ELECTRICAL SYSTEM WITH CIRCUIT FOR COOLING A POWER MODULE

Abstract

The invention relates to an electrical system (1702) comprising: - a switching cell (100) comprising: • a power module (102) and • a circuit (106) for cooling the power module with a cooling housing (108) defining a channel (110) for a coolant flow, a line (118) for inleting the coolant into the cooling housing (108) and a line (120) for outleting the coolant from the cooling housing (108), wherein the inlet line (118) and the outlet line (120) each have a segment (1716, 1718), the segment of the inlet line and the segment of the outlet line extending substantially parallel to each other in the same direction;and - a housing (1706) in which the switching cell (100) is arranged, wherein the housing (1706) has two through-openings (1720, 1722), wherein the segment of the inlet line is inserted into one of the two through-openings and the segment of the outlet line is inserted into the other of the two through-openings.;

Description

Technical field of the invention

[0001] The present invention relates to an electrical system with a circuit for cooling a power module. The invention also relates to an inverter and a mobility device with such an electrical system. Technological background

[0002] The prior art discloses an electrical system comprising: - a switchgear cell comprising: • at least one power module, • a circuit for cooling the power module, comprising a cooling housing defining a channel for a cooling fluid flow, and - a housing in which the switch cell is arranged.

[0003] To position the switchgear cell in the housing, it is known to equip the housing with positioning means, such as positioning pins. This makes the manufacture and assembly of the switchgear cell in the housing more complex.

[0004] Therefore, it may be desirable to provide an electrical system that can overcome at least some of the problems and limitations mentioned above. Summary of the invention

[0005] According to a first aspect of the invention, an electrical system is proposed, comprising: - a switchgear cell comprising: • at least one power module and • a circuit for cooling the power module with a cooling housing defining a channel for a cooling liquid flow, a line for inlet of the cooling liquid into the cooling housing and a line for outlet of the cooling liquid from the cooling housing, wherein the inlet line and the outlet line each have a segment, wherein the segment of the inlet line and the segment of the outlet line extend substantially parallel to each other in the same direction; and - a housing in which the switchgear cell is arranged, the housing having two through-openings, the segment of the inlet line being inserted into one of the two through-openings and the segment of the outlet line being inserted into the other of the two through-openings.

[0006] Thus, the inlet and outlet lines allow positioning of the switch cell with respect to the housing, eliminating the need to provide special positioning means.

[0007] The invention may further comprise one or more of the following optional features in all technically possible combinations.

[0008] Optionally, the switch cell is attached to the housing.

[0009] Optionally, the cooling housing has an upper cooling surface and a lower cooling surface, both of which are cooled by the flow of the cooling liquid in the channel, wherein the power module is pressed against the upper cooling surface to be cooled, and the inlet line segment and the outlet line segment extend vertically downward.

[0010] Optionally, the inlet line segment and / or the outlet line segment outside the housing has an end designed for connection to a cooling fluid circulation system.

[0011] Thus, the connection of the cooling circuit is made outside the general housing to reduce the risk of leaks in the overall housing if this connection is poorly sealed.

[0012] The openings can also optionally be equipped with a seal.

[0013] Also optionally, each opening is equipped with a seal that is arranged between the opening and the segment inserted into the opening.

[0014] The power module is also optionally designed to perform a conversion between a direct voltage and an alternating voltage.

[0015] Also optionally, the switchgear cell further comprises a first busbar, called the upper busbar, and a second busbar, called the lower busbar, which are connected to the power module so that a DC voltage is supplied to the latter, the upper and lower busbars each having a first plate, at least one capacitor with two terminals welded to the first and second busbars, respectively, and a support for the upper and lower busbars with a fastening pin, the first plate of the upper busbar having an opening for receiving the fastening pin, the latter being provided with a rivet head for fastening the first plate of the upper busbar to the support.

[0016] Optionally, the support for the upper and lower busbars has fastening pins, and the first plate of the upper busbar has openings for receiving the fastening pins, which are provided with a rivet head for fastening the first plate of the upper busbar to the support.

[0017] Optionally, each mounting pin can be accommodated in a different mounting opening.

