VOLTAGE CONVERSION SYSTEM INCLUDING A DOUBLE-SIDED DC LINK CAPACITOR SYSTEM

Abstract

Voltage conversion system (100) comprising a double-sided DC link capacitor system (200): a voltage conversion circuit (202); and the double-sided DC-link capacitor system (200) which is electrically coupled to the voltage conversion system (100), the double-sided DC-link capacitor system (200) comprising: a busbar system (210); a first capacitor unit (206) which is arranged on a first side of the busbar system (210) and electrically coupled to the busbar system (210); and a second capacitor unit (208) which is arranged on a second side of the busbar system (210) and is electrically coupled to the busbar system (210), wherein the second side of the busbar system (210) is opposite the first side of the busbar system (210), wherein a current flows through the busbar system (210) to the first capacitor unit (206) in a first current flow direction (212) and to the second capacitor unit (208) in a second current flow direction (214), wherein the second current flow direction (214) is opposite to the first current flow direction (212); wherein the first capacitor unit (206) comprises a first set of capacitors (500a, 500b, 500c) arranged on the first side of the busbar system (210); wherein the second capacitor unit (208) comprises a second set of capacitors arranged on the second side of the busbar system (210); and where a first number of capacitors in the first set of capacitors (500a, 500b, 500c) is the same as a second number of capacitors in the second set of capacitors; wherein the first set of capacitors (500a, 500b, 500c) is arranged in a C configuration with respect to the voltage conversion circuit (202) on the first side of the busbar system (210) and the second set of capacitors in the C configuration with respect to the voltage conversion circuit (202) is arranged on the second side of the busbar system (210).

Description

INTRODUCTION

[0001] The technical field generally refers to vehicles and in particular to a voltage conversion system that includes a double-sided DC link capacitor system.

[0002] Most electric motors incorporate a voltage conversion system. Voltage conversion systems have an inherent power loop in which high currents flow from a DC link capacitor to high-side power modules, to low-side power modules, and back. This power loop generates magnetic fields that create parasitic inductance. Wide bandgap (WBG) inverters, commonly used in electric vehicles, have faster switching stages where the presence of even small parasitic inductances can lead to significant voltage overshoot and / or generate high levels of electromagnetic interference (EMI), ringing, bearing currents, and switching losses, which can negatively impact the performance of the voltage conversion system and / or the motor.

[0003] The DC link capacitor typically contains several capacitors, often connected in a single-sided arrangement. This arrangement of capacitors can contribute to parasitic inductance levels during the operation of the voltage conversion system.

[0004] DE 10 2021 200 628 A1 describes a galvanically coupled DC-DC converter with a first side and a second side. The first side and the second side each have a first potential and a second potential. The DC-DC converter has a first and a second series connection, each consisting of a first, second, and third transistor array, which are connected in series via a first and a second connection point. The first series connection is located between the potentials of the first side. The second series connection is located between the potentials of the second side. The first connection point of the first series connection is connected to the first connection point of the second series connection via a first operating inductor. The second connection point of the first series connection is connected to the second connection point of the second series connection via a second operating inductor.

[0005] JP 2002 - 119 069 A describes a power converter equipped with a positive pole-side conductor and a negative pole-side conductor, which are connected in pairs to a plurality of positive and negative electrode terminals installed on a capacitor, and a semiconductor device is connected to the positive pole-side conductor and the negative pole-side conductor.

[0006] JP 2006 - 19 367 A describes a connection of electronic components, such as a plurality of electrolytic capacitors, and in particular a connecting body, a connecting structure for an electronic component, and an electronic component in which the inductance is reduced.

[0007] JP 2004 - 56 984 A describes a power conversion device with an inverter part to which a power module with a semiconductor element and an antiparallel connected diode is attached.

[0008] It is desirable to provide a voltage conversion system that incorporates a double-sided DC link capacitor system. Further desirable features and characteristics will become apparent from the detailed description below and the accompanying claims, which should be considered in conjunction with the accompanying drawings and the foregoing technical field and background. DESCRIPTION

[0009] A voltage conversion system according to the invention, which includes a double-sided DC link capacitor system, contains a voltage conversion circuit that is electrically coupled to the double-sided DC link capacitor system.The double-sided DC-link capacitor system comprises a busbar system; a first capacitor unit arranged on a first side of the busbar system and electrically coupled to the busbar system; and a second capacitor unit arranged on a second side of the busbar system and electrically coupled to the busbar system, the second side of the busbar system being opposite the first side of the busbar system, with a current flowing through the busbar system to the first capacitor unit in a first current flow direction and to the second capacitor unit in a second current flow direction, the second current flow direction being opposite to the first current flow direction.The first capacitor unit comprises a first set of capacitors arranged on the first side of the busbar system. The second capacitor unit comprises a second set of capacitors arranged on the second side of the busbar system. The first set of capacitors contains the same number of capacitors as the second set. The first set of capacitors is arranged in a C configuration with respect to the voltage conversion circuit on the first side of the busbar system, and the second set of capacitors is arranged in a C configuration with respect to the voltage conversion circuit on the second side of the busbar system.

[0010] In at least one embodiment, the first capacitor unit and the second capacitor unit are arranged on one and the other side of the busbar system.

[0011] In at least one embodiment, the first capacitor unit has a first capacitance value, the second capacitor unit has a second capacitance value, and the first capacitance value is equal to the second capacitance value.

[0012] In at least one embodiment, the first capacitor unit is a first single capacitor and the second capacitor unit is a second single capacitor.

[0013] In at least one embodiment, the voltage conversion circuit is an AC-DC conversion circuit, a DC-AC conversion circuit, an AC-AC conversion circuit, or a DC-DC conversion circuit.

[0014] In at least one embodiment, the first set of capacitors is arranged in a first row on the first side of the busbar system and the second set of capacitors is arranged in a second row on the second side of the busbar system.

[0015] In at least one embodiment, the first set of capacitors is arranged in a first plurality of adjacent rows on the first side of the busbar system and the second set of capacitors is arranged in a second plurality of adjacent rows on the second side of the busbar system.

