Electric current distribution system with electromagnetic fields control element

Abstract

The invention relates to an electric current distribution system (ECS) comprising: a first terminal set (1TS) comprising one or more first terminals (1T), a second terminal set (2TS) comprising one or more second terminals (2T), and at least one two electric current conductors (C) electrically connected between the terminals (1T, 2T) of the first and second terminal sets (1TS, 2TS), wherein the at least one two electric current conductors (C) comprises a middle section (MS) provided between a first end (1E) and a second end (2E) of the at least one two electric current conductors (C), and wherein the middle section (MS) comprises at least one bend portion and plurality of electromagnetic field control elements (G).

Description

ELECTRIC CURRENT DISTRIBUTION SYSTEM WITH ELECTROMAGNETIC FIELDS CONTROL ELEMENTField of the invention

[0001] The invention relates to an electric current distribution system with an electric conductor having electromagnetic fields control elements.Background of the invention

[0002] Electric systems having various types of busbars having various advantages are known in the art. One example is WO2024199608 disclosing an electric panel with an electrical conductor manufactured by additive manufacturing.

[0003] US6433271 discloses a busbar system for air insulated switchgear comprising cylindrical tubular busbars having a high copper content. The tubular busbars are joined together by inserting an insertion end of one tube into a receiving end of an adjacent tube, using a conductive contact element in the form of a coil spring to fix the tubes together and establish electrical contact. While the tubular busbars reduce space requirements compared to rectangular busbars and benefit from the skin effect, the system relies on modular straight tube segments that are connected at joints. The system does not address problems related to current distribution in the conductor.Summary of the invention

[0004] In an aspect, the invention relates to an electric current distribution system comprising: a first terminal set comprising one or more first terminals, a second terminal set comprising one or more second terminals, and at least two electric current conductors electrically connected between the terminals of the first and second terminal sets, wherein the at least two electric current conductors comprises a middle section provided between a first end and a second end of the at least two electric current conductors, and wherein the middle section comprises at least one bend portion.

[0005] One or more bend portions are advantageous in that it has the effect, that a monolithic, modular and / or self-supporting conductor can be manufactured and installed in the distribution system only by connecting its ends to terminals of electric components, conductor modules, conductors, interface modules and the like i.e. faster mounting with reduced electric losses in the electric system is facilitated. An electric system with two conductors may be a DC system and an electric system with three or more systems may be an AC system.

[0006] A conductor having one or more bend portions is advantageous in that it enables a monolithic conductor to connect two terminal sets that are located at different spatial coordinates (X, Y, Z). When a first terminal set e.g. is positioned at coordinates (X, Y, Z) and a second terminal set is positioned at coordinates (X1, Y', Z') where one of the coordinates are different, the conductor needs to change direction to connect the two terminal sets. By providing a conductor with one or more such as at least two bend portions, the conductor can be manufactured as a single monolithic piece that follows the required routing path without the need for connecting multiple conductor parts with bolts and nuts, weldings, or the like. This reduces the number of electrical connections, thereby reducing ohmic losses and heat generation. Furthermore, a monolithic conductor with one or more bend portions is faster to mount compared to traditional busbar assemblies that require multiple connections, and the precision of the conductor location in the system is improved as tolerances are only needed at the terminal connections rather than at each intermediate connection point.

[0007] According to an embodiment of the invention, the first terminal set and / or the second terminal set is comprised by an electric component, and wherein the first terminal set and / or the second terminal set is electrically connecting the electric current conductor and the electric component.

[0008] The first and second terminal sets may be comprised by an electric component. In an embodiment the first terminal set is comprised by a first electric component and the second terminal set is comprised by a second electric component. With this said, one of the first and second terminal sets may simply be terminals that are configured for being connected to other conductors or electric components.

[0009] The conductor of the present invention may be used as known busbars to connect electric components and supply power to and from electric components. Electric components may in this context include: power sources, loads, breakers, switchgears, power modules, converters, inverters, reactors, motors, generators, transformers, distribution conductors, etc. By using conductors of the present invention, the material used in the distribution system for conducting current is reduced significantly as described above.

[0010] According to an embodiment of the invention, the electric current conductor is a tubular conductor.

[0011] A tubular conductor is advantageous in that it has the effect, that the center of the conductor is air and thus reduces weight and cost of the conductor. Further, due to skin effect the middle part of a conductor is not used for conducting much of the total AC current conducted and therefore can be saved.

[0012] According to an embodiment of the invention, a first end of the electric current conductor is configured for being connected to the first terminal set in a first spatial point (X, Y, Z), wherein a second end of the electric current conductor is configured for being connected to the second terminal set in a second spatial point (X’, Y’, Z’), wherein the first and second spatial points are different, and wherein at least one of the X, Y and Z coordinates of the second spatial point is different from the corresponding X, Y or Z coordinates of the first spatial points.