[0018] Also optionally, the switchgear cell further comprises a first busbar, called the upper busbar, and a second busbar, called the lower busbar, which are connected to the power module so that a DC voltage is supplied thereto, wherein the upper busbar and the lower busbar each have a first plate, at least one capacitor with two terminals welded to the first and second busbars, respectively, wherein the upper busbar and the lower busbar are stacked one above the other and a support for the upper and lower busbars has a base on which the first plates of the stacked busbars extend, wherein the first plate of the lower busbar has an opening leaving a portion, called the connecting portion, of the first plate of the upper busbar, and the base has an opening leaving a portion, called the connecting portion,the first plate of the lower busbar and at least a portion of the opening of the first plate of the lower busbar is left free to connect, on the one hand, a first terminal of the capacitor to the connecting portion of the lower busbar through the opening of the base and, on the other hand, a second terminal of the capacitor to the connecting portion of the upper busbar through the opening of the base and through the opening of the lower busbar.

[0019] Also optionally, the two terminals of the at least one capacitor can be welded to the first plate of the first or second busbar.

[0020] Also optionally, the cooling housing has an upper cooling surface and a lower cooling surface, both of which are cooled by the flow of the cooling liquid in the channel, wherein the power module is pressed against the upper cooling surface to be cooled, and the first plate of the upper busbar is in thermal contact with the lower cooling surface to be cooled.

[0021] Also optionally, the upper busbar and the lower busbar may be stacked on top of each other, and the first plate of the lower busbar is held between the first plate of the upper busbar and the support.

[0022] Also optional, the lower busbar is designed to have a high electrical potential and the upper busbar is designed to have a low electrical potential.

[0023] Also optionally, the support has a base on which the first plates of the stacked busbars extend, wherein the first plate of the lower busbar has an opening leaving a portion, called the connecting portion, of the first plate of the upper busbar free, and wherein the base has an opening leaving a portion, called the connecting portion, of the first plate of the lower busbar and at least a portion of the opening of the first plate of the lower busbar free, in order to connect, on the one hand, a first terminal of the capacitor to the connecting portion of the lower busbar through the opening of the base and, on the other hand, a second terminal of the capacitor to the connecting portion of the upper busbar through the opening of the base and the opening of the lower busbar.

[0024] Optionally, a first insulating layer may be inserted between the first plates of the upper and lower busbars.

[0025] Optionally, a second insulating layer is arranged between the top of the first plate of the upper busbar and the bottom of the cooling shroud.

[0026] Also optionally, the connecting section of the first plate of the lower busbar has a smaller thickness than the rest of the first plate of the lower busbar.

[0027] Also optionally, the first plate of the upper busbar has a protrusion that extends into the opening of the first plate of the lower busbar.

[0028] Also optionally, the elevation has a flat lower connecting wall that is thinner than the rest of the first plate of the upper busbar.

[0029] Also optionally, the support has a pin for positioning the first plate of the lower busbar.

[0030] Also optionally, the positioning pin is arranged so that the first plate of the lower busbar is held in position perpendicular to the fixing pin.

[0031] Also optionally, the positioning pin extends parallel to the mounting pin.

[0032] Optionally, the positioning pin penetrates into an opening in the first plate of the lower busbar and allows the lower busbar to be held in position.

[0033] Optionally, the carrier has pins for positioning the first plate of the lower busbar.

[0034] Optionally, the positioning pins are arranged so that the first plate of the lower busbar is held in position perpendicular to the fixing pins.

[0035] Optionally, the positioning pins extend parallel to the mounting pins.

[0036] Optionally, each positioning pin penetrates into a corresponding opening in the first plate of the lower busbar and allows the lower busbar to be held in position.

[0037] According to a second aspect of the invention, an inverter with an electrical system according to the first aspect of the invention is also proposed.

[0038] According to a third aspect of the invention, a mobility device with a voltage converter according to the second aspect of the invention or with an electrical system according to the first aspect of the invention is also proposed.

[0039] A mobility device is, for example, a motor-powered land vehicle, a train, an aircraft or a drone.

[0040] A motor-driven land vehicle is, for example, a motor vehicle, a motorcycle, a motorized bicycle or a motorized wheelchair.