[0016] In at least one embodiment, the first set of capacitors is arranged in a configuration with respect to the voltage conversion circuit on the first side of the busbar system.

[0017] In at least one embodiment, the first set of capacitors includes at least one capacitor with a third capacitance value and at least one capacitor with a fourth capacitance value, and the second set of capacitors includes at least one capacitor with the third capacitance value and at least one capacitor with the fourth capacitance value.

[0018] In at least one embodiment, the voltage conversion system includes a housing, wherein the voltage conversion circuit and a capacitor system are arranged in the housing; and a composite resin arranged in the housing to mechanically position the capacitor system within the housing with respect to the voltage conversion circuit and to electrically isolate the voltage conversion circuit from the capacitor system.

[0019] A vehicle with a voltage conversion system that includes a double-sided DC link capacitor system contains a voltage conversion circuit and a double-sided DC link capacitor system that is electrically coupled to the voltage conversion circuit.The double-sided DC-link capacitor system comprises a busbar system; a first capacitor unit arranged on a first side of the busbar system and electrically coupled to the busbar system; and a second capacitor unit arranged on a second side of the busbar system and electrically coupled to the busbar system, the second side of the busbar system being opposite the first side of the busbar system, with a current flowing through the busbar system to the first capacitor unit in a first current flow direction and to the second capacitor unit in a second current flow direction, the second current flow direction being opposite to the first current flow direction.

[0020] In at least one embodiment, the first capacitor unit and the second capacitor unit are arranged on one and the other side of the busbar system.

[0021] In at least one embodiment, the first capacitor unit has a first capacitance value, the second capacitor unit has a second capacitance value, and the first capacitance value is equal to the second capacitance value.

[0022] In at least one embodiment, the first capacitor unit is a first single capacitor and the second capacitor unit is a second single capacitor.

[0023] In at least one embodiment, the voltage conversion circuit is an AC-DC conversion circuit, a DC-AC conversion circuit, an AC-AC conversion circuit, or a DC-DC conversion circuit.

[0024] In at least one embodiment, the first capacitor unit includes a first set of capacitors arranged on the first side of the busbar system; the second capacitor unit includes a second set of capacitors arranged on the second side of the busbar system; and a first number of capacitors in the first set of capacitors is the same as a second number of capacitors in the second set of capacitors.

[0025] In at least one embodiment, the first set of capacitors is arranged in a first row on the first side of the busbar system and the second set of capacitors is arranged in a second row on the second side of the busbar system.

[0026] A double-sided DC link capacitor system comprises a busbar system; a first capacitor unit arranged on a first side of the busbar system and electrically coupled to the busbar system; and a second capacitor unit arranged on a second side of the busbar system and electrically coupled to the busbar system, the second side of the busbar system being opposite the first side of the busbar system, with a current flowing through the busbar system to the first capacitor unit in a first current flow direction and to the second capacitor unit in a second current flow direction, the second current flow direction being opposite to the first current flow direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The exemplary embodiments are described below in conjunction with the following drawings, where identical numbers denote identical elements and where: Fig. 1 is a functional block diagram of a vehicle that includes a voltage conversion system in accordance with at least one embodiment; Fig. 2a is a functional block diagram of a voltage conversion system comprising a double-sided DC link capacitor system in accordance with at least one embodiment; Fig. 2b a functional block diagram of a double-sided DC link capacitor system in accordance with at least one embodiment; Fig. 2c is a functional block diagram of an exemplary double-sided DC-link capacitor system, which represents the electrical coupling of first and second capacitor units with a busbar system in accordance with at least one embodiment; Fig. 3 a functional block diagram of a double-sided DC-link capacitor system comprising first and second capacitor units with rows of capacitors arranged on both sides of a busbar system in accordance with at least one embodiment; Fig. 4 is a top view of a functional block diagram of a double-sided DC-link capacitor system comprising multiple capacitors arranged in adjacent rows on both sides of a busbar system in accordance with at least one embodiment; Fig. 5 is a top view of a functional block diagram of a double-sided DC-link capacitor system comprising multiple capacitors arranged in a C configuration with respect to a voltage conversion circuit on each side of a busbar system in accordance with at least one embodiment; Fig. 6 is a top view of a functional block diagram of a double-sided DC-link capacitor system comprising several capacitors with different capacitance values ​​arranged in a configuration with respect to a voltage conversion circuit on each side of a busbar system in accordance with at least one embodiment; and Fig. 7 is a functional block diagram illustrating the use of a system enclosure as a capacitor enclosure in accordance with at least one embodiment. DETAILED DESCRIPTION

[0028] The following detailed description is merely exemplary and is not intended to limit its application and use. Furthermore, it is not intended to be bound by any explicit or implicit theory presented in the preceding technical field, background, summary, or the following detailed description. As used herein, the term module refers to an application-specific integrated circuit (ASIC), an electronic circuit, a processor (common, dedicated, or as a group), and memory executing one or more software or firmware programs, a combinational logic circuit, and / or other suitable components providing the described functionality.

[0029] Embodiments of the present disclosure can be described here in the form of functional and / or logical block components and various processing steps. It should be noted that such block components can be implemented by any number of hardware, software, and / or firmware components configured to perform the specified functions. For example, an embodiment of the present disclosure may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, or the like, which can perform a variety of functions under the control of one or more microprocessors or other control devices.Furthermore, the person skilled in the art will recognize that embodiments of the present disclosure can be practiced in connection with any number of systems and that the systems described here are merely exemplary embodiments of the present disclosure.

[0030] For the sake of brevity, a detailed description of conventional techniques for signal processing, data transmission, signaling, control, and other functional aspects of the systems (and the individual operating components of the systems) is omitted. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and / or physical connections between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in an embodiment of this disclosure.

