Power module and uninterruptible power supply

Abstract

The application provides a power module and an uninterruptible power supply, and belongs to the technical field of power supplies. The power module comprises a shell, a power board, a power connector and a copper bar assembly. The power board and the copper bar assembly are arranged in the interior of the shell, and the copper bar assembly comprises a plurality of copper bars. The power connector is arranged on the shell wall of the shell, and the power connector comprises a plurality of terminals. The power connector is electrically connected with the power board through the plurality of copper bars, each terminal of the plurality of terminals has an outer end extending outward of the shell and an inner end extending inward of the shell, one end of the plurality of copper bars is connected with the power board, and the other end is connected with the inner end of the terminal. The application connects the power connector with the power board through the copper bar assembly, and the assembly efficiency of the power module can be improved.

Description

Technical Field

[0001] This application relates to the field of power supply technology, and in particular to a power module and an uninterruptible power supply. Background Technology

[0002] An uninterruptible power supply (UPS) is a device that continuously and uninterruptedly supplies power to a load. A UPS consists of multiple power modules. Each power module includes a power board, a power input connector, and a power output connector. The power board converts the AC or DC power input through the power input connector into stable AC power and outputs this stable AC power to the load through the power output connector.

[0003] In related technologies, the power input connector and the power output connector are connected to the power board via cables.

[0004] When assembling the power input connector, power output connector, and power board, multiple cables connected to the power input connector and power output connector need to be bent and shaped so that the end positions of the cables match the positions of multiple terminals on the power board. This reduces the assembly efficiency of the power input connector and power output connector. Utility Model Content

[0005] This application provides a power module and an uninterruptible power supply (UPS). The power board and power connector of the power module are connected by a copper busbar assembly, resulting in high assembly efficiency of the power module. The technical solutions of the power module and UPS are described below.

[0006] In a first aspect, this application provides a power module. The power module includes a housing, a power board, a power connector, and a copper busbar assembly. The power board and the copper busbar assembly are disposed inside the housing, and the copper busbar assembly includes multiple copper busbars. The power connector is disposed on the housing wall and includes multiple terminals. The power connector is electrically connected to the power board via the multiple copper busbars. Each of the multiple terminals has an outer end facing outward from the housing and an inner end facing inward from the housing in the extending direction. One end of the multiple copper busbars is connected to the power board, and the other end is connected to the inner end of the terminal. The power connector is either a power input connector or a power output connector.

[0007] The technical solution provided in this application connects the power board to the copper busbar assembly via a power connector through multiple terminals. Compared to related technologies where the power connector connects to the power board via cables, the copper busbar assembly does not require bending or shaping, thus improving the assembly efficiency of the power module. Furthermore, copper busbars offer superior heat dissipation compared to cables, and a stable heat dissipation distance can be maintained between copper busbars, reducing the possibility of overheating failure in the power module. Moreover, copper busbars can transmit larger currents, facilitating compatibility with higher module power capacities.

[0008] In one implementation, at least one of the plurality of copper busbars includes a first connecting segment, an intermediate segment, and a second connecting segment connected in sequence. The first connecting segment is connected to the inner end of the terminal of the power connector, and the second connecting segment is connected to the power board.

[0009] In one implementation, the middle section extends in the height direction of the power module, and the second connecting section extends in the depth direction of the power module.

[0010] In one implementation, the intermediate section is covered with insulating material. This prevents short circuits between different phases or poles when the arc moves to the intermediate section of the copper busbar, thus improving the reliability of the power module.

[0011] In one implementation, the power connector includes a front housing, a rear cover, and multiple terminals. The terminals are located on the front housing. The rear cover is connected to the front housing, and a first connecting segment is located between the front housing and the rear cover in the extending direction of the terminals. Thus, when an electric arc moves to the first connecting segment of the copper busbar, the rear cover can shield the arc, preventing it from short-circuiting the first connecting segment of different phases or polarities, reducing the possibility of short-circuit faults in the power module, and improving the reliability of the power module.

[0012] In one implementation, the stiffness of the middle section is less than that of the first connecting section and the second connecting section.

[0013] The technical solution provided in this application, due to the lower rigidity of the middle section, allows for easier adaptive deformation or deflection of the middle section during power module assembly, making it easier for the second connecting section to connect with the power board and improving assembly convenience. For example, due to manufacturing tolerances, when the power connector is installed at its target position on the housing, there may be a deviation between the position of the second connecting section and the connection position (such as the circuit breaker) on the power board. Since the middle section is relatively easy to bend, the operator can adaptively bend it to match the position of the second connecting section with the connection position on the power board.

