Rectifier bridge module with current monitoring function

Abstract

The utility model relates to a rectifier bridge module with a current monitoring function, which comprises pins, a carrier plate, a span bridge, a current monitoring span bridge, a Hall current sensor, an insulating cover and six rectifier diodes, and is characterized in that the carrier plate, the span bridge, the current monitoring span bridge, the Hall current sensor and the rectifier diodes are all positioned in the insulating cover; the pins comprise a direct-current anode pin, a direct-current cathode pin and three alternating-current pins; the carrier plate comprises a left current-conducting plate, a right current-conducting plate, a substrate, a current monitoring current-conducting plate and three middle current-conducting plates; the left current-conducting plate, the three middle current-conducting plates and the right current-conducting plate are sequentially arranged from left to right, the three middle current-conducting plates are sequentially arranged from top to bottom, and the current monitoring current-conducting plate is arranged below the right current-conducting plate. The beneficial effects of the utility model are that current monitoring can be realized, the Hall current sensor is arranged in the insulation cover, the anti-interference capability and the consistency are strong, the overall size is small, the installation steps are few, and the cost is reduced.

Description

Technical Field

[0001] This utility model relates to the technical field of rectifier bridge modules, and in particular to a rectifier bridge module with current monitoring function. Background Technology

[0002] A bridge rectifier is a common electronic component used to convert alternating current (AC) to direct current (DC). It consists of four or six diodes and typically uses a bridge-shaped structure, hence the name "rectifier bridge." In power electronics, industrial automation, and other applications requiring DC power, the rectifier bridge is a critical component. Rectifier bridges are commonly used in power supply equipment, chargers, motor drives, signal processing, and many other fields, serving as the core component for AC-DC conversion.

[0003] The working principle of a rectifier bridge is based on the unidirectional conductivity of diodes. Its main function is to convert the input alternating current (AC) signal into pulsating direct current (DC). 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 power, thereby achieving rectification of the AC power.

[0004] At the AC power input, the AC signal changes periodically, including positive and negative half-cycles. The rectifier bridge handles this as follows:

[0005] Positive half-cycle: When the input AC current is in the positive half-cycle, two diodes in the rectifier bridge will conduct, while the other two diodes will be cut off. 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 current is in the negative half-cycle, the rectifier bridge will conduct through the other two diodes to ensure that the current still flows to the load in the same direction, and the direction of the output current remains unchanged.

[0007] In this way, the rectifier bridge can utilize both half-cycles of the alternating current to output a current in a constant direction, forming pulsating direct current. If a smoother direct current is required, it can be further processed by a filter circuit.

[0008] The specific components are as follows:

[0009] Input terminals (AC terminals): These receive alternating current input and typically consist of two wires (L and N). These input terminals are connected to the AC power source via cables.

[0010] Output terminal (DC terminal): The output terminal usually consists of two connection terminals, one positive (+) and one negative (-). These terminals provide DC power to the load.

[0011] Thermal management structure: In high-power applications, the diodes of the rectifier bridge may generate a lot of 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 describes the current state of the rectifier bridge industry. However, with the increasing number of high-power devices, the application of rectifier bridge modules with current ratings exceeding 100A is also growing. These high-power rectifier bridge modules often require monitoring of their operating heat generation and load conditions. Monitoring these parameters necessitates the use of external temperature sensors and current transformers. However, external sensors have several drawbacks:

[0013] 1. Temperature sensors are fixed to devices with screws or glue, but the core temperature of the device cannot be measured.

[0014] 2. External current transformers require a relatively large space; a conventional current transformer is generally half the size of a rectifier module.

[0015] 3. External sensors increase installation complexity, have poor anti-interference capabilities, and poor consistency. Utility Model Content

[0016] One objective of this invention is to solve or alleviate the aforementioned technical problems.

[0017] The present invention employs a rectifier bridge module with current monitoring function, comprising pins, a carrier board, a bridge, a current monitoring bridge, a Hall current sensor, an insulating cover, and six rectifier diodes. The carrier board, bridge, current monitoring bridge, Hall current sensor, and rectifier diodes are all located within 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 sequentially from left to right, and the three middle conductive plates are arranged sequentially from top to bottom. The current monitoring conductive plate is located below the right conductive plate. The left conductive plate, the middle conductive plate, the right conductive plate, and the current monitoring conductive plate are all fixed to... On the substrate, the substrate is insulating and has a rectangular cross-section; the rectifier diodes include three left diodes and three right diodes, the negative terminals of the three left diodes are respectively welded to the left conductive plate, and the negative terminals of the three right diodes are respectively welded to the three middle conductive plates; the two ends of the three bridges are respectively welded to the positive terminals of the left diodes and the middle conductive plates, so that the three bridges are arranged in parallel from top to bottom; the two ends of the other three bridges are respectively welded to the positive terminals of the right diodes and the right conductive plates, so that the other three bridges are arranged in parallel from top to bottom; the two ends of the current monitoring 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 to a U-shaped magnetic core and fixed in the middle of the current monitoring bridge, the U-shaped magnetic core surrounding the middle of the current monitoring bridge.