[0031] With reference to Fig. Figure 1 shows a functional block diagram of a vehicle 10 that includes a voltage conversion system 100. The vehicle 10 includes one or more voltage conversion systems 100. One or more of the voltage conversion systems 100 include a double-sided DC link capacitor system that can be used to reduce parasitic inductance. The vehicle 10 generally comprises a chassis 12, a body 14, front wheels 16, and rear wheels 18. Although the vehicle 10 is shown as a passenger car in the illustrated embodiment, the vehicle 10 can also include other vehicle types, such as trucks, sport utility vehicles (SUVs), and motorhomes (RVs). In various embodiments, the body 14 is arranged on the chassis 12 and essentially encloses components of the vehicle 10. The body 14 and the chassis 12 can together form a frame.The wheels 16-18 are each rotatably coupled to the chassis 12 near a respective corner of the body 14.

[0032] In various embodiments, the vehicle 10 is an autonomous or semi-autonomous vehicle that is automatically controlled to transport passengers and / or cargo from one place to another. For example, in one exemplary embodiment, the vehicle 10 is a so-called Level Two, Level Three, Level Four, or Level Five automation system. Level Two automation means that the vehicle assists the driver with various driving tasks under the driver's supervision. Level Three automation means that, under certain circumstances, the vehicle can take over all driving functions. All major functions are automated, including braking, steering, and accelerating. At this level, the driver can completely disengage until the vehicle prompts the driver to do so. A Level Four system signifies a "high degree of automation," meaning that the vehicle is fully automated.An automated driving system performs all aspects of the dynamic driving task, even if a human driver does not respond appropriately to a request for intervention. A Level Five system means "full automation," i.e., that an automated driving system fully performs all aspects of the dynamic driving task under all road and environmental conditions that a human driver can handle.

[0033] As shown, the vehicle 10 generally includes a propulsion system 20, a transmission system 22, a steering system 24, a braking system 26, a sensor system 28, an actuator system 30, at least one storage device 32, at least one control unit 34, and a communication system 36. The control unit 34 is configured to implement an automated driving system (ADS). The propulsion system 20 is configured to generate energy for propelling the vehicle. The propulsion system 20 can, in various embodiments, include an internal combustion engine, an electric machine such as a traction motor, a fuel cell propulsion system, and / or any other type of propulsion configuration. The transmission system 22 is configured to transmit the power of the propulsion system 20 to the vehicle wheels 16-18 in selectable gear ratios.According to various embodiments, the transmission system 22 can comprise a continuously variable automatic transmission, a continuously variable transmission, or another suitable transmission. The braking system 26 is configured to provide a braking torque for the vehicle wheels 16-18. In various embodiments, the braking system 26 can comprise friction brakes, wire brakes, a regenerative braking system such as an electric motor, and / or other suitable braking systems.

[0034] The steering system 24 is configurable to influence the position of the vehicle wheels 16. For illustration, the steering system 24 is shown to include a steering wheel and a steering column; however, in some embodiments considered within the scope of this disclosure, the steering system 24 may also not include a steering wheel and / or a steering column. The steering system 24 includes a steering column coupled to an axle 50, which is connected to the front wheels 16, for example, via a rack and pinion or other mechanism (not shown). Alternatively, the steering system 24 may also include a wire-operated steering system comprising actuators connected to each of the front wheels 16.

[0035] The sensor system 28 includes one or more detection devices 40a-40n that detect observable states of the external environment and / or the internal environment of the vehicle 10. The detection devices 40a-40n may include, among others, radars, lidar, global positioning systems, optical cameras, thermal cameras, ultrasonic sensors, and / or other sensors. In various embodiments, the sensor system 28 includes a biometric sensor system configured to detect biometric data from one or more occupants of the vehicle 10. In various embodiments, the sensor system 28 includes a vehicle environment sensor system configured to detect vehicle environment data.

[0036] The vehicle dynamics sensors provide vehicle dynamics data, including longitudinal speed, yaw rate, lateral acceleration, and longitudinal acceleration. The vehicle dynamics sensors can include wheel sensors that measure information about one or more wheels of the vehicle 10. In one embodiment, the wheel sensors comprise wheel speed sensors coupled to each of the wheels 16-18 of the vehicle 10. Furthermore, the vehicle dynamics sensors can include one or more accelerometers (provided as part of an inertial measurement unit (IMU)) that measure information about the acceleration of the vehicle 10. In various embodiments, the accelerometers measure one or more acceleration values ​​for the vehicle 10, including lateral and longitudinal acceleration as well as yaw rate.

[0037] The actuator system 30 comprises one or more actuator devices 42a-42n that control one or more functions of the vehicle 10, such as, but not limited to, the drive system 20, the transmission system 22, the steering system 24, and the braking system 26. In various embodiments, the vehicle features may further include internal and / or external vehicle features, such as doors, a trunk, and cabin features such as air conditioning, music, lighting, etc. (not numbered).

[0038] The communication system 36 is configured to wirelessly transmit information to and from other units 48, such as other vehicles (“V2V” communication), infrastructure (“V2I” communication), remote systems, and / or personal devices. In one exemplary embodiment, the communication system 36 is a wireless communication system configured to communicate via a wireless local area network (WLAN) using IEEE 802.11 standards or via cellular data communication. However, additional or alternative communication methods, such as a dedicated short-range communication channel (DSRC), are also considered within the scope of this disclosure. DSRC channels are one-way or two-way short- to medium-range wireless communication channels specifically designed for use in motor vehicles, and a number of corresponding protocols and standards.

[0039] The storage device 32 stores data for use in the ADS of the vehicle 10. In various embodiments, the storage device 32 stores defined maps of the navigable environment. In various embodiments, the defined maps can be predefined and retrieved from a remote system. For example, the defined maps can be compiled by the remote system and transmitted to the vehicle 10 (wirelessly and / or via a wired connection) and stored in the storage device 32. As can be seen, the storage device 32 can be part of the control unit 34, separate from the control unit 34, or part of the control unit 34 and part of a separate system.

