conductive plate 23 and the current monitoring conductive plate 52. As Figure 2 shown, the whole of the current monitoring cross bridge 53 is U-shaped and its middle part is suspended.
[0050] As Figure 6 shown, the Hall current sensor 5 is connected with a U-shaped magnetic core 51 and is fixed in the middle part of the current monitoring cross bridge 53. The U-shaped magnetic core 51 surrounds the middle part of the current monitoring cross bridge 53. The U-shaped magnetic core 51 can be made of silicon steel.
[0051] The working principle is as follows: three-phase electricity is respectively connected to the three AC pins 11, or single-phase electricity (one phase of the three-phase electricity) is connected to one of the three AC pins 11. After the alternating current is rectified by the six rectifier diodes 3, direct current is output at the DC positive pin 12 and the DC negative pin 13.
[0052] Connect the VCC pole of the Hall current sensor 5 to the positive pole of the DC power supply, and connect the GND pole of the Hall current sensor 5 to the negative pole of the DC power supply. When current passes through the current monitoring cross-bridge 53, the magnetic field change generated in the middle of the current monitoring cross-bridge 53 due to the current is mutually sensed by the Hall current sensor 5. The Hall current sensor 5 converts this magnetic field change into a voltage signal proportional to the current and outputs it. A voltage signal is output from the Vout terminal of the Hall current sensor 5, so that current monitoring can be realized. Moreover, the Hall current sensor 5 is arranged in the insulating cover 92, with strong anti-interference ability and consistency, small overall volume and few installation steps, which is beneficial to cost reduction.
[0053] As one of the specific implementation manners, the U-shaped magnetic core 51 is fixed in the middle of the current monitoring cross-bridge 53 by high-temperature glue. The high-temperature glue is a prior art, which is in a liquid state at high temperature and in a solid state after cooling. It can further simplify the installation process.
[0054] As one of the specific implementation manners, the left upper end of the lowermost middle conductive plate 22 and the right upper end of the middle middle conductive plate 22 respectively extend to form L-shaped extension parts 221, and two of the three AC pins 11 are respectively arranged on the two extension parts 221. The three AC pins 11 can be arranged in a row for convenient wiring.
[0055] As one of the specific implementation manners, the insulating cover 92 is provided with a power connection hole 7, and the VCC pole, GND pole, and Vout terminal of the Hall current sensor 5 are respectively exposed from the power connection hole 7. For the embodiment of the thermistor 6 described later, both ends of the thermistor 6 can also be respectively exposed from the power connection hole 7. The Hall current sensor 5 can be connected through a pluggable connector, powered to the Hall current sensor 5 and signals can be obtained, which is convenient for use.
[0056] As one of the specific implementation manners, it further includes a thermistor 6. The thermistor 6 is fixed on the left conductive plate 21, and the carrier board 2 is a copper-clad ceramic board. Usually, the thermistor 6 is fixed at the lower right corner of the substrate 29. The carrier board 2 is a copper-clad ceramic board, and the left conductive plate 21, the middle conductive plate 22 and the cross-bridge 4 have very high heat conduction efficiency. The thermistor 6 can indirectly measure the overall average temperature of the rectifier diodes 3, so that the internal temperature of the rectifier bridge module with current monitoring function can be monitored in real time, so as to make timely overheat protection and other treatments when overheating occurs.
[0057] As one of the specific embodiments, the thermistor 6 is a glass-encapsulated thermistor, and the thermistor 6 is fixed on the left conductive plate 21 by high-temperature glue.
[0058] As one of the specific embodiments, it further includes a mounting substrate 91. The mounting substrate 91 is fixedly connected to the insulating cover 92 and fits against the bottom end of the substrate 29, facilitating the installation and use of the rectifier bridge module with current monitoring function.
[0059] In the present invention, terms such as first, second, etc. do not represent any order, quantity, or importance, but are only used for distinction.
[0060] In the present invention, terms such as a, an, etc. do not represent a limitation of quantity, but represent the existence of at least one of the mentioned objects.