[0018] The advantages of this invention are that it enables current monitoring, and the Hall current sensor is set inside an insulating cover, which has strong anti-interference ability and consistency. The overall size is small and the installation steps are few, which helps to reduce costs.

[0019] A further technical solution involves fixing the U-shaped magnetic core to the middle of the current monitoring bridge using high-temperature adhesive.

[0020] This can further simplify the installation process.

[0021] In a further technical solution, the upper left end of the bottom middle conductive plate and the upper right end of the middle middle conductive plate extend to form L-shaped extensions, and two of the three AC pins are respectively set on the two extensions.

[0022] The three AC pins can be arranged in a row for easy wiring.

[0023] A further technical solution involves providing an electrical connection hole in the insulating cover, through which the VCC, GND, and Vout terminals of the Hall current sensor are exposed.

[0024] It can connect to Hall current sensors via plug-in connectors, power Hall current sensors and acquire signals, making it easy to use.

[0025] Further technical solutions also include a thermistor, which is fixed on the left conductive plate, and the carrier plate is a copper-clad ceramic plate.

[0026] It can monitor the internal temperature of the rectifier bridge module with current monitoring function in real time.

[0027] A further technical solution involves using a glass-encapsulated thermistor, which is then fixed to the left conductive plate with high-temperature adhesive.

[0028] A further technical solution also includes a mounting substrate, which is fixedly connected to the insulating cover and attached to the bottom end of the substrate.

[0029] This facilitates the installation and use of rectifier bridge modules with current monitoring capabilities. Attached Figure Description

[0030] Figure 1 This is a three-dimensional schematic diagram of a rectifier bridge module with current monitoring function according to an embodiment of the present invention.

[0031] Figure 2 yes Figure 1 A schematic diagram showing the concealed insulating cover 92.

[0032] Figure 3 This is a side view of a rectifier bridge module with current monitoring function according to an embodiment of the present invention; the insulating cover 92 is not shown.

[0033] Figure 4 This is a top view of a rectifier bridge module with current monitoring function according to an embodiment of the present invention; the insulating cover 92 is not shown.

[0034] Figure 5 This is a schematic diagram of cross-section SEC1; mounting substrate 91 is not shown.

[0035] Figure 6 This is a schematic diagram of section SEC2.

[0036] Figure 7 This is a circuit diagram of a rectifier bridge module with current monitoring function according to an embodiment of the present invention.

[0037] The accompanying drawings in the specification that best illustrate the technical features of this utility model are: Figure 2 .

[0038] Section 1 (SEC1); Section 2 (SEC2); Pin 1; AC Pin 11; DC Positive Pin 12; DC Negative Pin 13; Pin Notch 19; Carrier Plate 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; Bridge 4; Hall Current Sensor 5; U-shaped Magnetic Core 51; Current Monitoring Conductive Plate 52; Current Monitoring Bridge 53; Thermistor 6; Connection Hole 7; Mounting Substrate 91; Insulating Cover 92. Detailed Implementation

[0039] The specific embodiments of this utility model will now be described with reference to the accompanying drawings.

[0040] As a specific embodiment, the rectifier bridge module with current monitoring function of this utility model includes pin 1, carrier board 2, bridge 4, current monitoring bridge 53, Hall current sensor 5, insulating cover 92, and six rectifier diodes 3. The carrier board 2, bridge 4, current monitoring bridge 53, Hall current sensor 5, and rectifier diodes 3 are all located inside the insulating cover 92. The insulating cover 92 can be a plastic outer cover 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, bridge 4, and current monitoring bridge 53 are all made of conductive material and are conductive; the three AC pins 11 in pin 1 are used to connect to the three phase poles of the three-phase AC power, and the DC positive pin 12 and DC negative pin 13 serve as the positive and negative outputs of DC power, respectively.