[0014] In addition, the high rigidity of the first and second connecting sections improves the reliability of the connection between the first connecting section and the terminal, as well as the reliability of the connection between the second connecting section and the terminal on the power board.

[0015] In one implementation, the intermediate section is a flexible copper busbar. The first connecting section is a rigid copper busbar and is welded to the intermediate section. The second connecting section is a rigid copper busbar and is welded to the intermediate section; alternatively, the second connecting section is a flexible copper busbar and is integrally connected to the intermediate section, with the multiple layers of copper foil in the flexible copper busbar of the second connecting section being pressed together. This allows the stiffness of the intermediate section to be less than that of the first and second connecting sections. Although both are flexible copper busbars, the second connecting section has multiple layers of copper foil pressed together, while the intermediate section does not, resulting in a greater stiffness for the second connecting section than for the intermediate section.

[0016] In one implementation, the housing wall containing the power connector is the rear wall of the power module along the depth direction, and the terminals extend in the same direction as the depth direction. Specifically, after the power module is inserted into a slot in the rack, the power connector on the rear wall of the power module mates with the power interface at the bottom of the slot.

[0017] In one implementation, the power connector includes three-phase terminals among its multiple terminals, and multiple copper busbars each include a copper busbar corresponding to each phase of the three-phase terminals. The power connector is either a power output connector or a power output connector. The multiple copper busbars can transmit AC power input from the three-phase terminals to the power board, or output AC power from the power board to the three-phase terminals.

[0018] In one implementation, the power connector includes positive and negative terminals among its multiple terminals. Multiple copper busbars include positive and negative busbars, one end of which is connected to the power board, and the other end is connected to the positive and negative terminals, respectively. This power connector is a power input connector. The positive and negative copper busbars are used to output the DC power input from the positive and negative terminals to the power board.

[0019] In one implementation, the copper busbar is riveted, welded, or screwed to the terminal. Riveting, welding, or screwing offers higher reliability compared to the wire-to-terminal crimping connection method used in related technologies. Welding can be ultrasonic welding or laser welding.

[0020] In one implementation, a power board is provided with a power conversion circuit and a fuse, with one end of the fuse connected to the power conversion circuit and the other end connected to a copper busbar.

[0021] Secondly, this application provides an uninterruptible power supply (UPS). The UPS includes a cabinet and a plurality of power modules as described in any of the first aspects located within the cabinet. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of an application scenario of a UPS provided in an embodiment of this application;

[0023] Figure 2 This is a schematic diagram of the internal circuit principle of a UPS provided in an embodiment of this application;

[0024] Figure 3 This is a schematic diagram of the circuit principle of a power module provided in an embodiment of this application;

[0025] Figure 4 This is a schematic diagram of the circuit principle of a power module provided in an embodiment of this application;

[0026] Figure 5 This is a front view of a UPS provided in an embodiment of this application;

[0027] Figure 6 This is a schematic diagram of the front side of a power module provided in an embodiment of this application;

[0028] Figure 7 This is a schematic diagram of the rear side of a power module provided in an embodiment of this application;

[0029] Figure 8 This is a schematic diagram of a connection method between a power input connector and a power board in related technologies;

[0030] Figure 9 This is a schematic diagram illustrating a connection method between a power input connector and a power board according to an embodiment of this application;

[0031] Figure 10 This is an exploded view of a power input connector and copper busbar assembly provided in an embodiment of this application;

[0032] Figure 11 This is a schematic diagram of a copper busbar provided in an embodiment of this application;

[0033] Figure 12 This is a schematic diagram of a copper busbar and terminal provided in an embodiment of this application;

[0034] Figure 13 This is a schematic diagram of a power input connector and copper busbar assembly provided in an embodiment of this application;

[0035] Figure 14 This is a schematic diagram of another power input connector and copper busbar assembly provided in an embodiment of this application;

[0036] Figure 15 This is an exploded view of another power input connector and copper busbar assembly provided in an embodiment of this application.