[0041] According to a fourth aspect of the invention, a method for assembling an electrical system according to the first aspect of the invention is also proposed, comprising: - Positioning the switch cell in the housing by inserting the segment of the inlet line and the outlet line into the through holes to guide the positioning of the switch cell within the housing; then - Attach the switch cell to the housing. Short description of the characters

[0042] The invention will become more clearly understood from the following description, which is given by way of example only and refers to the accompanying drawings, in which: - Fig. 1 is a sectional view of an example of a switchgear cell in which the invention is implemented, - Fig. 2 a three-dimensional view of the switchgear cell, - Fig. 3 a three-dimensional view of the switchgear cell with a control board, a cover and a spring system removed, - Fig. 4 a three-dimensional view of a capacitor of the switch cell, - Fig. 5 is a block diagram of a method for manufacturing the capacitor, - Fig. 6 a three-dimensional sectional view of busbars and a busbar support of the switchgear cell, - Fig. 7 a three-dimensional view of the busbars, their support and the capacitors of the switchgear cubicle, showing the fastening pins before they are fitted with rivet heads, - Fig. 8 a Fig. 7 similar view after the fastening pins have been provided with rivet heads, - Fig. 9 a three-dimensional view of the underside of the busbar support, - Fig. 10 is a three-dimensional sectional view of the busbars, their support and the capacitors of the switchgear compartment, showing the connection of the capacitors to the busbars, - Fig. 11 is a block diagram of a method for welding the capacitor, - Fig. 12 is a sectional view of one of the capacitors, the busbars and their support, illustrating a step of the welding process, - Fig. 13 a three-dimensional view of control pins of power modules of the switchgear cell and their surroundings, - Fig. 14 a three-dimensional view of a variant of the control pins, - Fig. 15 a three-dimensional view showing the protrusions of the control pins from Fig. 14 illustrates, - Fig. 16 a block diagram of a method for producing the switchgear cell, - Fig. 17 is a three-dimensional sectional view of an electrical system, such as an inverter, incorporating the switchgear cell, and - Fig. 18 a block diagram of a method for assembling the electrical system. Detailed description of the invention

[0043] In the following description and the claims, the various parts and elements are spatially arranged with respect to an orthogonal coordinate system XYZ of any orientation with an X direction, a Y direction, and a Z direction. For clarity, the X direction is referred to as the left-to-right direction (in the figures, the arrow points left in the X direction), the Y direction as the front-to-back direction (in the figures, the arrow points backward in the Y direction), and the Z direction as the bottom-to-top direction (in the figures, the arrow points upward in the Z direction).

[0044] With reference to the figures, an example of a switchgear cell 100 in which the invention is implemented will now be described.

[0045] With reference to Fig. 1, the switchgear cell 100 initially comprises several power modules 102. In the example shown, three power modules 102 are provided. The power modules 102 are arranged side by side, for example.

[0046] The switchgear cell 100 further comprises a control board 104 of the power modules 102. The control board 104 is located, for example, above the power modules 102.

[0047] The switchgear cell 100 further comprises a circuit 106 for cooling the power modules 102.

[0048] The cooling circuit 106 includes a cooling housing 108 that defines a channel 110 for a cooling fluid flow. The cooling housing 108 has an upper cooling surface 112 and a lower cooling surface 113, both of which are cooled by the flow of the cooling fluid in the channel 110. The power modules 102 are thus pressed against the upper cooling surface 112 to be cooled.

[0049] To keep the power modules 102 pressed against the upper cooling surface 112, the switchgear cell 100 initially has, for example, a cover 114 that extends over the power modules 102, for example, between the control board 104 and the power modules 102. The cover 114 is fastened to the cooling housing 108, for example, with screws. The switchgear cell 100 further has a spring system arranged between the cover 114 and the power modules 102. This spring system is thus designed to bear against the cover 114 and press the power modules 102 toward the upper cooling surface 112. The spring system comprises, for example, a flexible sheet 116 for each power module 102, which is compressed between the cover 114 and the power module 102.

[0050] The cooling circuit 106 further comprises a line 118 for admitting the cooling liquid into the cooling housing 108 and a line 120 for discharging the cooling liquid from the cooling housing 108. The channels 118, 120 are arranged, for example, to the right and left of the cooling housing 108, respectively, and protrude vertically downwards therefrom.

[0051] The switchgear cubicle 100 further comprises a busbar, referred to as positive busbar 128, and a busbar, referred to as negative busbar 130, which are stacked one above the other. One of the two busbars 128, 130 thus forms a lower busbar, while the other forms an upper busbar. The busbar, referred to as positive busbar 130, and the busbar, referred to as negative busbar 128, each comprise a first plate and a second plate, the first plate being integrally formed with the second plate.

[0052] In the example described, the first plate of each of the two busbars is a flat plate.

[0053] For example, the first plate of the positive busbar 128 extends under the first plate of the negative busbar 130, and the first plate of the negative busbar 130 extends under the cooling shroud 108. Thus, the positive busbar 128 forms the lower busbar, and the negative busbar 130 forms the upper busbar. The reverse configuration is also possible.