[0042] The carrier plate 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] like Figure 5 As shown, the left conductive plate 21, three middle conductive plates 22, and the right conductive plate 23 are arranged sequentially from left to right, and the three middle conductive plates 22 are arranged sequentially from top to bottom. The current monitoring conductive plate 52 is located below the right conductive plate 23. It should be noted that pin 1 has a pin notch 19; although... Figure 5 The DC positive pin 12 spans the left conductive plate 21 and the lowest middle conductive plate 22, but due to the pin notch 19, the right end of the DC positive pin 12 does not contact the lowest middle conductive plate 22; the same is true for the DC negative pin 13.

[0044] The left conductive plate 21, the middle conductive plate 22, the right conductive plate 23, and the current monitoring conductive plate 52 are all fixed on the substrate 29. The substrate 29 is insulating and has a rectangular cross-section. It is easy to understand that the left conductive plate 21, the middle conductive plate 22, the right conductive plate 23, and the current monitoring conductive plate 52 are arranged within the rectangle of the substrate 29, and the whole is rectangular.

[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 soldered to the left conductive plate 21, and the cathodes of the three right diodes 32 are respectively soldered to the three middle conductive plates 22.

[0046] The two ends of the three bridges 4 are respectively welded to the positive terminal of the left diode 31 and the middle conductive plate 22, so that the three bridges 4 are arranged in parallel from top to bottom.

[0047] The two ends of the other three bridges 4 are respectively welded to the positive terminal of the right diode 32 and the right conductive plate 23, so that the other three bridges 4 are arranged in parallel from top to bottom.

[0048] Typically, the carrier plate 2 is a copper-clad ceramic plate, and the ceramic plates in the copper-clad ceramic plate are the substrate 29, the left conductive plate 21, the right conductive plate 23, the substrate 29, and the three middle conductive plates 22, etc., corresponding to the copper-clad portion of the copper-clad ceramic plate.

[0049] The two ends of the current monitoring bridge 53 are welded to the bottom end of the right conductive plate 23 and the current monitoring conductive plate 52, respectively. For example... Figure 2 As shown, the current monitoring bridge 53 is U-shaped with its middle section suspended.

[0050] like Figure 6 As shown, the Hall current sensor 5 is connected to a U-shaped magnetic core 51 and fixed in the middle of the current monitoring bridge 53. The U-shaped magnetic core 51 surrounds the middle of the current monitoring bridge 53. The U-shaped magnetic core 51 can be made of silicon steel.

[0051] The working principle is as follows: the three-phase power is connected to the three AC pins 11 respectively, or the single-phase power (one phase of the three-phase power) is connected to one of the three AC pins 11. After the AC power is rectified by the six rectifier diodes 3, the DC power is output at the DC positive pin 12 and the DC negative pin 13.

[0052] Connect the VCC terminal of the Hall current sensor 5 to the positive terminal of the DC power supply, and connect the GND terminal of the Hall current sensor 5 to the negative terminal of the DC power supply. When current flows through the current monitoring bridge 53, the magnetic field change generated in the middle of the current monitoring bridge 53 due to the current mutually induces the Hall current sensor 5. The Hall current sensor 5 converts this magnetic field change into a voltage signal output proportional to the current. The voltage signal is output from the Vout terminal of the Hall current sensor 5, thereby realizing current monitoring. Furthermore, the Hall current sensor 5 is set inside the insulating cover 92, which has strong anti-interference ability and consistency. The overall size is small and the installation steps are few, which helps to reduce costs.

[0053] As one specific implementation method, the U-shaped magnetic core 51 is fixed to the middle of the current monitoring bridge 53 using high-temperature adhesive. The high-temperature adhesive is existing technology; it is in a liquid state at high temperatures and solidifies upon cooling. This further simplifies the installation process.

[0054] As one specific implementation, the upper left end of the lowest middle conductive plate 22 and the upper right end of the middle conductive plate 22 extend to form L-shaped extensions 221, respectively. Two of the three AC pins 11 are respectively disposed on the two extensions 221. The three AC pins 11 can be arranged in a row for easy wiring.

[0055] As one specific implementation, the insulating cover 92 has a power connection hole 7, through which the VCC, GND, and Vout terminals of the Hall current sensor 5 are exposed. In the embodiment of the thermistor 6 described later, both ends of the thermistor 6 can also be exposed through the power connection hole 7. The Hall current sensor 5 can be connected via a pluggable connector, power is supplied to the Hall current sensor 5, and signals are acquired, facilitating its use.