[0037] Legend

[0038] 10. Power module; 20. Bypass module; 30. Cabinet; 301. Slot;

[0039] 1. Shell; 11. Front wall; 12. Rear wall;

[0040] 2. Power board, 210. Power conversion circuit, 211. Rectifier circuit, 212. Inverter circuit, 213. DC-DC converter circuit, 220. Fuse;

[0041] 3. Power input connector, 31. Front housing, 311. Snap-on, 32. Rear cover, 321. Snap-on hole, 33. Terminal, 331. Phase A terminal, 332. Phase B terminal, 333. Phase C terminal, 334. Positive terminal, 335. Negative terminal, 336. Ground terminal;

[0042] 4. Power output connector;

[0043] 5. Copper busbar assembly; 50. Copper busbar; 501. First connecting section; 5011. Mounting hole; 502. Second connecting section; 503. Intermediate section; 504. Insulating material; 51. Phase A copper busbar; 52. Phase B copper busbar; 53. Phase C copper busbar; 54. Positive electrode copper busbar; 55. Negative electrode copper busbar; 56. Ground electrode copper busbar.

[0044] X: width direction; Y: depth direction; Z: height direction. Detailed Implementation

[0045] An uninterruptible power supply (UPS) is used to provide uninterrupted power to loads, such as servers, lighting, or temperature control systems in data centers, commercial buildings, or residential buildings.

[0046] Figure 1 A schematic diagram of an application scenario for a UPS is shown. For example... Figure 1 As shown, the UPS power input includes multiple AC inputs. Figure 1 The diagram illustrates two AC inputs. One AC input comes from mains power, serving as the main input. The other AC input can come from a generator, serving as a bypass input. Both mains power and the generator can supply power to the UPS through the input distribution cabinet. (Continue to refer to...) Figure 1 As shown, the UPS power input also includes a DC input, which comes from a battery. The battery can be integrated into the UPS cabinet or located in a separate battery cabinet. Figure 1 As shown, a UPS can supply power to multiple loads through its output distribution cabinet.

[0047] Figure 2 A schematic diagram of the circuit principle corresponding to the UPS is shown. Figure 2 As shown, the UPS includes multiple power modules 10 and a bypass module 20. Each power module 10 has an AC input and a DC input. The AC input is connected to the mains input to receive power from the mains. The DC input is connected to a battery to receive power from the battery. The bypass module 20 has its power input connected to the bypass input to receive power from a generator.

[0048] like Figure 2 As shown, each power module 10 contains a power board 2 including a power conversion circuit 210, which includes a rectifier circuit 211, an inverter circuit 212, and a DC-DC converter circuit 213. The input terminal of the rectifier circuit 211 is electrically connected to the main input, and its output terminal is connected to the input terminal of the inverter circuit 212. The output terminal of the inverter circuit 212 is used to connect to the load. The input terminal of the DC-DC converter circuit 213 is electrically connected to the battery, and its output terminal is connected to the input terminal of the inverter circuit 212.

[0049] Thus, as Figure 2 As shown, under normal main input conditions, the main input provides AC voltage to rectifier circuit 211. Rectifier circuit 211 converts the AC voltage of the main input into a stable DC voltage and outputs it to inverter circuit 212. Inverter circuit 212 converts the stable DC voltage into a stable AC voltage and supplies power to the load. Under abnormal main input conditions, the battery provides DC voltage to DC-DC converter circuit 213. DC-DC converter circuit 213 converts the DC voltage into a stable DC voltage and outputs it to inverter circuit 212. Inverter circuit 212 converts the stable DC voltage into a stable AC voltage and supplies power to the load.

[0050] Because the battery's energy storage is limited, in the event of a continuous main input anomaly, the UPS switches its power supply from the battery input to the bypass input. The bypass input provides AC power to the bypass module 20, which then directly supplies the AC power to the load. Therefore, the UPS can provide continuous power to the load.

[0051] Figure 3 for Figure 2 A schematic diagram of the structure of any one of the power modules 10 is shown below, such as Figure 3As shown, the power module 10 includes a housing 1 and a power board 2 located inside the housing 1. The power board 2 integrates a power conversion circuit 210, which includes the aforementioned rectifier circuit 211, inverter circuit 212, and DC-DC converter circuit 213. Figure 3 As shown, a power input connector 3 and a power output connector 4 are installed on the housing 1.

