System and method for voltage conversion

Abstract

Systems and methods for voltage conversion are provided. The system includes a power converter configured to convert a current from a primary voltage to a secondary voltage; a housing, in which the power converter is fixed to an outer surface of the housing; a stack including bus bars enclosed within the housing, each configured to conduct a current at a secondary voltage from the power converter, where each of the bus bars is electrically isolated from each other and from the housing, where the first power converter is electrically coupled to the first bus bar and not electrically coupled to the second bus bar, and where the second power converter is electrically coupled to the second bus bar. And the second power converter is electrically coupled to the second bus and is not electrically coupled to the first bus; and a terminal fixed to the housing and configured to conduct the current at the secondary voltage from the bus bar to the electrical system.

Description

Technical Field

[0001] The technical field generally relates to voltage conversion systems, and more specifically to systems and methods including redundant power converters and bus systems with stacked configurations. Background Technology

[0002] Electric and hybrid vehicles include a rechargeable energy storage system (RESS), which comprises a battery or a group of batteries for storing and supplying electrical energy to power the vehicle's electric motor and other electrical systems. RESS typically includes high-capacity lithium-ion batteries, but may also contain other types of rechargeable batteries, such as nickel-metal hydride (NiMH) or solid-state batteries.

[0003] The voltage output of a RESS can vary due to a variety of factors, including the design of the battery pack and the specific requirements of the vehicle it powers. For example, the voltage output of a RESS can range from several hundred volts to over 800 volts. This higher voltage may be necessary to efficiently power the electric motors and other electrical systems in the vehicle.

[0004] In some cases, integration between the RSS and the vehicle's conventional 12-volt electrical system may be desirable. Therefore, a vehicle may include an Accessory Power Module (APM) configured to manage and distribute power to various accessory devices and systems within the vehicle. The APM can function as a central hub to control the power flow to components such as interior lighting, audio systems, infotainment displays, climate control systems, and other electrical systems (collectively referred to herein as vehicle accessories). The APM can receive power from the RSS and regulate and distribute that power to different accessory circuits based on the vehicle's needs and user input. Due to the high-voltage output of the RSS, the APM can provide DC-DC voltage conversion to reduce the RSS voltage output to the 12-volt level.

[0005] Due to the ongoing need to improve energy efficiency and reliability in electric and hybrid vehicles, systems and methods for improving the efficiency and operation of APMs (e.g., DC-to-DC voltage conversion functions) are desired. Furthermore, other desired features and characteristics of this disclosure will become apparent from the accompanying drawings and the foregoing introduction, based on the following detailed description and the appended claims. Summary of the Invention

[0006] A system for voltage conversion and current distribution is provided. In one example, the system includes: at least two power converters configured to convert current from a primary voltage to a secondary voltage; a housing having walls and a cavity defined therebetween, wherein the at least two power converters are fixed to an outer surface of the housing; a stack including at least two buses enclosed within the housing, each bus configured to conduct current at the secondary voltage from the at least two power converters, wherein each of the at least two buses within the stack is electrically isolated from each other and from the housing, wherein a first power converter of the at least two power converters is electrically coupled to the first bus of the at least two power converters and not electrically coupled to the second bus of the at least two power converters, and a second power converter of the at least two power converters is electrically coupled to the second bus and not electrically coupled to the first bus; and a terminal fixed to the housing and configured to conduct current at the secondary voltage from the at least two buses to an electrical system coupled to the terminal.

[0007] In various examples, the system may include an isolation layer that is enclosed within a housing and disposed between each of at least two buses and between at least two buses and the housing.

[0008] In various examples, the system's isolation layer may comprise a low-conductivity polymer material.

[0009] In various examples, the system housing can be elongated, and at least two power converters can be aligned along the housing.

[0010] In various examples, the system’s power converter may be a printed circuit board that is directly attached to the outer surface of the housing, wherein the housing may be configured to conduct heat from the power converter.

[0011] In various examples, the system may include conductive members extending from the power converter and into the housing, wherein a first conductive member of the conductive member electrically couples a first power converter to a first busbar, and a second conductive member of the conductive member electrically couples a second power converter to a second busbar. In various examples, the power converter of the system may be fixed to a first side of the housing, wherein each of the conductive members extends through a hole in each of at least two buses and extends from a second side of the housing opposite to the first side, wherein the conductive member is coupled to a terminal at the second side of the housing.