[0013] An example of a spatial point is the location of a terminal of a component at which the conductor is to be connected. Another example is a center of a terminal of a component at which the conductor is to be connected. Hence, a spatial point may be a plane or center of a plane defined e.g. by X,Y, X,Z, or Y,Z coordinates of the spatial point. Hence, a terminal or interface area may define a plane and the spatial point may be the center of this plane.

[0014] According to an embodiment of the invention, the electric current conductor, between the first and second spatial points, travels through a third spatial point (X”,Y”, Z”) wherein all of the X, Y and Z coordinates of the third spatial points are different from all of the X, Y and Z coordinates of the first and second spatial points.

[0015] Spatial points are defined by X, Y and Z coordinates. Hence, spatial points that are different are different points in space i.e. at least one of the X, Y and Z coordinates are different. This is advantageous in that the conductor may then connect two components located in the same Y and Z coordinates but with different X coordinate. This would correspond to a system layout where two components are located side-by-side, and which are connected by the conductor.

[0016] When all of the X, Y and Z coordinates are different, it indicates that a spatial point (such as the third), with respect to another spatial point (such as the first or second) are different along two or all three axes. Hence, the conductor may be connected to a component / terminal set and then extend away, along the Y axis, down, along the Z axis and to one of the sides along the X axis until it can be connected to another component / terminal set. Hence a longitudinal center axis of the conductor may start and stop at first and second spatial end points. Following this center axis between first and second spatial end points, the center axis passes through the third spatial point and the center axis will at this third spatial point have at least two of its three coordinates different from the coordinates of the first and second end points. Further, it may have one coordinate identical with one coordinate of either the first and the second end points.

[0017] According to an embodiment of the invention, the electric conductor between the first and second spatial points is monolithic.

[0018] It is advantageous to have a monolithic conductor between two spatial points in that it is much faster to mount compared to traditional busbars that require providing a plurality of holes, in two busbars, for bolts and connection of these two busbars. This is true when the distance, along a longitudinal center axis, between the spatial points at which the conductor passes through / is connected is long. Long in this context is more than e.g. 30cm and up and could be several meters such as 10m, 15m, 20m and even longer. It is especially true when these connection points are located differentlyin space i.e. at different X, Y andZ coordinates. This is because no busbar connections are needed between the two spatial points contrary to traditional busbar systems.

[0019] According to an embodiment of the invention, the electric current conductor is monolithic between a conductor terminal of a first end of the electric current conductor and a conductor terminal of a second end of the electric current conductor.

[0020] A monolithic conductor is advantageous in that it has the effect that it is faster and easier to mount. Further, the risk of human errors in relation to mounting is reduced.

[0021] According to an embodiment of the invention, the electric current conductor is self-supporting.

[0022] A conductor that is self-supporting between two terminals is advantageous in that no support brackets are needed between the conductor and other system elements. If the conductor is both monolithic and self-supporting, the conductor is easy and fast to mount and handle in general.

[0023] According to an embodiment of the invention, the electric current conductor comprises at least one electromagnetic field control element.

[0024] A conductor with electromagnetic field control elements is advantageous in that it has the effect that the current conducted through the middle section is controlled according to a plurality of predetermined current paths, referred to as branches, defined by the plurality of electromagnetic field control elements. This has the effect, that material used for conducting current in the system is reduced and therefrom cost of the system is reduced. This is especially true when there are current conducting elements, within a distance of e.g. 100cm of the conductor, creating electromagnetic coupling effect. This is because the electromagnetic field control elements control how the current is conducted through the conductor and thereby is able to eliminate the effect of electromagnetic coupling effect from such current conducting elements. An example of a current conducting element is an electric current conductor.

[0025] Hence, an effect of a conductor of the present invention is that the current density in a conductor is controlled thereby, eliminating the negative effects of proximity effect from e.g. a nearby conductor. Following this, material consumption can be reduced and heat generation from the conductor can be reduced, which is beneficial with respect to lifetime of electric components and cooling system of the electric current distribution system.

[0026] According to an embodiment of the invention, the middle section is comprised by an electric cabinet.

[0027] The electric distribution system comprising a conductor with an electromagnetic field control element of the present invention is particularly advantageous for high-power electrical systems, e.g. from lOkW and up, such as 22kW, 50kW, HOkW, 150kW, 225kW, 300kW, 350kW, 500kW, 800kW, 1MW, 2MW, 3MW, or even higher, such as e.g. 5MW or 10MW systems, with voltages of e.g. 110V, 230V, 400V, 690V, 800V, 1000V, 1500V, 6kV or e.g. lOkV, and currents from e.g. 16A, 32A or 64A, to several hundreds, e.g. 100A, 200A or 500A, or even thousands, e.g. lOOOAto 5000A.