[0040] The control unit 34 includes at least one processor 44 and a computer-readable storage device or medium 46. The processor 44 can be any custom-designed or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), a supporting processor among several processors connected to the control unit 34, a semiconductor-based microprocessor (in the form of a microchip or chipset), a macroprocessor, any combination thereof, or generally any instruction-executing device. The computer-readable storage devices or media 46 can include volatile and non-volatile memory, such as read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables while the processor 44 is powered off.The computer-readable storage device or medium 46 can be implemented using any number of known storage devices such as PROMs (programmable read-only memory), EPROMs (electrically erasable PROMs), EEPROMs (electrically erasable PROMs), flash memory, or other electrical, magnetic, optical, or combined storage devices capable of storing data, some of which constitute executable instructions used by the control unit 34 in controlling the vehicle 10.

[0041] The instructions can include one or more separate programs, each comprising an ordered list of executable instructions for implementing logical functions. When executed by the processor 44, the instructions receive and process signals from the sensor system 28, perform logic, calculations, procedures, and / or algorithms for the automatic control of the vehicle 10's components, and generate control signals for the actuator system 30 to automatically control the vehicle 10's components based on the logic, calculations, procedures, and / or algorithms. Although in Fig. While only one control unit 34 is shown in Figure 1, embodiments of the vehicle 10 may include any number of control units 34 that communicate via any suitable communication medium or combination of communication media and cooperate to process the sensor signals, perform logic, calculations, procedures and / or algorithms, and generate control signals to automatically control features of the vehicle 10. In various embodiments, the control unit(s) 34 is / are configured for the implementation of the ADS.

[0042] With reference to Fig. Figure 2a shows a functional block diagram of a voltage conversion system 100, which includes a double-sided DC-link capacitor system 200 according to at least one embodiment. The voltage conversion system 100 includes a voltage conversion circuit 202 and the double-sided DC-link capacitor system 200. In at least one embodiment, the voltage conversion circuit 202 is configured to be electrically coupled to a current source 204. Examples of voltage conversion circuits 202 include, but are not limited to, an AC-to-DC conversion circuit, a DC-to-AC conversion circuit, an AC-to-AC conversion circuit, and a DC-to-DC conversion circuit.In at least one embodiment, the voltage conversion circuit 202 can be arranged on a busbar system 210.

[0043] The double-sided DC-link capacitor system 200 comprises a first capacitor unit 206, a second capacitor unit 208, and the busbar system 210. The first capacitor unit 206 and the second capacitor unit 208 have the same or very similar capacitance values. The first capacitor unit 206 is located on the first side of the busbar system 210. The second capacitor unit 208 is located on the second side of the busbar system 210. The first and second sides of the busbar system 210 are opposite sides of the busbar system 210. The first capacitor unit 206 on the first side of the busbar system 210 is aligned with the second capacitor unit 208 on the second side of the busbar system 210. The busbar system 210 is electrically coupled to the first capacitor unit 206, the second capacitor unit 208, and the voltage conversion circuit 202.

[0044] A current flows through the busbar system 210 to the first capacitor unit 206 in a first current flow direction 212 and to the second capacitor unit 208 in a second current flow direction 214. The second current flow direction 214 is opposite to the first current flow direction 212. In at least one embodiment, the current flow is an alternating current flow, so that the first current flow direction 212 and the second current flow direction 214 change in accordance with the alternating current flow. The second current flow direction 214 is always opposite to the first current flow direction 212. In at least one embodiment, the first and second capacitor units 206, 208 are polarized capacitors. In at least one embodiment, the first and second capacitor units 206, 208 are unpolarized capacitors.

[0045] The current generated by source 204 or voltage conversion circuit 202 flows through the busbar system 210 to the first capacitor unit 206 in the first current flow direction 212 and to the second capacitor unit 208 in the second current flow direction 214. Source 204 is a constant voltage source or a current source. Once the first and second capacitor units 206 and 208 are fully charged, no more current flows from source 204. However, the voltage conversion circuit 202 generates a ripple current during the conversion process. The AC ripple current flows continuously through the double-sided DC-link capacitor system 200. The main function of the double-sided DC-link capacitor system 200 is to filter the AC ripple current.

[0046] The current flowing into the first capacitor unit 206 in the first current flow direction 212 generates a first electromagnetic field. The direction of the first magnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. The current flowing into the second capacitor unit 208 in the second current flow direction 214 generates a second electromagnetic field. The direction of the second electromagnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. The first circular direction of the first electromagnetic field is opposite to the second circular direction of the second electromagnetic field.

[0047] Since the first capacitor unit 206 has the same capacitance value as the second capacitor unit 208, the first and second electromagnetic fields have the same electromagnetic field strengths. The opposite directions of rotation of the first and second electromagnetic fields cause the first electromagnetic field to cancel out the second electromagnetic field. This cancellation of the first and second electromagnetic fields minimizes the parasitic inductance caused by the current flow to the first and second capacitor units 206 and 208. Furthermore, the relatively smaller busbar system 210 used in a double-sided DC-link capacitor system 200, compared to a busbar system used in a single-sided DC-link capacitor system, results in a smaller current commutation loop, leading to lower parasitic inductance in the double-sided DC-link capacitor system 200.

[0048] With reference to Fig. Figure 2b shows a functional block diagram of a double-sided DC-link capacitor system 200 according to at least one embodiment. The double-sided DC-link capacitor system 200 comprises a first capacitor unit 206, a second capacitor unit 208, and a busbar system 210. The busbar system 210 includes an upper busbar 216 and a lower busbar 218. An insulating layer 220 is located between the upper busbar 216 and the lower busbar 218.