[0012] In various examples, the system enclosure can be configured to provide electrical grounding and electromagnetic shielding. In various examples, the system enclosure may include at least two components that can be electrically isolated from each other, and the at least two components may be configured to independently provide electrical grounding.

[0013] A method for voltage conversion and current distribution is provided. In one example, the method includes: converting current from a primary voltage to a secondary voltage using at least two power converters fixed to the outer surface of a housing; conducting the secondary voltage current from the power converters using a stack comprising at least two buses enclosed within a cavity of the housing, wherein each of the at least two buses within the stack is electrically isolated from each other and from the housing, wherein a first power converter of the at least two power converters is electrically coupled to the first bus of the at least two power converters and not electrically coupled to the second bus of the at least two power converters, and a second power converter of the at least two power converters is electrically coupled to the second bus and not electrically coupled to the first bus; and supplying the secondary voltage current to an electrical system.

[0014] In various examples, the method may include electrically isolating at least two buses from each other and from the enclosure using an isolation layer enclosed within the enclosure.

[0015] In various examples, the method may include securing power converters to a housing, wherein the housing is elongated and at least two power converters are aligned along the housing.

[0016] In various examples, the power converter may be a printed circuit board, and attaching the power converter to the housing may include attaching the power converter directly to the outer surface of the housing, such that the housing conducts heat from the power converter during operation.

[0017] In various examples, the method may include electrically coupling a first power converter to a first busbar using a first conductive member extending from a first power converter and entering the housing, and electrically coupling a second power converter to a second busbar using a second conductive member extending from a second power converter and entering the housing. In various examples, the power converter may be fixed to a first side of the housing, wherein each of the first and second conductive members extends through a hole in each of at least two buses and protrudes from a second side of the housing opposite the first side, and the method may include coupling the first and second conductive members to terminals at the second side of the housing.

[0018] In various examples, the method may include using the enclosure to provide electrical grounding and electromagnetic shielding.

[0019] In various examples, the housing of the method may include at least two workpieces, wherein the at least two workpieces are electrically isolated from each other, and the method may include independently providing electrical grounding using the at least two workpieces of the housing.

[0020] A vehicle is provided, in one example, comprising: a rechargeable energy storage system (RESS) configured to output current at a first or primary voltage; a power conversion system configured to convert current from the primary voltage to a second or secondary voltage; and an electrical system configured to provide current at the secondary voltage to one or more accessories of the vehicle. The power conversion system includes: at least two power converters configured to convert current from a primary voltage to a secondary voltage; an elongated housing having walls and a cavity defined therebetween, wherein the at least two power converters are fixed to an outer surface of the elongated housing; a stack including at least two buses enclosed within the elongated housing, each bus configured to conduct current at the secondary voltage from the at least two power converters, wherein each of the at least two buses in the stack is electrically isolated from each other and from the elongated housing by an isolation layer disposed between each of the at least two buses and between the at least two buses and the elongated housing, wherein a first power converter of the at least two power converters is electrically coupled to the first bus of the at least two power converters and not electrically coupled to the second bus of the at least two power converters, and a second power converter of the at least two power converters is electrically coupled to the second bus and not electrically coupled to the first bus; and terminals fixed to the elongated housing and configured to conduct current at the secondary voltage from the at least two buses.

[0021] In various examples, the vehicle may include conductive members extending from the power converter and into an elongated housing, wherein a first conductive member of the conductive member electrically couples the first power converter to a first busbar, and a second conductive member of the conductive member electrically couples the second power converter to a second busbar, wherein the power converter is fixed to a first side of the elongated housing, each of the conductive members extending through a hole in each of at least two buses and extending from a second side of the elongated housing opposite to the first side, wherein the conductive member is coupled to a terminal at the second side of the elongated housing.

[0022] In various examples, the elongated housing of a vehicle may include at least two components, wherein the at least two components are electrically isolated from each other, and the at least two components are configured to independently provide electrical grounding. Attached Figure Description

[0023] The following description will use the accompanying drawings to illustrate examples, where the same numbers represent the same elements, and where:

[0024] Figure 1 It is a functional diagram of a vehicle that includes an electric system, based on the example;

[0025] Figure 2 This is shown based on the example. Figure 1A schematic diagram of certain aspects of a power system;

[0026] Figure 3 It is a cross-sectional view based on the example voltage conversion component;

[0027] Figure 4 It is based on the example. Figure 3 A cross-sectional view of a portion of the component;

[0028] Figure 5 It is based on the example. Figure 3 An exploded view of the components;

[0029] Figure 6 It is a cross-sectional view of the voltage conversion component in the example; and

[0030] Figure 7 This is a flowchart illustrating a method for converting current from a primary voltage to a secondary voltage, based on an example. Detailed Implementation

[0031] The following detailed description is merely exemplary in nature and is not intended to limit application and use. Furthermore, it is not intended to be bound by any express or implied theory presented in the foregoing introduction or the following detailed description.