[0054] In addition, the second plate of the positive bus bar 128 and the second plate of the negative bus bar 130 extend along one side of the cooling housing 108.

[0055] The positive busbar 128 is designed to have a high electrical potential, while the negative busbar 130 is designed to have a low electrical potential that is lower than the high electrical potential, so that the busbars 128, 130 are designed to have a DC voltage U DC is present.

[0056] The busbars 128, 130 are both connected to each of the power modules 102 via at least one terminal extending from their second plate in order to supply the DC voltage U DC to supply.

[0057] To hold the busbars 128, 130 in position, the switchgear cell 100 comprises, for example, a support 132, which is made in particular of an electrically insulating material, for example, plastic. More specifically, the support 132 has a base 134 on which the first plates of the busbars 128, 130 extend. The support 132 is attached to the cooling housing 108 such that the first plates of the busbars 128, 130 extend between the lower cooling surface 113 of the cooling housing 108 and the base 134 of the support 132. The busbars 128, 130 can thus be cooled by the lower cooling surface 113.

[0058] The switchgear cell 100 further comprises capacitors 136 each having two terminals 138, 140, which are connected to the busbars 128, 130 to respectively generate the DC voltage U DC These capacitors 136 are designed to provide the DC voltage U DCsmooth, and are generally referred to as “DC link capacitors”.

[0059] The capacitors 136 are arranged, for example, under the busbars 128, 130 and in particular under the bottom 134 of the support 132, with their terminals 138, 140 traversing the bottom 134 of the support to reach the busbars 128, 130, as described in more detail below.

[0060] With reference to Fig. 2, each power module 102 is designed, for example, to convert between the DC voltage U DC and a corresponding alternating voltage, for example phase voltages of an electrical machine.

[0061] Each power module 102 therefore has an external connector 202 designed for this AC voltage. The external connector 202 is, for example, in the form of a flat bar, which preferably has a thickness of at least 0.8 mm.

[0062] The switch cell 100 further includes a magnetic core 204 of a current sensor around each external connector 202. The magnetic core 204 is loop-shaped and has a gap in which, for example, a Hall-effect sensor for current measurement can be arranged.

[0063] To hold the magnetic cores 204 in position, the switchgear cell 100 further includes a frame 206 that supports the magnetic cores 204. This frame 206 is molded around the magnetic cores and secured to the cooling housing 108, for example, with screws.

[0064] With reference to Fig. 3, each power module 102 includes, in addition to the external AC connector 202, an external connector 302, called the positive connector, and an external connector 304, called the negative connector, designed to connect to the positive busbar 128 and the negative busbar 130, respectively. These external connectors 302, 304 are, for example, in the form of flat bars with a thickness of preferably at least 0.8 mm. In the example shown, two negative external connectors 304 are provided for each power module 102.

[0065] To perform the voltage conversion, each power module 102 has, for example, a switching arm and thus comprises, in a housing 305, two switches 306, 308 connected to each other at a center point, which is itself connected to the external AC connector 202 to obtain the AC voltage. The switching arm is connected between the external connectors 302, 304 so that it receives the DC voltage U DC These switches 306, 308 are in Fig. 3 is shown schematically for a single one of the power modules 102 and, for the sake of clarity, not for the others.

[0066] Each switch 306, 308 is preferably a controllable semiconductor switch, e.g. a switch with a transistor such as a metal oxide semiconductor field effect transistor (also referred to by the acronym MOSFET) or an insulated gate bipolar transistor (also referred to by the acronym IGBT) or a gallium nitride field effect transistor (also referred to by the acronym GaN-FET).

[0067] Each power module 102 further includes control pins 312, which specifically enable the control board 104 to control the switching of the switches 306, 308. These control pins 312 are bent to have a horizontal segment protruding from the housing 305 of the power module 102 and a vertical segment extending upwards toward the control board 104.

[0068] With reference to Fig. 4, each capacitor 136 includes a main body 402, wherein each terminal 138, 140 includes an inner portion 404 within the main body 402 and an outer portion 406 outside the main body 402 and protruding therefrom.

[0069] The main body 402 includes, for example, a capacitive device 408 and a molded-on portion 410 that covers the capacitive device 408. The capacitive device 408 is the part of the capacitor 136 in which electrical energy is stored. The molded-on portion 410 is made of resin, for example. The inner portion 404 of each terminal 138, 140 thus extends, for example, into the molded-on portion 410 to reach the capacitive device 408.