[0056] As one specific implementation, a thermistor 6 is also included. The thermistor 6 is fixed on the left conductive plate 21, and the carrier plate 2 is a copper-clad ceramic plate. Typically, the thermistor 6 is fixed at the lower right corner of the substrate 29. The carrier plate 2 is a copper-clad ceramic plate, and the left conductive plate 21, the middle conductive plate 22, and the bridge 4 have very high thermal conductivity. The thermistor 6 can indirectly measure the overall average temperature of the rectifier diode 3, thereby enabling real-time monitoring of the internal temperature of the rectifier bridge module with current monitoring function, so as to promptly take measures such as overheat protection in case of overheating.

[0057] As one specific implementation method, the thermistor 6 is a glass-encapsulated thermistor, and the thermistor 6 is fixed to the left conductive plate 21 by high-temperature adhesive.

[0058] As one specific implementation, it also includes a mounting substrate 91, which is fixedly connected to the insulating cover 92 and abuts against the bottom end of the substrate 29. This facilitates the installation and use of the rectifier bridge module with current monitoring function.

[0059] The terms used in this invention, such as "first," "second," etc., do not indicate any order, quantity, or importance, but are merely for distinction.

[0060] In this invention, terms such as "a" or "an" are used to indicate not a limitation on the quantity, but rather to indicate the existence of at least one of the mentioned objects.

[0061] In this utility model, terms indicating direction or location such as top, bottom, side, longitudinal, transverse, middle, center, outside, inside, horizontal, vertical, left, right, above, and below are used to indicate relative positions rather than absolute positions.

[0062] Terms used in this invention, such as "approximately," "generally," "approximately," and "similar," are limiting terms used to indicate features that are present but allow for certain deviations. The amount of deviation allowed may vary depending on the specific context; for example, regarding dimensional deviations, the specific context may include, but is not limited to, relevant standards for dimensional tolerances.

Claims

1. A rectifier bridge module with current monitoring function, including pins (1), carrier board (2), bridge (4), current monitoring bridge (53), Hall current sensor (5), insulating cover (92), and six rectifier diodes (3). Its characteristics are, The carrier board (2), the bridge (4), the current monitoring bridge (53), the Hall current sensor (5), and the rectifier diode (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 from left to right, the three middle conductive plates (22) are arranged from top to bottom, and the current monitoring conductive plate (52) is located below the right conductive plate (23); the left conductive plate (21), the middle conductive plate (22), the right conductive plate (23), and the current monitoring conductive plate (52) are all fixed on the substrate (29), the substrate (29) is insulating and its cross-section is rectangular; the rectifier diode The diode (3) includes three left diodes (31) and three right diodes (32). The negative terminals of the three left diodes (31) are respectively welded to the left conductive plate (21), and the negative terminals of the three right diodes (32) are respectively welded to the three middle conductive plates (22). The two ends of the three bridges (4) are respectively welded to the positive terminals of the left diodes (31) and the middle conductive plates (22) so that the three bridges (4) are arranged in parallel from top to bottom. The two ends of the other three bridges (4) are respectively welded to the positive terminals of the right diodes (32) and the right conductive plates (23) so that the other three bridges (4) are arranged in parallel from top to bottom. The two ends of the current monitoring 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 to a U-shaped magnetic core (51) and fixed in the middle of the current monitoring bridge (53). The U-shaped magnetic core (51) surrounds the middle of the current monitoring bridge (53).

2. The rectifier bridge module with current monitoring function according to claim 1, characterized in that, The U-shaped magnetic core (51) is fixed to the middle of the current monitoring bridge (53) with high-temperature glue.

3. The rectifier bridge module with current monitoring function according to claim 1, characterized in that, The upper left end of the lowest middle conductive plate (22) and the upper right end of the middle middle conductive plate (22) extend to form L-shaped extensions (221), and two of the three AC pins (11) are respectively set on the two extensions (221).

4. The rectifier bridge module with current monitoring function according to claim 1, characterized in that, The insulating cover (92) has a power connection hole (7), and the VCC, GND and Vout terminals of the Hall current sensor (5) are exposed from the power connection hole (7).

5. The rectifier bridge module with current monitoring function according to claim 1, characterized in that, It also includes a thermistor (6), which is fixed on the left conductive plate (21), and the carrier plate (2) is a copper-clad ceramic plate.

6. The rectifier bridge module with current monitoring function according to claim 5, characterized in that, The thermistor (6) is a glass-encapsulated thermistor, which is fixed to the left conductive plate (21) by high-temperature glue.

7. The rectifier bridge module with current monitoring function according to claim 1, characterized in that, It also includes a mounting base (91), which is fixedly connected to the insulating cover (92) and attached to the bottom end of the base plate (29).

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