[0052] As described above, the power input of the power module 10 includes AC input and DC input. In one embodiment, such as... Figure 3 As shown, the AC input and DC input are integrated into a single power input connector 3, which includes an AC input terminal and a DC input terminal. In another embodiment, the AC input forms an AC input connector, and the DC input forms a single DC input connector. This application uses the integration of AC and DC inputs into a single power input connector 3 as an example for illustration.

[0053] like Figure 3 As shown, to improve the reliability and safety of the power module 10, the power module will also include a fuse 220. For example, a fuse 220 is arranged at the input terminal of the power conversion circuit 210, and a fuse 220 is also arranged at the output terminal of the power conversion circuit 210. Since the power conversion circuit 210 includes AC input and DC input, then, referring to... Figure 3 As shown, a fuse 220 is arranged at both the AC and DC input terminals of the power conversion circuit 210. The AC voltage generally includes multiple phases, such as two-phase or three-phase AC voltage, while the DC voltage includes a positive and a negative terminal.

[0054] Figure 4 for Figure 2 The schematic diagram of any one of the power modules 10 shown is specifically as follows: Figure 3 A schematic diagram illustrating the multiphase, positive, and negative electrodes. Figure 4 Multiphase alternating current includes three phase lines and one neutral line, denoted as phase A, phase B, phase C, and line N. (Reference) Figure 4As shown, on the input side of the power module, a fuse 220 is connected between the A-phase input of the rectifier circuit 211 and the A-phase input of the power input connector 3. A fuse 220 is also connected between the B-phase input of the rectifier circuit 211 and the B-phase input of the power input connector 3. A fuse 220 is also connected between the C-phase input of the rectifier circuit 211 and the C-phase input of the power input connector 3. Since the neutral (N) line is not energized, no fuse 220 is needed between the neutral (N) line input of the rectifier circuit 211 and the neutral (N) line input of the power input connector 3. A fuse 220 is connected between the positive input of the DC-DC converter circuit 213 and the positive input of the power input connector 3. A fuse 220 is also connected between the negative input of the DC-DC converter circuit 213 and the negative input of the power input connector 3.

[0055] Continue to refer to Figure 4 As shown, on the output side of power module 10, a fuse 220 is connected between the A-phase output of inverter circuit 212 and the A-phase output of power output connector 4. A fuse 220 is also connected between the B-phase output of inverter circuit 212 and the B-phase output of power output connector 4. A fuse 220 is also connected between the C-phase output of inverter circuit 212 and the C-phase output of power output connector 4. No fuse 220 is required between the N-line output of inverter circuit 212 and the N-line output of power output connector 4.

[0056] Of course, in other examples, the power module 10 may not have a fuse 220, or the fuse 220 may be located elsewhere, so that the power input connector 3 is directly connected to the rectifier circuit 211 or the DC-DC converter circuit 213, and the power output connector 4 is directly connected to the inverter circuit 212.

[0057] Figure 5 A front view of a UPS is shown. Figure 6 A schematic diagram of the front side of a power module 10 is shown. Figure 7 A schematic diagram of the rear side of a power module 10 is shown. (As shown) Figure 5 As shown, the UPS cabinet 30 has multiple slots 301, and the power module 10 is inserted into the slots 301 of the cabinet 30.

[0058] The bottom of slot 301 can have a power input interface (as the input terminal of the UPS) and a power output interface (as the output terminal of the UPS). The power input connector 3 of each power module 10 is inserted into one of the power input interfaces, and the power output connector 4 of each power module 10 is inserted into one of the power output interfaces. Additionally, the power input connector and power output connector of the bypass module 20 are also inserted into one of the power input interfaces. The power input interfaces within the cabinet are used to connect to power supply equipment, such as connecting to AC power or a generator. Since the power modules also have DC input, the power input interfaces are also connected to batteries.

[0059] like Figure 5-7 As shown, for ease of description of the technical solutions provided in the embodiments of this application, the embodiments of this application define the width direction X, the depth direction Y, and the height direction Z, which are mutually perpendicular. Figure 6 and Figure 7 As shown, the housing 1 of the power module 10 includes a front wall 11 and a rear wall 12 arranged along the depth direction Y. The power input connector 3 and the power output connector 4 are disposed on the rear wall 12, which is positioned opposite to the bottom of the slot 301.

[0060] Figure 8 A schematic diagram illustrating the connection method between the power connector (taking power input connector 3 as an example) and the power board 2 in the related art is shown. Figure 8 As shown, the power connector is connected to the power board via a cable. One end of the cable is connected to the terminal of the power connector, and the other end is used to connect to the power board 2.