[0070] The outer part 406 of each of the terminals 138, 140 initially has a support section 412. The support section 412, for example, transitions into the inner part 404. The support section 412 is, for example, flat.

[0071] The outer portion 406 of each of the terminals 138, 140 further includes a connecting portion 414 configured for welding to a corresponding busbar 128, 130, as described in more detail below. The connecting portion 414 is attached to the support portion 412 via a bend and is spaced from the main body 402. The connecting portion 414 has an upper surface configured to be pressed against the associated busbar 128, 130 for welding thereto, for example, by laser welding.

[0072] To prevent the heat generated by welding from passing through the connecting portion 414 and reaching the main body 402, the outer part 406 of each of the terminals 138, 140 further includes a protective portion 416 attached to the connecting portion 414 by means of a bend so that it is bent between the connecting portion 414 and the main body 402. The bend between the connecting portion 414 and the protective portion 416 is opposite, for example, the bend between the support portion 412 and the connecting portion 414.

[0073] The outer part 406 of each of the terminals 138, 140 further comprises, for example, at least one auxiliary support portion 418 which is attached to the connecting portion 414 by means of a bend so that it extends in the direction of the main body 402, for example vertically downwards as in the example shown.

[0074] The auxiliary support portion 418 has an end opposite the connecting portion 414 that is in contact with the main body 402 and, for example, extends into it. This end is, for example, inserted into the molded-on portion 410, as shown in the illustrated example.

[0075] Furthermore, the end preferably has a hook 420, i.e., a protrusion. This protrusion is covered by the molded-on portion 410 in the projection direction of the auxiliary support portion 418, i.e., in the vertical direction in the example shown. This hook 420 limits the risk of the auxiliary support portion 418 being torn out of the molded-on portion 410 and the risk of deformation of the connecting portion 414 when the auxiliary support portion 418 is pulled parallel to the projection direction.

[0076] Thus, the connecting portion 414 is supported by the support portion 412 and, if appropriate, by the auxiliary support portion(s) 418.

[0077] Preferably, each terminal 138, 140 or at least its outer portion 406 is formed from a single bent, flat plate.

[0078] With reference to Fig. 5, an example of a method 600 for manufacturing the capacitors 136 will now be described.

[0079] In a step 602, the terminals 138, 140 are obtained, with the protective section 416 for each of them merging into the connecting section 414. Each resulting terminal 138, 140 is, for example, flat and cut from a plate. Before this plate is bent, the outer part 406 and the inner part 404 are coplanar and merge into one another.

[0080] In a step 604, in particular, the outer part 406 between the protective section 416 and the connecting section 414 is bent in order to bring the protective section 416 under the connecting section 414. Further bending operations on the outer part 406 of the terminal 138, 140 can also be carried out in step 604, for example, to give it the Fig. 4. After bending the protective section 416 under the connecting section 414, for example, the auxiliary support section(s) 418 can be bent with respect to the connecting section 414. Finally, the inner part 404 and the support section 412 can also be bent completely with respect to the connecting section 414, for example.

[0081] In a step 606, the inner parts 404 of the terminals 138, 140 are attached to the capacitive device 408. Thus, the protective portion 416 extends between the connecting portion 414 and the main body 402, which does not have a molded-on portion 410.

[0082] In a step 608, the overmolded portion 410 is formed around the capacitive device 408, around the inner part 404 of the terminal 138, 140 and around the hooks 420, if provided.

[0083] With reference to Fig. 6, for example, an insulating layer 502 is provided over the first plate of the upper busbar 130 to insulate it from the cooling housing 108. Likewise, an insulating layer 504 is arranged between the busbars 128, 130.

[0084] With reference to Fig. 7, the support 132 includes mounting pins 702, each of which is received in openings formed in the first plate of the upper busbar 130. The mounting pins 702 extend upwardly, for example, from the bottom 134 of the support 132.

[0085] The support 132 further comprises, for example, pins 704 for positioning the lower busbar 128. Each positioning pin 704 penetrates a corresponding opening in the first plate of the lower busbar 128 and allows the lower busbar 128 to be held in position. The positioning pins 704 are arranged, in particular, to hold the first plate of the lower busbar 128 in position perpendicular to the fastening pins 702. The positioning pins 704 extend, for example, parallel to the fastening pins 702, i.e., upwards.