[0061] In the present invention, terms indicating orientation or position, such as top, bottom, side, longitudinal, transverse, middle, center, outer, inner, horizontal, vertical, left, right, above, below, etc., mean relative position rather than absolute position.
[0062] In the present invention, terms such as approximately, overall, nearly, similar, etc. are limiting terms used to indicate the existence of features but allowing certain deviations. The amount of allowable deviation may vary depending on the specific background; for example, for dimensional deviations, the specific background that can be depended on includes but is not limited to relevant standards for dimensional tolerances.
Claims
1. A rectifier bridge module with a current monitoring function, including a pin (1), a carrier board (2), a cross bridge (4), a current monitoring cross bridge (53), a Hall current sensor (5), an insulating cover (92), and six rectifier diodes (3). It is characterized in that The carrier board (2), the cross bridge (4), the current monitoring cross bridge (53), the Hall current sensor (5), and the rectifier diodes (3) are all located inside the insulating cover (92); the pin (1) includes a DC positive pin (12), a DC negative pin (13), and three AC pins (11); the carrier board (2) includes a left conductive plate (21), a right conductive plate (23), a substrate (29), a current monitoring conductive plate (52), and three middle conductive plates (22); the left conductive plate (21), the three middle conductive plates (22), and the right conductive plate (23) are arranged in sequence from left to right, the three middle conductive plates (22) are arranged in sequence from top to bottom, and the current monitoring conductive plate (52) is arranged below the right conductive plate (23); the left conductive plate (21), the middle conductive plates (22), the right conductive plate (23), and the current monitoring conductive plate (52) are all fixed on the substrate (29), and the substrate (29) has insulation and its cross section is rectangular; the rectifier diodes (3) include three left diodes (31) and three right diodes (32), the negative electrodes of the three left diodes (31) are respectively welded on the left conductive plate (21), and the negative electrodes of the three right diodes (32) are respectively welded on the three middle conductive plates (22); the two ends of the three cross bridges (4) are respectively welded to the positive electrodes of the left diodes (31) and the middle conductive plates (22) so that the three cross bridges (4) are arranged in parallel from top to bottom in sequence; the two ends of the other three cross bridges (4) are respectively welded to the positive electrodes of the right diodes (32) and the right conductive plate (23) so that the other three cross bridges (4) are arranged in parallel from top to bottom in sequence; the two ends of the current monitoring cross bridge (53) are respectively welded to the bottom end of the right conductive plate (23) and the current monitoring conductive plate (52); the Hall current sensor (5) is connected with a U-shaped magnetic core (51) and is fixed in the middle of the current monitoring cross bridge (53), and the U-shaped magnetic core (51) surrounds the middle of the current monitoring cross bridge (53).
2. The rectifier bridge module with a current monitoring function according to claim 1, characterized in that, The U-shaped magnetic core (51) is fixed in the middle of the current monitoring cross bridge (53) by high-temperature glue.
3. The rectifier bridge module with a current monitoring function according to claim 1, characterized in that, The left upper end of the lowermost middle conductive plate (22) and the right upper end of the middle middle conductive plate (22) respectively extend to form L-shaped extension parts (221), and two of the three AC pins (11) are respectively arranged on the two extension parts (221).
4. The rectifier bridge module with a current monitoring function according to claim 1, characterized in that, The insulating cover (92) is provided with a power connection hole (7), and the VCC pole, GND pole, and Vout terminal of the Hall current sensor (5) are respectively exposed from the power connection hole (7).
5. The rectifier bridge module with a current monitoring function according to claim 1, characterized in that, It further includes a thermistor (6), the thermistor (6) is fixed on the left conductive plate (21), and the carrier board (2) is a copper-clad ceramic board.
6. The rectifier bridge module with a current monitoring function according to claim 5, characterized in that, The thermistor (6) is a glass-encapsulated thermistor, and the thermistor (6) is fixed on the left conductive plate (21) by high-temperature glue.
7. The rectifier bridge module with a current monitoring function according to claim 1, characterized in that, It further includes a mounting substrate (91), the mounting substrate (91) is fixedly connected with the insulating cover (92) and is attached to the bottom end of the substrate (29).