[0049] In at least one embodiment, the upper busbar 216 is connected via a +V DC -Busbar terminal electrically connected to a +V DC -voltage coupled and the lower busbar 218 via a -VDC -Busbar terminal electrically with a -V DC -voltage coupled. In at least one embodiment, the upper busbar 216 is coupled via a -V DC -Busbar terminal electrically with a -V DC -voltage coupled, and the lower busbar 218 is connected via a +V DC -Busbar terminal electrically connected to a +V DC -voltage coupled. In at least one embodiment, the upper busbar 216 is coupled via a +V DC -Busbar terminal electrically connected to a +V DC -voltage coupled and the lower busbar 218 via a -V DC -Busbar terminal electrically with a -V DC -Voltage coupled. The +V DC busbar terminal and the -V DCThe busbar terminals are electrically coupled to the voltage conversion circuit 202 and to the source 204. The source 204 is a voltage or current source. In at least one embodiment, the first and second capacitor units 206, 208 are installed and electrically coupled to the busbar system 210 via pluggable brass terminals. In at least one embodiment, the first and second capacitor units 206, 208 are installed and electrically coupled to the busbar system 210 by soldering them to the busbar system 210.

[0050] With reference to Fig. Figure 2c shows a functional block diagram of an exemplary double-sided DC-link capacitor system 200, illustrating the electrical coupling of first and second capacitor units 206, 208 to a busbar system 210 in accordance with at least one embodiment. The exemplary first and second capacitor units 206, 208 are shown to include a single capacitor. However, if the first and second capacitor units 206, 208 include more than one capacitor, each of the capacitors is similarly electrically coupled to the busbar system 210.

[0051] The busbar system 210 includes an upper busbar 216 and a lower busbar 218. The upper busbar 216 is connected via a busbar terminal +V. DC and the lower busbar 218 via a busbar terminal -V DC electrically with a voltage of -V DC coupled.

[0052] The capacitor in the first capacitor unit 206 is electrically connected to a +V DC -capacitor connection 222a and a -V DC Capacitor terminal 224a is coupled. The capacitor in the second capacitor unit 208 is electrically connected to a +V DC -capacitor connection 222b and a -V DC Capacitor connection 224b is coupled. The +V DC Capacitor terminals 222a and 222b are electrically coupled to the upper busbar 216. The -V DC Capacitor terminals 224a, 224b are electrically coupled to the lower busbar 218. At least in one embodiment, the +V DC -Capacitor connections 222a, 222b with the upper busbar 216 and the -V DC -Capacitor connections 222a, 222b integrated with the lower busbar 218.

[0053] In at least one embodiment, the capacitor in the first capacitor unit 206 is electrically connected to the +V DCCapacitor connection 222a and the -V DC Capacitor connection 224a is coupled by plugging it in via brass terminals. In at least one embodiment, the capacitor in the first capacitor unit 206 is electrically connected to the +V DC -capacitor connection 222a and the -V DC Capacitor terminal 224a is coupled by connecting the capacitor in the first capacitor unit 206 to the +V DC -capacitor connection 222a and the -V DC Capacitor connection 224a is soldered.

[0054] In at least one embodiment, the capacitor in the second capacitor unit 208 is connected to the +V DC Capacitor terminal 222b and the -V DC Capacitor connection 224b is electrically coupled by plugging it in via brass terminals. In at least one embodiment, the capacitor in the second capacitor unit 208 is electrically connected to the +V DC -capacitor connection 222b and the -V DCCapacitor terminal 224b is coupled by connecting the capacitor in the second capacitor unit 208 to the +V DC -capacitor connection 222b and the -V DC Capacitor connection 224b is soldered.

[0055] The illustrated electrical coupling of the first capacitor unit 206 and the second capacitor unit 208 leads to a first current flow with a first current flow direction 212, which is via the +V DC -Capacitor connection 222a to the capacitor in the first capacitor unit 206 flows and via the -V DC -capacitor terminal 224a flows away and to a second current flow with a second current flow direction 214, which leads to the capacitor in the second capacitor unit 208 via the +V DC -Capacitor terminal 222b flows and via the -V DC-capacitor terminal 224b. In at least one embodiment, the current flow is an alternating current flow, so that the first current flow direction 212 and the second current flow direction 214 change in accordance with the alternating current flow. The second current flow direction 214 is always opposite to the first current flow direction 212.

[0056] With reference to Fig. Figure 3 shows a functional block diagram of a double-sided DC-link capacitor system 200, comprising first and second capacitor units 206, 208, which contain rows of capacitors arranged on both sides of a busbar system 210 according to at least one embodiment. The double-sided DC-link capacitor system 200 includes the first capacitor unit 206 and the second capacitor unit 208, which are arranged on opposite sides of the busbar system 210. In at least one embodiment, the voltage conversion circuit 202 can be arranged on a busbar system 210.

[0057] The first capacitor unit 206 comprises a first set of capacitors 302a, 302b, 302c, 302d, arranged in a first row on a first side of the busbar system 210. The first set of capacitors 302a, 302b, 302c, 302d is arranged on the first side of the busbar system 210, with the current flow direction of each of the capacitors 302a, 302b, 302c, 302d being in a first current flow direction 212. The second capacitor unit 208 comprises a second set of capacitors 304a, 304b, 304c, 304d, arranged in a second row on a second side of the busbar system 210. The second set of capacitors 304a, 304b, 304c, 304d is arranged on the second side of the busbar system 210, wherein the current flow direction of each of the capacitors 304a, 304b, 304c, 304d is in a second current flow direction 214 which is opposite to the first current flow direction 212.In at least one embodiment, the current flow is an alternating current flow, such that the first current flow direction 212 and the second current flow direction 214 change in accordance with the alternating current flow. The second current flow direction 214 is always opposite to the first current flow direction 212.

[0058] The first and second sides of the busbar system 210 are opposite sides of the busbar system 210. The first set of capacitors 302a, 302b, 302c, 302d on the first side of the busbar system 210 is aligned with the second set of capacitors 304a, 304b, 304c, 304d on the second side of the busbar system 210. The busbar system 210 is electrically coupled to the first set of capacitors 302a, 302b, 302c, 302d, the second set of capacitors 304a, 304b, 304c, 304d, the voltage conversion circuit 202, and the source 204.