[0032] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, and other functional aspects of the system (and its various operating components) are not described in detail herein. Furthermore, the connecting lines shown in the various figures included herein are intended to represent exemplary functional relationships and / or physical couplings between various components. It should be noted that many alternative or additional functional relationships or physical connections may exist in the examples disclosed herein.

[0033] Figure 1 A vehicle 10 is shown according to an example. In some examples, vehicle 10 includes a car. In various examples, vehicle 10 can be any of a variety of different types of cars, such as sedans, vans, trucks, or sports utility vehicles (SUVs), and in some examples can be two-wheel drive (2WD) (i.e., rear-wheel drive or front-wheel drive), four-wheel drive (4WD), or all-wheel drive (AWD) and / or various other types of vehicles or mobile platforms.

[0034] like Figure 1 As depicted, the exemplary vehicle 10 typically includes a chassis 12, a body 14, front wheels 16, and rear wheels 18. The body 14 is mounted on the chassis 12 and substantially surrounds the components of the vehicle 10. The body 14 and the chassis 12 may together form a frame. The wheels 16-18 are each rotatably coupled to the chassis 12 near a corresponding angle of the body 14.

[0035] Vehicle 10 further includes a propulsion system 20 having an electric motor 26 and an optional internal combustion engine 24 (e.g., a gasoline or diesel fuel-powered internal combustion engine). A transmission system 22 transmits power from the propulsion system 20 to the wheels 16-18 according to a selectable speed ratio. Depending on various examples, the transmission system 22 may include a step-ratio automatic transmission, a continuously variable transmission (CVT), or other suitable transmission. A rechargeable energy storage system (RESS) 28 is provided for storing and supplying power to the electric motor 26 and / or other systems connected to one or more electrical grids or systems 30 on vehicle 10. Electrical system 30 may couple the RESS 28 to one or more accessories 32 of vehicle 10, such as audio equipment, lighting equipment, etc.

[0036] Figure 2A schematic diagram of a power system 11 with a redundant allocation configuration according to various examples is shown. The power system is operable to redundantly supply power from RESS 28 to electrical system 30, which is shown as including a first electrical system 30A and a second electrical system 30B for illustrative purposes, as it may include more or fewer electrical systems. RESS 28 may be of the type having multiple battery cells arranged according to multiple battery packs 34 (shown as first, second, and third battery packs 34A, 34B, and 34C), wherein each battery pack 34 is associated with a power converter 36 (shown as power converters 36A, 36B, and 36C). The power converter 36 may be a unidirectional and / or bidirectional DC-DC converter or other type of device operable for managing power delivery. RESS28 may include a high-voltage (HV) interface 40 and a low-voltage (LV) interface 38, wherein the HV interface 40 is operable to exchange HV power with the motor 26 and / or the HV bus, and the LV interface 38 is operable via connection 48 to exchange LV power with a first electrical system 30A and a second electrical system 30B. For non-limiting purposes, electrical systems 30A and 30B are described in relation to DC power, as this disclosure contemplates one or more electrical systems utilizing AC power, which may consequently include one or more power converters 36 as DC-AC converters. Power system 11 may be configured to provide a redundant distribution system having at least two buses 44 and 46 configured to redundantly connect electrical systems 30A and 30B to the LV interface 38. The redundancy configuration may be operable to maintain the operability of electrical systems 30A and 30B during disconnection events, such as events caused by the unavailability of one or more of buses 44 and 46 due to driving or other events. Redundancy configurations can help eliminate or improve the need for LV batteries or other backup systems that supply power to electrical systems 30A and 30B independently of RESS 28 during normal operation; that is, electrical systems 30A and 30B can rely entirely on power exchange with RESS 28. Vehicle 10 may include a charging module or other features (not shown) to facilitate charging of RESS 28 and / or power supply to electrical systems 30A and 30B from additional sources outside vehicle 10 via charging stations, public power grids, etc. This disclosure contemplates RESS 28 configurations that may not rely on separate branches for each battery pack 34 and power converter 36, which in turn may result in different arrangements of buses 44 and 46. Each of the power converters 36 may be configured to provide at least one LV output 42. In various examples, some of the LV outputs 42 may be connected to a first bus 44, and some of the LV outputs 42 may be connected to a second bus 46.In this example, LV output 42 is connected alternately to either the first bus 44 or the second bus 46. Ground (unlabeled) is shown to indicate power converters 36, electrical systems 30A and 30B, etc., connected to the vehicle ground, as will be understood by those skilled in the art, to facilitate the operation and configuration envisioned herein.