[0061] When assembling the power module 10, the power input connector 3 and power output connector 4 are already connected to cables. Therefore, it is only necessary to install the power input connector 3 and power output connector 4 at the target positions on the housing 1 and connect the cables to the power board 2. However, before connecting the cables to the power board 2, multiple cables need to be bent and shaped to match the cable ends with multiple connection points (such as fuses 220) on the power board 2. This reduces the assembly efficiency of the power module 10. Furthermore, with the increasing demand for higher power density in power modules, the cable diameter is also increasing, making cable bending and shaping more difficult and reducing the assembly space, which further reduces the assembly efficiency of the power module 10. Moreover, due to the limited assembly space, the cable diameter cannot be too large, making it difficult for the cables to be compatible with higher power modules 10. In addition, some residual stress remains after the cables are bent and shaped, which makes the connection between the cables and terminals (e.g., Figure 8The area outlined in the dashed box may experience cable sheathing damage, resulting in exposed wire cores. When the wire cores of cables of different phases or different poles are exposed, the power conversion circuit 210 may generate an electric arc. Therefore, if the arc short-circuits the wire cores of cables of different phases or different poles, the power module 10 will malfunction.

[0062] In view of the above-mentioned technical problems, this application provides a power module 10. Figure 6 and Figure 7 This can be considered as the outline drawing of the power module 10. Figure 3 and Figure 4 This can be considered as the circuit schematic of the power module 10. Figure 9 A schematic diagram showing the connection between the power connector of the power module 10 and the power board 2 is shown.

[0063] like Figures 3-7 As shown, the power module 10 includes a housing 1, a power board 2, and power connectors (including a power input connector 3 and a power output connector 4). The power board 2 is disposed inside the housing 1. The power connectors are disposed on the housing wall of the housing 1, and the power connectors include multiple terminals 33, each terminal 33 having an outer end facing outwards from the housing 1 in the extending direction (which can be the depth direction Y) and an inner end facing inwards from the housing 1. Figure 9 As shown, the power module 10 also includes a copper busbar assembly 5, which is located inside the housing 1 and includes multiple copper busbars 50. The power connector is electrically connected to the power board 2 through the multiple copper busbars 50, with one end of each copper busbar 50 connected to the power board 2 and the other end connected to the inner end of the terminal 33.

[0064] The technical solution provided in this application embodiment connects the power board 2 via multiple copper busbars 50 of the copper busbar assembly 5 using a power connector. Compared to the related technology where the power connector connects the power board 2 via cables, the copper busbar assembly 5 does not require bending or shaping, thus improving the assembly efficiency of the power module 10. Furthermore, the copper busbars 50 have superior heat dissipation performance compared to cables, and a stable heat dissipation distance can be maintained between them, reducing the possibility of overheating failure in the power module 10. Moreover, the copper busbars 50 can transmit larger currents, which is beneficial for compatibility with higher module power capacities.

[0065] This application does not limit whether the power connector connected to the power board 2 via the copper busbar assembly 5 is the power input connector 3 or the power output connector 4. In some examples, both the power input connector 3 and the power output connector 4 are connected to the power board 2 via the copper busbar assembly 5. In other examples, the power input connector 3 is connected to the power board 2 via the copper busbar assembly 5, and the power output connector 4 is connected to the power board 2 via a cable. In still other examples, the power input connector 3 is connected to the power board 2 via a cable, and the power output connector 4 is connected to the power board 2 via the copper busbar assembly 5.

[0066] This application embodiment does not limit the connection position of the copper busbar 50 of the copper busbar assembly 5 on the power board 2. In some examples, such as Figure 3 and Figure 4 As shown, the power board 2 includes a power conversion circuit 210 and a fuse 220. One end of the fuse 220 is connected to the power conversion circuit 210, and the other end is connected to a copper busbar 50. That is, the copper busbar 50 is connected to one end of the fuse 220. Of course, in some other examples, the copper busbar 50 may not be connected to the fuse 220, but may be directly connected to the power conversion circuit 210.