[0059] In at least one embodiment, the number of capacitors in the first set of capacitors 302a, 302b, 302c, 302d is the same as the number of capacitors in the second set of capacitors 304a, 304b, 304c, 304d. In at least one embodiment, the number of capacitors in the first set of capacitors 302a, 302b, 302c, 302d is not the same as the number of capacitors in the second set of capacitors 304a, 304b, 304c, 304d. The total capacitance of the first set of capacitors 302a, 302b, 302c, 302d is equal to the total capacitance of the second set of capacitors 304a, 304b, 304c, 304d. The busbar system 210 includes an upper busbar 216 and a lower busbar 218. The total length of the upper busbar 216 is equal to the total length of the lower busbar 218.

[0060] Current flowing to the first set of capacitors 302a, 302b, 302c, 302d in the first capacitor unit 206 in the first current flow direction 212 generates a first electromagnetic field. The direction of the first magnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. Current flowing to the second set of capacitors 304a, 304b, 304c, 304d in the second capacitor unit 208 in the second current flow direction 214 generates a second electromagnetic field. The direction of the second electromagnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. The first circular direction of the first electromagnetic field is opposite to the second circular direction of the second electromagnetic field.

[0061] Since the total capacitance of the first set of capacitors 302a, 302b, 302c, 302d is equal to the total capacitance of the second set of capacitors 304a, 304b, 304c, 304d, the first and second electromagnetic fields have the same electromagnetic field strength. The opposite directions of rotation of the first and second electromagnetic fields cause the first electromagnetic field to cancel out the second. This cancellation of the first and second electromagnetic fields minimizes the parasitic inductance caused by the current flow to the first set of capacitors 302a, 302b, 302c, 302d and to the second set of capacitors 304a, 304b, 304c, 304d.

[0062] While the first capacitor unit 206 is shown to include four capacitors in the first set of capacitors 302a, 302b, 302c, 302d, and the second capacitor unit 208 is shown to include four capacitors in the second set of capacitors 304a, 304b, 304c, 304d, in alternative embodiments the first and second sets of capacitors may include a larger or smaller number of capacitors. In at least one embodiment, the first capacitor unit 206 includes a single capacitor and the second capacitor unit 208 includes a single capacitor.

[0063] With reference to Fig. Figure 4 shows a top view of a functional block diagram of a double-sided DC-link capacitor system 200, which includes several capacitors 400 arranged in adjacent rows on each side of a busbar system 210 in accordance with at least one embodiment. In at least one embodiment, the voltage conversion circuit 202 can be arranged on a busbar system 210. The double-sided DC-link capacitor system 200 includes a first capacitor unit 206 and a second capacitor unit 208 (not shown) arranged on opposite sides of the busbar system 210.

[0064] The first capacitor unit 206 comprises a first set of capacitors 400 arranged in adjacent rows on a first side of the busbar system 210, the current flow direction of each of the capacitors 400 being in a first current flow direction 212. The second capacitor unit 208 (not shown) comprises a second set of capacitors arranged in adjacent rows on a second side of the busbar system 210, the current flow direction of each of the capacitors in the second set of capacitors being in a second current flow direction 214, which is opposite to the first current flow direction 212. In at least one embodiment, the current flow is an alternating current flow, such that the first current flow direction 212 and the second current flow direction 214 change in accordance with the alternating current flow. The second current flow direction 214 is always opposite to the first current flow direction 212.

[0065] The first and second sides of the busbar system 210 are opposite sides of the busbar system 210. The first set of capacitors 400, arranged in adjacent rows on the first side of the busbar system 210, is aligned with the second set of capacitors, arranged in adjacent rows on the second side of the busbar system 210. The busbar system 210 is electrically coupled to the first set of capacitors 400, the second set of capacitors, the voltage conversion circuit 202, and the power source 204.

[0066] In at least one embodiment, the number of capacitors in the first set of capacitors 400 is equal to the number of capacitors in the second set of capacitors. In at least one embodiment, the number of capacitors in the first set of capacitors 400 is not equal to the number of capacitors in the second set of capacitors. The total capacitance of the first set of capacitors 400 is equal to the total capacitance of the second set of capacitors. The busbar system 210 includes an upper busbar 216 and a lower busbar 218. The total length of the upper busbar 216 is equal to the total length of the lower busbar 218.

[0067] Current flowing to the first set of capacitors 400 in the first capacitor unit 206 in the first current flow direction 212 generates a first electromagnetic field. The direction of the first magnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. Current flowing to the second set of capacitors in the second capacitor unit 214 in the second current flow direction generates a second electromagnetic field. The direction of the second electromagnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. The first circular direction of the first electromagnetic field is opposite to the second circular direction of the second electromagnetic field.

[0068] Since the total capacitance of the first set of 400 capacitors is equal to the total capacitance of the second set of capacitors, the first and second electromagnetic fields have the same electromagnetic field strength. The opposite directions of rotation of the first and second electromagnetic fields cause the first electromagnetic field to cancel out the second. This cancellation of the first and second electromagnetic fields minimizes the parasitic inductance caused by the current flowing between the first and second sets of capacitors.

[0069] While the first capacitor unit 206 is shown to contain twelve capacitors in the first set of capacitors 400, the first and second sets of capacitors may, in alternative embodiments, include a larger or smaller number of capacitors.

[0070] With reference to Fig. Figure 5 shows a top view of a functional block diagram of a double-sided DC-link capacitor system 200, which includes a plurality of capacitors 500a, 500b, 500c arranged in a C-configuration with respect to a voltage conversion circuit 202 on each side of a busbar system 210 in accordance with at least one embodiment. In at least one embodiment, the voltage conversion circuit 202 can be arranged on a busbar system 210. The double-sided DC-link capacitor system 200 includes a first capacitor unit 206 and a second capacitor unit 208 (not shown) arranged on opposite sides of the busbar system 210.