[0037] Figures 3-5 Various aspects of a voltage conversion component 100 configured to provide redundant DC-DC conversion are shown according to various examples. In some examples, component 100 may be mounted on... Figure 2 In the power system, and it defines the power converter 36 and the LV interface 38.

[0038] Component 100 includes a housing 118 and two or more DC-DC converters 110 fixed to the housing 118. In this example, the housing 118 includes a first member 142 and a second member 144 extending along its longitudinal axis 101, and the DC-DC converters 110 are fixed to the outer surface of the second member 144 and aligned along the longitudinal axis 101. However, component 100 is not limited to this arrangement, and the housing 118 may have other shapes, and the DC-DC converters 110 may be fixed thereto in other patterns.

[0039] DC-DC converter 110 is configured to receive a current at a first or primary voltage and output a current at a second or secondary voltage. DC-DC converter 110 can be any type of DC-DC converter configured to modify the voltage of the current. Although examples are described herein with reference to DC electrical systems, component 100 may alternatively include a DC-to-AC (AC-AC) converter configured to modify the voltage of the AC in an AC electrical system. Figures 3-6 In the example, the DC-DC converter 110 is a printed circuit board that is directly attached to the outer surface of the housing 118.

[0040] The housing 118 includes walls defining a cavity therebetween. A stack 111 comprising at least a first busbar 112 and a second busbar 114 is enclosed within the cavity of the housing 118. Busbars 112 and 114 are each elongated and substantially planar. Busbars 112 and 114 extend within the housing 118 along their longitudinal axis 101 and are parallel to each other in this example. Busbars 112 and 114 are electrically isolated from each other and from the housing 118. In this example, a first isolation layer 115, a second isolation layer 116, and a third isolation layer 117 are enclosed within the housing 118 and are arranged in combination around each of the busbars 112 and 114. That is, the first isolation layer 115 is disposed between the first busbar 112 and the housing 118, the second isolation layer 116 is disposed between the busbars 112 and 114, and the third isolation layer 117 is disposed between the second busbar 114 and the housing 118. In some examples, the insulating layers 115, 116, and 117 are each formed of a low-conductivity polymer material, i.e., having a conductivity of, for example, less than 1 × 10⁻⁶. -8 Siemens / M's conductive polymer material. It is worth noting that, depending on the application, stack 111 can have more busbars and isolation layers.

[0041] DC-DC converter 110 is electrically coupled to buses 112 and 114, and buses 112 and 114 are each configured to conduct current at a secondary voltage output from DC-DC converter 110. Various methods can be used to electrically couple DC-DC converter 110 to buses 112 and 114. In this example, component 100 includes a conductive member 126 extending from DC-DC converter 110 through a hole 140 in second component 144, through a hole 138 in third isolation layer 117, through a hole 136 in second bus 114, through a hole 134 in second isolation layer 116, through a hole 132 in first bus 112, and through a hole 130 in first isolation layer 115 into a housing 118, and protruding from the hole 128 in second component 144 at a second side of housing 118 opposite to a first side to which DC-DC converter 110 is attached. The distal end of conductive member 126 opposite to DC-DC converter 110 is coupled to first, second, and third sets of terminals 120, 122, and 124 at the second side of housing 118. Buses 112 and 114 and conductive member 126 may each be formed of various conductive materials, such as certain metallic materials, such as, but not limited to, copper, aluminum, and their alloys.