[0067] In some examples, such as Figure 10 As shown, the power connector includes an A-phase terminal 331, a B-phase terminal 332, and a C-phase terminal 333. Multiple copper busbars 50 include an A-phase copper busbar 51, a B-phase copper busbar 52, and a C-phase copper busbar 53. One end of each of the A-phase copper busbar 51, B-phase copper busbar 52, and C-phase copper busbar 53 is connected to the power board 2, and the other end is connected to the A-phase terminal 331, B-phase terminal 332, and C-phase terminal 333, respectively.

[0068] In some examples, such as Figure 10 As shown, the power connector includes multiple A-phase terminals 331, multiple B-phase terminals 332, and multiple C-phase terminals 333. One end of the A-phase copper busbar 51 is connected to the power board 2, and the other end is connected to the multiple A-phase terminals 331. One end of the B-phase copper busbar 52 is connected to the power board 2, and the other end is connected to the multiple B-phase terminals 332. One end of the C-phase copper busbar 53 is connected to the power board 2, and the other end is connected to the multiple C-phase terminals 333.

[0069] In related technologies, each terminal 33 needs to be connected to a cable. However, in this embodiment, a copper busbar 50 is set to connect all terminals 33 of the same phase, so that the total number of copper busbars 50 is less than the total number of cables. This also improves the assembly efficiency of the power module 10.

[0070] In some examples, such as Figure 10As shown, the power connector includes two A-phase terminals 331, two B-phase terminals 332, and two C-phase terminals 333. One end of the A-phase copper busbar 51 is connected to the power board 2, and the other end is connected to the two A-phase terminals 331. One end of the B-phase copper busbar 52 is connected to the power board 2, and the other end is connected to the two B-phase terminals 332. One end of the C-phase copper busbar 53 is connected to the power board 2, and the other end is connected to the two C-phase terminals 333.

[0071] In some examples, such as Figure 10 As shown, the power connector also includes an N-phase terminal 336. There can be only one N-phase terminal 336. The N-phase terminal 336 connects to the N-phase copper busbar 56 of the copper busbar assembly.

[0072] In some examples, such as Figure 10 As shown, the power connector includes a positive terminal 334 and a negative terminal 335. The multiple copper busbars 50 also include a positive copper busbar 54 and a negative copper busbar 55, one end of which is connected to the power board 2, and the other end is connected to the positive terminal 334 and the negative terminal 335, respectively.

[0073] In some examples, such as Figure 10 As shown, the power connector includes multiple positive terminals 334 and multiple negative terminals 335. One end of the positive copper busbar 54 is connected to the power board 2, and the other end is connected to the multiple positive terminals 334. One end of the negative copper busbar 55 is connected to the power board 2, and the other end is connected to the multiple negative terminals 335. For example, the power connector includes three positive terminals 334 and three negative terminals 335. The three positive terminals 334 are connected to the same positive copper busbar 54. The three negative terminals 335 are connected to the same negative copper busbar 55.

[0074] The technical solution provided in this application embodiment connects all terminals 33 of the same polarity using a copper busbar 50, so that the total number of copper busbars 50 is less than the total number of cables, thus improving the assembly efficiency of the power module 10.

[0075] This application does not limit the connection method between the copper busbar 50 and the terminal 33. The copper busbar 50 can be riveted, welded, or screwed to the terminal 33. Welding can be ultrasonic welding or laser welding. Among these methods, riveting, welding, or screwing connections are more reliable than the connection method of crimping the cable to the terminal 33 in related technologies.

[0076] In some examples, such as Figure 11 and Figure 12As shown, the copper busbar 50 includes a first connecting segment 501, an intermediate segment 502, and a second connecting segment 503 connected in sequence. The first connecting segment 501 is connected to the terminal 33 of the power connector, and the second connecting segment 503 is connected to the power board 2. For example, both the first connecting segment 501 and the second connecting segment 503 are bent relative to the intermediate segment 502.

[0077] In some examples, such as Figure 11 and Figure 12 As shown, the first connecting segment 501 is provided with a mounting hole 5011, and the terminal 33 is fixed to the first connecting segment 501 through the mounting hole 5011. For example, a screw can pass through the mounting hole 5011 and be tightened in the terminal 33 to fix the terminal 33 to the first connecting segment 501.

[0078] In some examples, such as Figure 11 As shown, the extension direction of the middle section 502 is the height direction Z of the power module 10, and the extension direction of the second connecting section 503 is the depth direction Y of the power module 10.