[0086] With reference to Fig. 8, the fastening pins 702 are each provided with rivet heads to fasten the first plate of the upper busbar 130 to the support 132. The lower busbar 128 is held in position because its first plate is clamped between the first plate of the upper busbar 130 and the base 134 of the support 132. The formation of rivet heads consists in deforming the end of each positioning pin 704, for example, by hot forming, to form a stop for the first plate of the upper busbar 130.

[0087] With reference to Fig. 9, the first plate of the lower busbar 128 has an opening 902 (e.g., a window or cutout) for each capacitor 136, leaving a portion 904 of the first plate of the upper busbar 130 visible. This portion 904 is designed for connection to one of the terminals 138, 140 of the capacitor 136 and is referred to below as "connection portion 904."

[0088] For example, the connecting portion 904 of the upper busbar 130 has a protrusion 906 that extends into the opening 902 of the first plate of the lower busbar 128.

[0089] Furthermore, for each capacitor 136, the base 134 of the support 132 has an opening 908 (e.g., a window or cutout) that exposes a portion 910 of the first plate of the lower busbar 128. This portion 910 is designed to connect to the other of the terminals 138, 140 of the capacitor 136 and is referred to below as the “connecting portion 910.” Preferably, the connecting portion 910 of the first plate of the lower busbar 128 has a smaller thickness than the rest of the first plate of the lower busbar 128, for example, a thickness at least 25% smaller. The connecting portion 910 has, for example, a thickness of at most 0.6 mm, while the first plate of the lower busbar 128 has a thickness of at least 1 mm around the connecting portion 910. This smaller thickness can simplify the welding of the terminals 138, 140 of the capacitor 136.

[0090] The opening 908 of the base 134 also exposes the opening 902 of the first plate of the lower busbar 128. Thus, the connecting portion 904 of the first plate of the upper busbar 130, and in particular the protrusion 906, is visible through the opening 908 of the base 134 and through the opening 902 of the first plate of the lower busbar 128.

[0091] The elevation 906 has, for example, a flat lower connecting wall 912. This connecting wall 912 preferably has a smaller thickness than the remaining first plate of the upper busbar 130, for example, a thickness at least 25% smaller. The connecting wall 912 has, for example, a thickness of at most 0.6 mm, while the first plate of the lower busbar 128 has a thickness of at least 1 mm around the elevation 906. This smaller thickness can simplify the welding of the terminals 138, 140 of the capacitor 136.

[0092] In addition, the first plate of the upper busbar 130 has an opening (e.g., a window or cutout) for each connecting portion 910 of the first plate of the lower busbar 128, which leaves the connecting portion 910 visible.

[0093] With reference to Fig. 10, for each capacitor 136, one of the terminals (in the example shown, the negative terminal 140) is connected, for example, by welding, to the connecting portion 904 of the upper busbar 130 and in particular to the connecting wall 912 of the elevation 906. The other of the terminals (in the example shown, the positive terminal 138) is connected, for example, by welding, to the connecting portion 910 of the lower busbar 128.

[0094] With reference to Fig. 11, an example of a method 1100 for welding the capacitors 136 to the busbars 128, 130 will now be described.

[0095] In a step 1102, the terminals 138, 140 of the capacitor 136 are each pressed against the busbars 128, 130. The connecting sections 414 of the terminals 138, 140 are pressed, for example, against the connecting wall 912 of the elevation 906 of the upper busbar 130 or against the connecting section 910 of the lower busbar 128. The pressing preferably takes place surface to surface, for example, over a surface of at least 20 mm 2 .

[0096] In a step 1104, in order to weld each terminal 138, 140 to the busbar 128, 130 against which this terminal 138, 140 is pressed, a laser beam is directed onto the busbar 128, 130 opposite to the adjacent terminal 138, 140.

[0097] With reference to Fig. 12, the laser beam 1202 is directed by a laser 1204 in a direction 1206 that passes sequentially through the busbar 128, 130, the connecting portion 414 of the pressed terminal 138, 140, the protective portion 416 of the pressed terminal 138, 140, and the main body 402 of the capacitor 136. The direction 1206 is thus perpendicular to the connecting portion 414.

[0098] In addition, the presence of an opening in the first plate of the upper busbar 130 allows the laser beam to directly reach the connecting portion 910 of the first plate of the lower busbar 128 in order to weld this connecting portion 910 to the terminal of the capacitor 136 against which it is pressed.

[0099] With reference to Fig. 13, a notch 1302 is provided in the frame 206 for each control pin 312 for positioning this control pin 312. For the sake of clarity, this positioning notch 1302 has been provided with a reference numeral in the figures for only one of the control pins.