[0071] The first capacitor unit 206 comprises a first set of capacitors 500a, 500b, 500c arranged in a C configuration with respect to the voltage conversion circuit 202 on a first side of the busbar system 210, wherein the current flow direction of each of the capacitors 500a, 500b, 500c is in a first current flow direction 212. The second capacitor unit 206 (not shown) comprises a second set of capacitors arranged in a C configuration with respect to the voltage conversion circuit 202 on a second side of the busbar system 210, wherein the current flow direction of each of the capacitors is in a second current flow direction 214, which is opposite to the first current flow direction 212. In at least one embodiment, the current flow is an alternating current flow, such that the first current flow direction 212 and the second current flow direction 214 change in accordance with the alternating current flow.The second current flow direction 214 is always opposite to the first current flow direction 212.

[0072] The first and second sides of the busbar system 210 are opposite sides of the busbar system 210. Each of the capacitors in the first set of capacitors 500a, 500b, 500c, arranged in a C configuration on the first side of the busbar system 210, is aligned with a corresponding capacitor in the second set of capacitors, arranged in a C configuration on the second side of the busbar system 210. Each of the capacitors in the first set of capacitors 500a, 500b, 500c, arranged in a C configuration on the first side of the busbar system 210, has the same capacitance value as the corresponding capacitor in the second set of capacitors, arranged in a C configuration on the second side of the busbar system 210.The busbar system 210 is electrically coupled to the first set of capacitors 500a, 500b, 500c, the second set of capacitors, the voltage conversion circuit 202 and the source 204.

[0073] In at least one embodiment, the capacitors in the first set of capacitors 500a, 500b, 500c and the capacitors in the second set of capacitors all have the same capacitance value. In at least one embodiment, individual capacitors in the first set of capacitors 500a, 500b, 500c can have different capacitance values, and individual capacitors in the second set of capacitors that correspond to a capacitor in the first set of capacitors 500a, 500b, 500c have the same capacitance value as the corresponding capacitor in the first set of capacitors 500a, 500b, 500c.

[0074] Current flowing to the first set of capacitors 500a, 500b, 500c in the first capacitor unit 206 in the first current flow direction 212 generates a first electromagnetic field. The direction of the first magnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. Current flowing to the second set of capacitors in the second capacitor unit 208 in the second current flow direction 214 generates a second electromagnetic field. The direction of the second electromagnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. The first circular direction of the first electromagnetic field is opposite to the second circular direction of the second electromagnetic field.

[0075] Since the total capacitance of the first set of capacitors 500a, 500b, 500c is equal to the total capacitance of the second set of capacitors, the first and second electromagnetic fields have the same electromagnetic field strength. The opposite directions of rotation of the first and second electromagnetic fields cause the first electromagnetic field to cancel out the second. This cancellation of the first and second electromagnetic fields minimizes the parasitic inductance caused by the current flow to the first set of capacitors 500a, 500b, 500c and to the second set of capacitors.

[0076] While the first capacitor unit 206 is shown to include three capacitors in the first set of capacitors 500a, 500b, 500c, the first and second sets of capacitors may, in alternative embodiments, include a larger or smaller number of capacitors. In at least one embodiment, the multiple capacitors arranged in the C configuration may be a single-sided capacitor system. Although one C configuration has been described, various configurations of the other configurations may be used in alternative embodiments.

[0077] With reference to Fig. Figure 6 shows a top view of a functional block diagram of a double-sided DC-link capacitor system 200, which includes several capacitors 600a, 600b, 600c with different capacitance values, arranged in a configuration with respect to a voltage conversion circuit 202 on each side of a busbar system 210 in accordance with at least one embodiment. In at least one embodiment, the voltage conversion circuit 202 can be arranged on a busbar system 210. The double-sided DC-link capacitor system 200 includes a first capacitor unit 206 and a second capacitor unit 208 (not shown) arranged on opposite sides of the busbar system 210.

[0078] The first capacitor unit 206 comprises a first set of capacitors 600a, 600b, 600c arranged in the following configuration with respect to the voltage conversion circuit 202 on a first side of the busbar system 210, wherein the current flow direction of each of the capacitors 600a, 600b, 600c is in a first current flow direction 212. The second capacitor unit 206 (not shown) comprises a second set of capacitors arranged in the same configuration with respect to the voltage conversion circuit 202 on a second side of the busbar system 210, wherein the current flow direction of each of the capacitors is in a second current flow direction 214, which is opposite to the first current flow direction 212. In at least one embodiment, the current flow is an alternating current flow, such that the first current flow direction 212 and the second current flow direction 214 change in accordance with the alternating current flow.The second current flow direction 214 is always opposite to the first current flow direction 212.

[0079] The first and second sides of the busbar system 210 are opposite sides of the busbar system 210. Each of the capacitors in the first set of capacitors 600a, 600b, 600c, arranged in the configuration on the first side of the busbar system 210, is aligned with a corresponding capacitor in the second set of capacitors, arranged in the same configuration on the second side of the busbar system 210. Each of the capacitors in the first set of capacitors 600a, 600b, 600c, arranged in the configuration on the first side of the busbar system 210, has the same capacitance value as the corresponding capacitor in the second set of capacitors, arranged in the same configuration on the second side of the busbar system 210.The busbar system 210 is electrically coupled to the first set of capacitors 600a, 600b, 600c, the second set of capacitors, the voltage conversion circuit 202, and the source 204. The busbar system 210 is also electrically coupled to the first set of capacitors 500a, 500b, 500c, the second set of capacitors, the voltage conversion circuit 202, and the source 204.

[0080] Individual capacitors in the first group (600a, 600b, 600c) can have different capacitance values, and individual capacitors in the second group that correspond to a capacitor in the first group (600a, 600b, 600c) have the same capacitance value. For example, capacitor 600a can have a first capacitance value, and capacitors 600b, 600c can have a second capacitance value that differs from the first.

[0081] Current flowing to the first set of capacitors 600, 600b, 600c in the first capacitor unit 206 in the first current flow direction 212 generates a first electromagnetic field. The direction of the first magnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. Current flowing to the second set of capacitors in the second capacitor unit 208 in the second current flow direction 214 generates a second electromagnetic field. The direction of the second electromagnetic field is perpendicular to the busbar system 210 and surrounds the busbar system 210 in a circular direction. The first circular direction of the first electromagnetic field is opposite to the second circular direction of the second electromagnetic field.