[0079] The following explains the insulation protection method for copper busbars of 50mm. In some examples, such as... Figure 11 and Figure 12 As shown, the intermediate section 502 is covered with insulating material 504. This prevents short circuits between different phases or poles of the intermediate section 502 after the arc moves to the intermediate section 502 of the copper busbar 50, thus improving the reliability of the power module. The implementation of the insulating material 504 will be explained below.

[0080] In some examples, the outer wall of the intermediate section 502 is coated with an insulating coating. In other examples, the intermediate section 502 is fitted with a heat-shrink tubing. In still other examples, the outer wall of the intermediate section 502 is wrapped with insulating tape.

[0081] In some examples, such as Figure 13 As shown, the power connector includes a front housing 31, a rear cover 32, and multiple terminals 33. The terminals 33 are located on the front housing 31, with one end for external connection and the other end connected to a first connection segment 501. The rear cover 32 is connected to the front housing 31, and the first connection segment 501 is located between the front housing 31 and the rear cover 32. Thus, when the electric arc moves to the first connection segment 501 of the copper busbar 50, the rear cover 32 can shield the arc, preventing it from short-circuiting the first connection segment 501 of different phases or polarities, reducing the possibility of short-circuit faults in the power module, and improving the reliability of the power module.

[0082] In some examples, the front cover 31 and the rear cover 32 snap together. For example, as shown... Figure 13As shown, the front cover 31 has a buckle 311 on its side wall and the rear cover 32 has a locking hole 321 on its side wall, and the buckle 311 engages with the locking hole 321.

[0083] In some examples, the stiffness of the intermediate section 502 is less than that of the first connecting section 501 and the second connecting section 503. This lower stiffness of the intermediate section 502 allows for more adaptive deformation or deflection during power module assembly, making it easier for the second connecting section 503 to connect to the power board 2, thus improving assembly convenience.

[0084] For example, due to manufacturing tolerances, when the power connector is installed at the target position on the housing 1, the position of the second connecting section 503 may deviate from the position of the connection position (such as the circuit breaker 220) on the power board 2. Since the middle section 502 is more prone to bending, the operator can make the middle section 502 bend adaptively so that the position of the second connecting section 503 matches the position of the connection position on the power board 2.

[0085] In addition, since the first connecting section 501 and the second connecting section 503 have high rigidity, the reliability of the connection between the first connecting section 501 and the terminal 33 and the reliability of the connection between the second connecting section 503 and the power board 2 are improved.

[0086] In some examples, the intermediate section 502 is a soft copper busbar, and the first connecting section 501 is a hard copper busbar, which is welded to the intermediate section 502. In this way, the connection between the first connecting section 501 and the terminal 33 is more reliable and easier to weld, rivet or screw together.

[0087] In some examples, the second connection segment 503 is a hard copper busbar and is welded to the middle segment 502.

[0088] In other examples, the second connecting segment 503 is a flexible copper busbar and is integrally connected to the intermediate segment 502. Furthermore, the flexible copper busbar of the second connecting segment 503 comprises multiple layers of copper foil pressed together. Thus, although both are flexible copper busbars, the rigidity of the second connecting segment 503 is greater than that of the intermediate segment 502 because of the multiple layers of copper foil pressed together. It should be noted that because the second connecting segment 503 comprises multiple layers of copper foil pressed together, resulting in greater rigidity, it can also be considered a rigid copper busbar. That is, the second connecting segment 503 can be considered either a flexible copper busbar pressed together or a rigid copper busbar.

[0089] It should be noted that, Figure 14 and Figure 15A schematic diagram of another power connector (such as power input connector 3) and copper busbar assembly 5 is shown. Unlike the previous power connector and copper busbar assembly 5, Figure 14 and Figure 15 Each copper busbar 50 shown is connected to a terminal 33. That is, the power connector includes an A-phase terminal, a B-phase terminal, a C-phase terminal, an N-phase terminal, a positive terminal, and a negative terminal. Each terminal 33 is connected to one copper busbar 50. Additionally, Figure 14 and Figure 15 The power connector shown also includes a front housing 31 and a rear cover 32, and a section of the copper busbar 50 for connecting the terminal 33 is also located between the front housing 31 and the rear cover 32.

[0090] This application also provides a UPS, such as Figure 1 and Figure 5 As shown, the UPS includes a cabinet 30 and multiple power modules 10 located within the cabinet 30. The power modules 10 can be connected in parallel to share the load evenly. If one power module 10 fails, it automatically disconnects from the system, and the load is taken over by the other power modules 10.