[0100] The positioning notch can ensure the position of the control pin 312, thereby simplifying the connection of the control pin 312 to the control board 104. Furthermore, when this connection is established by force insertion, the positioning notch 1302 reduces the risk of the control pin 312 twisting during force insertion.

[0101] The positioning notch 1302 has, for example, two walls 1304, 1306, between which an angle is enclosed that is between 80° and 100°, preferably between 90° and 95°, and more preferably 90°, so that the control pin 312 is correctly positioned. The control pin 312 thus has an end segment 1308 that ends in a tip 1310. The control pin 312 is designed for insertion into a corresponding receiving hole in the control board 104 via its tip 1310. This end segment 1308 is, for example, straight (vertical in the example shown) and has a positioning section 1312 with a length of at least 5 mm, which extends over its entire length at most 0.5 mm from each of the walls 1304, 1306 of the positioning notch 1302.

[0102] The Fig. The control pin 312 shown in Figure 13 is thus designed, for example, to be freely inserted (not by force) into the receiving hole and then welded to the control board 104.

[0103] With reference to Fig. 14 shows another embodiment.

[0104] In this further example, the control pin 312 is designed, for example, to be inserted with force into the receiving hole of the control board 104.

[0105] For this purpose, the end segment 1308 has a force-insertion section 1402 that is wider than the receiving hole of the control board. The force-insertion section 1402 comprises, for example, two rods that converge at their ends and are separated by a gap in the middle.

[0106] Preferably, the frame 206 has at least one bevel 1404 for guiding the control pin 312 and, in particular, its bending in the direction of the positioning notch 1302. Thus, the bevel 1404 simplifies the insertion of the control pin 312 into the positioning notch 1302, in particular in the vertical direction.

[0107] With reference to Fig. 15, the end segment 1308 further includes a protuberance 1502 projecting perpendicular to the vertical direction so as to extend vertically above the bearing member, preferably less than 0.1 mm vertically from the frame 206 and preferably in contact with the frame 206.

[0108] Thus, when the control pin 312 is forcibly inserted, the protrusion 1502 comes into contact with the bearing part, thereby exerting a counteraction on the pin. This avoids the need to temporarily install a removable stop during the force insertion process. In particular, the absence of this temporary stop allows for a significant simplification of the tools used for force insertion.

[0109] This protrusion 1502 is located, for example, between the force insertion section 1402 and the positioning section 1312.

[0110] With reference to Fig. 16, a method 1600 for manufacturing the switch cell 100 includes, for example, the following steps.

[0111] In a step 1602, the power module 102 is obtained with the control pins 312 protruding from the housing 305.

[0112] In a step 1604, the control board 104 is provided with a hole for receiving each control pin 312.

[0113] In a step 1606, the power module 102 is attached to the cooling housing supporting the frame 206. During this attachment process, the power module 102 is lowered vertically so that the control pins 312, which are guided in particular by the bevels 1502, each penetrate the positioning notches 1302.

[0114] In a step 1608, the control board 104 is lowered vertically toward the power modules 102 so that the control pins extending in the positioning notch are each inserted into the receiving holes.

[0115] With reference to Fig. 17, the switchgear cell 100 is designed, for example, to be part of an electrical system, for example an inverter 1702.

[0116] The inverter 1702 comprises, for example, an electromagnetic compatibility (EMC) filter 1704 connected between the two busbars 128, 130, and a housing referred to as the overall housing 1706 in which the EMC filter 1704 and the switchgear cell 100 are arranged.

[0117] The overall housing 1706 includes, for example, a main part 1708 with an upper opening 1710 and a cover (not shown) designed to close this upper opening 1710. The overall housing 1706 further includes, for example, a lower opening 1712 for the passage of the capacitors 136 and a cover 1714 for closing this lower opening 1712.

[0118] The inlet conduit 118 and the outlet conduit 120 have two segments 1716 and 1718, respectively, which extend substantially parallel to each other in the same direction.

[0119] The overall housing 1706 then has two openings 1720, 1722 for the passage of the segments 1716 and 1718, respectively. Each opening 1720, 1722 has, for example, a seal 1724, 1726, which is intended to interact with the inserted segment 1716, 1718.

[0120] The segments 1716, 1718 thus have respective ends 1728, 1730 outside the overall housing 1706, which are designed for connection to a cooling fluid circulation system. These ends 1728, 1730 can, for example, have inlet bevels. Thus, the cooling circuit connection is established outside the overall housing 1706 to reduce the risk of leaks in the overall housing if this connection is poorly sealed.