[0042] To promote redundancy and reliability of component 100, buses 112 and 114 can each be electrically coupled to a separate group of DC-DC converter 110. Figure 3In this example, DC-DC converter 110 is independently coupled to one of buses 112 and 114 in an alternating manner. Specifically, the first DC-DC converter 110A is coupled to the first bus 112 but not to the second bus 114, the second DC-DC converter 110B is coupled to the second bus 114 but not to the first bus 112, the third DC-DC converter 110C is coupled to the first bus 112 but not to the second bus 114, and the fourth DC-DC converter 110D is coupled to the second bus 114 but not to the first bus 112. Using this exemplary arrangement, all of the first set of terminals 120 are electrically coupled to the first bus 112, and all of the second set of terminals 122 are electrically coupled to the second bus 114. The third set of terminals 124 is not electrically coupled to either bus 112 or 114, but instead provides grounding for the corresponding DC-DC converter 110. In some examples, the third set of terminals 124 provides grounding through electrical contact with the housing 118. In some examples, the third set of terminals 124 is electrically coupled to the housing 118 via a conductive washer 152. In some examples, the first set of terminals 120 and the second set of terminals 122 are electrically isolated from the housing 118 via an insulating washer 150.

[0043] exist Figure 5 In the examples, buses 112 and 114 can be electrically coupled to or not coupled to each of the DC-DC converter 110 via conductive member 126 in various ways. For example, the diameters of holes 132 and 136 can vary depending on whether buses 112 and 114 are intended to be coupled to each of conductive members 126, wherein a larger diameter allows conductive member 126 to pass through without creating electrical contact, and wherein a smaller diameter allows conductive member 126 to pass through and create electrical contact, or is close enough that electrical contact can be made therebetween using, for example, solder, conductive paste, etc. In some examples, conductive member 126 is each soldered to one of buses 112 and 114, and not soldered to the other of buses 112 and 114. Figure 3 In one example, busbar 112 is physically coupled to terminal 120 via a first conductive cylinder 121 extending therebetween, and busbar 114 is physically coupled to terminal 122 via a second conductive cylinder 123 extending therebetween. In some examples, the first conductive cylinder 121 and the second conductive cylinder 123 may be soldered to busbars 112 and 114, respectively. In some examples, conductive cylinders 121 and 123 may be replaced by bends in busbars 112 and 114 extending to terminals 120 and 122, respectively.

[0044] Figure 6An alternative arrangement is presented in which conductive cylinders 121 and 123 are disposed between the DC-DC converter 110 and buses 112 and 114, and terminals 120 and 122 are recessed within housing 118. Despite this alternative arrangement, the voltage conversion assembly 100 can function in substantially the same manner and / or provide the same functionality.

[0045] exist Figures 3-6 In the example, the DC-DC converter 110 is fixed to a housing 118, and buses 112 and 114 within the housing 118 are arranged in a stack 111. This arrangement offers various advantages, including ease of manufacture and reduced space compared to, for example, a planar arrangement. Further advantages may be provided depending on the specific components used in the assembly 100. For example, the housing 118 may be configured to completely or substantially enclose buses 112 and 114 and is configured to provide electromagnetic shielding. This shielding function can protect the DC-DC converter 110 as well as any other potential devices in the vicinity of the assembly 100. The housing 118 may be in direct or thermal contact with the DC-DC converter 110 and is configured to conduct heat from the DC-DC converter 110, i.e., act as a heat sink. The housing 118 may be conductive and is configured to provide electrical grounding (e.g., to the DC-DC converter 110).

[0046] The housing 118 may comprise various materials, including certain metallic materials. In some examples, the housing 118 may be formed of a metallic material that has sufficient electrical conductivity to provide grounding, sufficient thermal conductivity to provide heat sink functionality, and sufficient electromagnetic shielding to prevent or significantly reduce the possibility of interference with the operation of the DC-DC converter 110. In some examples, the housing 118 may be formed of steel.

[0047] In some examples, such as Figures 3-6 For example, housing 118 may include at least two assembled components (e.g., first component 142 and second component 144), and these components may be electrically isolated from each other. In such an example, the components of housing 118 may be configured to independently provide electrical grounding. The components of housing 118 may be electrically isolated from each other via, for example, intermediate components formed of a non-conductive material (such as a non-conductive polymer seal). Figures 3-6 In the example, the first component 142 and the second component 144 of the housing 118 are electrically isolated from each other by the outermost portion of the second insulating layer 116. The components of the housing 118 can be coupled to each other in various ways, such as using non-conductive adhesive materials, non-conductive fasteners, etc. Figure 5 In the middle, the second component 144 includes a fastener 146 configured to clamp on the outer edge of the first component 142, thereby securing the first component 142 and the second component 142 with the stack 111 therebetween.