[0091] In some examples, such as Figure 1 As shown, the UPS also includes a bypass module 20.

[0092] In some examples, such as Figure 5 As shown, the cabinet 30 includes multiple slots 301, in which multiple power modules 10 are inserted. The power connector on the rear wall of the power module 10 is electrically connected to the power interface provided at the bottom of the slot 301.

[0093] It should be noted that for details regarding UPS, please refer to the aforementioned content, which will not be repeated here.

[0094] The above description is merely an optional embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the principles of this application should be included within the protection scope of this application.

Claims

1. A power module, characterized in that, Includes housing (1), power board (2), power connector and copper busbar assembly (5); The power board (2) and the copper busbar assembly (5) are disposed inside the housing (1), and the copper busbar assembly (5) includes a plurality of copper busbars (50); the power connector is disposed on the shell wall of the housing (1), and the power connector includes a plurality of terminals (33). The power connector is electrically connected to the power board (2) via the plurality of copper busbars (50). Each of the plurality of terminals (33) has an outer end facing outward from the housing (1) and an inner end facing inward from the housing (1) in the extending direction. One end of the plurality of copper busbars (50) is connected to the power board (2), and the other end is connected to the inner end of the terminal (33).

2. The power module according to claim 1, characterized in that, One or more of the plurality of copper busbars (50) include a first connecting segment (501), an intermediate segment (502), and a second connecting segment (503) connected in sequence. The first connecting segment (501) is connected to the inner end of the terminal (33) of the power connector, and the second connecting segment (503) is connected to the power board (2).

3. The power module according to claim 2, characterized in that, The extension direction of the intermediate section (502) is the height direction (Z) of the power module, and the extension direction of the second connecting section (503) is the depth direction (Y) of the power module.

4. The power module according to claim 2, characterized in that, The intermediate section (502) is covered with insulating material.

5. The power module according to any one of claims 2-4, characterized in that, The power connector includes a front housing (31), a rear cover (32), and the plurality of terminals (33). The plurality of terminals (33) are disposed on the front shell (31); the rear cover (32) is connected to the front shell (31), and the first connecting segment (501) is disposed between the front shell (31) and the rear cover (32) in the extending direction of the terminals (33).

6. The power module according to any one of claims 2-4, characterized in that, The stiffness of the intermediate section (502) is less than that of the first connecting section (501) and the second connecting section (503).

7. The power module according to any one of claims 2-4, characterized in that, The intermediate section (502) is a soft copper busbar; The first connecting segment (501) is a hardened copper busbar and is welded to the intermediate segment (502); The second connecting segment (503) is a hard copper busbar and is welded to the middle segment (502); or, the second connecting segment (503) is a soft copper busbar and is integrally connected to the middle segment (502), and the soft copper busbar of the second connecting segment (503) includes multiple layers of copper foil sheets pressed together.

8. The power module according to any one of claims 1-4, characterized in that, In the depth direction (Y) of the power module, the housing wall where the power connector is located is the rear wall (12) of the power module, and the extension direction of the terminal (33) is the same as the depth direction (Y).

9. The power module according to any one of claims 1-4, characterized in that, The plurality of terminals (33) include three-phase terminals, and the plurality of copper busbars (50) include copper busbars (50) corresponding to each phase terminal of the three-phase terminals respectively.

10. The power module according to any one of claims 1-4, characterized in that, The plurality of terminals (33) include a positive terminal (334) and a negative terminal (335); The plurality of copper busbars (50) include a positive copper busbar (54) and a negative copper busbar (55). One end of the positive copper busbar (54) and the negative copper busbar (55) are connected to the power board (2), and the other end is connected to the positive terminal (334) and the negative terminal (335) respectively.

11. The power module according to any one of claims 1-4, characterized in that, The copper busbar (50) is riveted, welded or screwed to the terminal (33).

12. The power module according to any one of claims 1-4, characterized in that, The power board (2) is provided with a power conversion circuit (210) and a fuse (220). One end of the fuse (220) is connected to the power conversion circuit (210), and the other end is connected to a copper busbar (50).

13. An uninterruptible power supply, characterized in that, The uninterruptible power supply (100) includes a cabinet and a plurality of power modules (10) as described in any one of claims 1-12 located in the cabinet.

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