[0121] With reference to Fig. 18, a method 1800 for assembling the electrical system 1702 is now described.

[0122] In a step 1802, the switch cell 100 is inserted into the overall housing 1706 through the upper opening 1710. Segments 1716, 1718 of the leads 118, 120 are inserted into the openings 1720 and 1722, respectively, formed in the main part 1708 to guide the positioning of the switch cell 100 within the main housing 1706.

[0123] In a step 1804, the switch cell 100 is attached to the main part 1708 of the overall housing 1706, for example by screwing.

[0124] In a step 1806, the upper opening 1710 of the main part 1708 is closed by the cover (not shown) of the overall housing 1706.

[0125] Finally, it should be noted that the invention is not limited to the embodiments described above. In particular, it will be apparent to those skilled in the art that various modifications to the embodiments described above can be made based on the teachings disclosed above.

[0126] In particular, the order of the steps of the methods described above could be changed according to any technically possible order.

[0127] In the above detailed description of the invention, the terms used are not to be interpreted as limiting the invention to the embodiments described in the present specification, but are to be interpreted as including all equivalents that a person skilled in the art can provide by applying his or her general knowledge to the implementation of the teachings disclosed above.

Claims

[1] Electrical system (1702), which includes: - a switch cell (100) comprising: • at least one power module (102) and • a circuit (106) for cooling the power module, comprising a cooling housing (108) defining a channel (110) for a cooling liquid flow, a line (118) for inlet of the cooling liquid into the cooling housing (108), and a line (120) for outlet of the cooling liquid from the cooling housing (108), wherein the inlet line (118) and the outlet line (120) each have a segment (1716, 1718), wherein the segment of the inlet line and the segment of the outlet line extend substantially parallel to each other in the same direction; and - a housing (1706) in which the switching cell (100) is arranged, wherein the housing (1706) has two through-openings (1720, 1722), wherein the segment of the inlet line is inserted into one of the two through-openings and the segment of the outlet line is inserted into the other of the two through-openings. [2] The electrical system (1702) of the preceding claim, wherein the cooling housing (108) has an upper cooling surface (112) and a lower cooling surface (113), both of which are cooled by the flow of the cooling liquid in the channel (110), the power module (102) being pressed against the upper cooling surface (112) to be cooled, and the segment of the inlet conduit and the segment of the outlet conduit extending vertically downwards. [3] Electrical system (1702) according to any one of the preceding claims, wherein the segment of the inlet conduit and / or the segment of the outlet conduit have an end (1728, 1730) outside the housing adapted for connection to a system for circulating the cooling fluid. [4] Electrical system (1702) according to one of the preceding claims, wherein the openings (1720, 1722) are each provided with a seal (1724, 1726). [5] Electrical system (1702) according to one of the preceding claims, wherein the at least one power module (102) is designed to perform a conversion between a direct current voltage and an alternating current voltage. [6] Electrical system according to one of claims 1 to 5, wherein the switchgear cell further comprises a first busbar (130), called the upper busbar, and a second busbar (128), called the lower busbar, connected to the power module (102) so as to supply a direct current (UDC) thereto, the upper and lower busbars each comprising a first plate, at least one capacitor (136) with two terminals welded to the first and second busbars (128, 130) respectively, and a support (132) for the upper and lower busbars (128, 130) with a fastening pin (702), the first plate of the upper busbar (128, 130) having an opening for receiving the fastening pin (702), the latter being provided with a rivet head for fastening the first plate of the upper busbar (130) to the support (132). [7] Electrical system according to the preceding claim, wherein the cooling housing (108) has an upper cooling surface (112) and a lower cooling surface (113), both of which are cooled by the flow of the cooling liquid in the channel (110), the power module (102) being pressed against the upper cooling surface (112) to be cooled, and the first plate of the upper busbar being in thermal contact with the lower cooling surface (113) to be cooled. [8] An inverter comprising an electrical system (1702) according to any one of claims 1 to 6. [9] Mobility device with an electrical system according to one of claims 1 to 6 or an inverter according to claim 7. [10] A method of assembling an electrical system (1702) according to any one of claims 1 to 6 or an inverter according to claim 7, comprising: - positioning the switch cell (100) in the housing by inserting the segment (1716, 1718) of the inlet line and the outlet line (118, 120) into the through-openings (1720, 1722) to guide the positioning of the switch cell (100) within the housing; then - Fasten the switch cell (100) to the housing (1706).

Images