[0082] Since the total capacitance of the first set of capacitors 600a, 600b, 600c is equal to the total capacitance of the second set of capacitors, the first and second electromagnetic fields have the same electromagnetic field strength. The opposite directions of the first and second electromagnetic fields cause the first electromagnetic field to cancel out the second. This cancellation of the first and second electromagnetic fields minimizes the parasitic inductance caused by the current flow to the first set of capacitors 600a, 600b, 600c and the second set of capacitors. Due to their smaller size and lower parasitic inductance, capacitors 600b and 600c are placed closer to the voltage conversion circuit 202 to allow for a smaller commutation loop with lower loop inductance, thus reducing voltage and current overshoot, ringing, and EMI.

[0083] While the first capacitor unit 206 is shown to include three capacitors in the first set of capacitors 600a, 600b, 600c, the first and second sets of capacitors may, in alternative embodiments, include a larger or smaller number of capacitors. Similarly, while the first capacitor unit 206 is shown to include three capacitors in the first set of capacitors 500a, 500b, 500c, the first and second sets of capacitors may, in alternative embodiments, include a larger or smaller number of capacitors. In at least one embodiment, the multiple capacitors arranged in the configuration may constitute a single-sided capacitor system.

[0084] In at least one embodiment, the voltage conversion system 100 is housed in a casing. The voltage conversion circuit 202 and the double-sided DC-link capacitor system 200 are arranged inside the casing. Alternatively, the voltage conversion circuit 202 and the double-sided DC-link capacitor system 200 are not housed in separate casings. A composite resin is arranged inside the casing to mechanically position the voltage conversion circuit 202 relative to the double-sided DC-link capacitor system 200 within the casing and to electrically isolate the voltage conversion circuit 202 from the double-sided DC-link capacitor system 200.

[0085] With reference to Fig.Figure 7 shows a functional block diagram illustrating the use of a system enclosure 700 (also referred to as the enclosure) as a capacitor enclosure in accordance with at least one embodiment. The one or more capacitors in the first and second capacitor units 206, 208 may be capacitor coils 702. The system enclosure 700 is used as a capacitor enclosure for the capacitor coils 702 by incorporating the capacitor coils 702 into the system enclosure 700 using a composite casting process. The composite form 704 provides cooling and high-voltage insulation.

[0086] In at least one embodiment, each of the capacitor coils 702 consists only of cores without individual housings. In at least one embodiment, the capacitor coils 702 can have different shapes. In at least one embodiment, the capacitor coils 702 can be of different sizes. In at least one embodiment, the capacitor coils 702 can be of different numbers.

[0087] The System Enclosure 700 can be used as a capacitor enclosure in a double-sided DC-link capacitor system 200 or in a single-sided system. The System Enclosure 700 can be made of metal, other materials, or a combination of metal and other materials. Using a System Enclosure 700 can reduce the size, weight, and cost, and improve the thermal performance of the double-sided DC-link capacitor system 200 or the single-sided system.

[0088] Although at least one exemplary embodiment has been presented in the preceding detailed description, it should be understood that there are numerous variations. It is also understood that the exemplary embodiment or embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the preceding detailed description provides the person skilled in the art with a convenient roadmap for implementing the exemplary embodiment or embodiments. It is understood that various modifications to the function and arrangement of elements can be made without deviating from the scope of the disclosure as set forth in the appended claims and their legal equivalents.

Claims

[1] Voltage conversion system (100) comprising a double-sided DC link capacitor system (200), comprising: a voltage conversion circuit (202); and the double-sided DC-link capacitor system (200) which is electrically coupled to the voltage conversion system (100), the double-sided DC-link capacitor system (200) comprising: a busbar system (210); a first capacitor unit (206) which is arranged on a first side of the busbar system (210) and electrically coupled to the busbar system (210); and a second capacitor unit (208) which is arranged on a second side of the busbar system (210) and is electrically coupled to the busbar system (210), wherein the second side of the busbar system (210) is opposite the first side of the busbar system (210), wherein a current flows through the busbar system (210) to the first capacitor unit (206) in a first current flow direction (212) and to the second capacitor unit (208) in a second current flow direction (214), wherein the second current flow direction (214) is opposite to the first current flow direction (212); wherein the first capacitor unit (206) comprises a first set of capacitors (500a, 500b, 500c) arranged on the first side of the busbar system (210); wherein the second capacitor unit (208) comprises a second set of capacitors arranged on the second side of the busbar system (210); and where a first number of capacitors in the first set of capacitors (500a, 500b, 500c) is the same as a second number of capacitors in the second set of capacitors; wherein the first set of capacitors (500a, 500b, 500c) is arranged in a C configuration with respect to the voltage conversion circuit (202) on the first side of the busbar system (210) and the second set of capacitors in the C configuration with respect to the voltage conversion circuit (202) is arranged on the second side of the busbar system (210). [2] Voltage conversion system (100) according to claim 1, wherein the first capacitor unit (206) and the second capacitor unit (208) are aligned on one and the other side of the busbar system (210). [3] Voltage conversion system (100) according to claim 1, wherein the first capacitor unit (206) has a first capacitance value, the second capacitor unit (208) has a second capacitance value and the first capacitance value is equal to the second capacitance value. [4] Voltage conversion system (100) according to claim 1, wherein the voltage conversion circuit (202) is an AC-DC conversion circuit, a DC-AC conversion circuit, an AC-AC conversion circuit or a DC-DC conversion circuit. [5] Voltage conversion system (100) according to claim 1, wherein the first set of capacitors (500a, 500b, 500c) includes at least one capacitor with a third capacitance value and at least one capacitor with a fourth capacitance value, and the second set of capacitors includes at least one capacitor with the third capacitance value and at least one capacitor with the fourth capacitance value.

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