[0048] Now for reference Figure 7 And continue to refer to Figures 1-6 According to various examples, the flowchart provides a method 600 for converting current from a first or primary voltage to a second or secondary voltage, performed, for example, by component 100. It will be understood from this disclosure that the sequence of operations within method 600 is not limited to, for example, Figure 7 The order of execution shown may be used, but may be performed in one or more different orders as applicable and in accordance with this disclosure.

[0049] In one example, method 600 may begin at 610. At 612, method 600 may include converting current from a first or primary voltage to a second or secondary voltage using at least two DC-DC converters fixed to the outer surface of a housing. At 614, method 600 may include conducting current at the secondary voltage from the DC-DC converters using a stack comprising at least two buses enclosed within a cavity of the housing. In some examples, a first DC-DC converter of the at least two DC-DC converters is electrically coupled to a first bus and not electrically coupled to a second bus, and a second DC-DC converter of the at least two DC-DC converters is electrically coupled to a second bus and not electrically coupled to a first bus. At 616, method 600 may include supplying the current at the secondary voltage to an electrical system. Method 600 may end at 618.

[0050] While at least one example has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the examples are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the examples. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A system comprising: At least two power converters are configured to convert current from a primary voltage to a secondary voltage; A housing having walls and a cavity defined therebetween, wherein the at least two power converters are fixed to the outer surface of the housing; A stack comprising at least two buses enclosed within a housing, each bus configured to conduct current at the secondary voltage from the at least two power converters, wherein each of the at least two buses within the stack is electrically isolated from each other and from the housing, wherein a first power converter of the at least two power converters is electrically coupled to the first bus and not electrically coupled to the second bus, and a second power converter of the at least two power converters is electrically coupled to the second bus and not electrically coupled to the first bus; and Terminals are fixed to the housing and configured to conduct the current at the secondary voltage from the at least two buses to the electrical system coupled to the terminals.

2. The system of claim 1, further comprising an isolation layer enclosed within the housing and disposed between each of the at least two busbars and between the at least two busbars and the housing.

3. The system according to claim 1, wherein, The housing is elongated, and the at least two power converters are aligned along the housing, wherein the power converters are printed circuit boards directly attached to the outer surface of the housing, and wherein the housing is configured to conduct heat from the power converters.

4. The system of claim 1, further comprising a conductive member extending from the power converter and into the housing, wherein, The first conductive member of the conductive members electrically couples the first power converter to the first busbar, and the second conductive member of the conductive members electrically couples the second power converter to the second busbar, wherein the power converter is fixed to a first side of the housing, each of the conductive members extends through a hole in each of the at least two buses and extends from a second side of the housing opposite to the first side, wherein the conductive member is coupled to the terminal at the second side of the housing.

5. The system according to claim 1, wherein, The housing includes at least two components that are electrically isolated from each other and are configured to independently provide electrical grounding.

6. A method comprising: At least two power converters fixed to the outer surface of the housing convert current from primary voltage to secondary voltage; The current at the secondary voltage is conducted from the power converter using a stack of at least two buses enclosed within the housing, wherein each of the at least two buses within the stack is electrically isolated from each other and from the housing, wherein a first power converter of the at least two power converters is electrically coupled to the first bus of the at least two power converters and not electrically coupled to the second bus of the at least two power converters, and a second power converter of the at least two power converters is electrically coupled to the second bus and not electrically coupled to the first bus; and The current at the secondary voltage is supplied to the electrical system.

7. The method of claim 6, further comprising electrically isolating the at least two busbars from each other and from the housing using an isolation layer enclosed within the housing.

8. The method of claim 6, further comprising securing the power converter to the housing, wherein, The housing is elongated, and the at least two power converters are aligned along the housing, wherein the power converters are printed circuit boards, and securing the power converters to the housing includes securing the power converters directly to the outer surface of the housing, such that the housing conducts heat from the power converters during operation of the power converters.

9. The method of claim 6, further comprising electrically coupling the first power converter to the first bus using a first conductive member extending from the first power converter and entering the housing, and electrically coupling the second power converter to the second bus using a second conductive member extending from the second power converter and entering the housing, wherein, The power converter is fixed to a first side of the housing, each of the first conductive member and the second conductive member extends through a hole in each of the at least two busbars and protrudes from a second side of the housing opposite to the first side, the method comprising coupling the first conductive member and the second conductive member to a terminal at the second side of the housing.

10. The method according to claim 6, wherein, The housing includes at least two workpieces electrically isolated from each other, and the method includes independently providing electrical grounding using the at least two workpieces of the housing.

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