[0028] A conductor of the distribution system may be used for local connections inside such a high-power electrical system, e.g. contained inside an electrical cabinet housing a power converter, inverter, transformer, generator, electric motor, breaker, high-power battery system, battery charger, or similar power systems, possibly including capacitors, reactors or inductors, power resistors, dump loads, etc. A system, component or conductor may be categorized as a high-power system, component or conductor if it is operating at currents in the range of 500- 1000 A or higher.

[0029] Non-limiting examples of such electrical installations / systems include energy facilities such as grid components such as substations with grid support, voltage regulation, power to x plants, etc., energy generating systems such as wind turbines, wind farms, solar plants, etc., electric installations in a private homes and industry, industrial machines, household appliances, etc. and means for transportation such asairplanes, heavy duty vehicles, light duty vehicles such as automobiles, trains, ships, etc.

[0030] According to an embodiment of the invention, the length of the middle section at least 200cm, such as at least 400cm such as between 100cm and 20.000cm.

[0031] The electric system of the present invention is not limited to systems that can be comprised by one or more electric cabinets. In fact, the longer distance the system needs current conduction, and where it is possible to use a system of the present invention with conductors having electromagnetic field control elements the better with respect to losses, cost, heat, mounting, etc.

[0032] According to an embodiment of the invention, the middle section has an outer perimeter length of at least 4cm.

[0033] No matter if the conductor has a spheric, square or other geometry that has a massive center or non-massive center it is advantageous to have an outer perimeter that is at least 4cm to be able to conduct the high currents indicated above. In fact, the perimeter may be significantly higher such as up to or above 20cm. The large perimeter is typically rectangular conductors but not limited to this geometry. Hence, any perimeter between 4cm and 30cm would not be considered unusual.

[0034] It should be noted that it is the cross-sectional area of the current conducting material that is decisive for the number of amps a given conductor can conduct. Hence, the distance between the inner and outer perimeter of e.g. a tubular conductor may be relative to the skin depth. Hence, if the thickness from outer to inner perimeter is 10mm (and e.g. the skin depth is 10mm) and the outer diameter of the conductor is 100mm, the cross-sectional area may be pi*(50A2-40A2)= 2874mmA2.

[0035] According to an embodiment of the invention, the electric current conductor follows a path between two spatial points that is longer than the direct distance between the two spatial points.

[0036] This is advantageous in that it has the effect, that more than one conductor can connect two components without the two conductors physically touch each other.

[0037] According to an embodiment of the invention, the electric current conductor comprises a contact surface.

[0038] According to an embodiment of the invention, the middle section comprises a contact surface.

[0039] A contact surface such as a planer surface part of a circular conductor is advantageous in that it has the effect that other conductors, terminals, components, conductor support, etc. can be connected to the conductor at the contact surface.

[0040] According to an embodiment of the invention, a part of the contact surface comprises a divergent portion

[0041] A divergent portion is advantageous if it matches divergent portions of another component such as an end part. Then the connection between the divergent portion of the end part and the divergent portion of the contact surface is optimized from an electric resistance point of view.

[0042] According to an embodiment of the invention, the electric current conductor has an internal cooling channel.

[0043] In case of a tubular conductor, the area between the inner perimeter and the center of the conductor can be used for conducting a cooling fluid thereby assisting in temperature regulating. This results in that it is possible to conduct more current through the same cross-sectional area of conductive material.

[0044] According to an embodiment of the invention, theat least one electromagnetic field control element is non-electric conductive.

[0045] A non-electric conductive control element should be understood as part of the conductor than is electrically isolating one part of the conductor from another part. This has the effect, that the total current through the conductor is separated into controllable current fractions.

[0046] According to an embodiment of the invention, the at least one electromagnetic field control element is implemented in the electric current conductor as air gaps in the perimeter of the electric current conductor.

[0047] The current separating effect of the electromagnetic field control elements can be obtained by various implementation hereof. One is by providing a groove from the outer perimeter of the conductor that extends into the electric current conducting material towards the center of the conductor. Such groove can be filled with a material the complies with specific requirements to electric isolation.

[0048] One such material is air which is advantageous in that it fills the groove as the groove is provided. Further, air is advantageous in that it is a free and can fill even the tiniest groove.

[0049] According to an embodiment of the invention, air gaps can be filled with a material of the list of materials comprising: ceramics, glass, polymer and paper.

[0050] A filling material is advantageous in that it has the effect, that current separation in the conductor is maintained even though the cable is flexing such as bending or vibrating. The choice of filling material is based on the electric system in which the conductor is to be used. Typical filling materials could be a polymer material sometimes referred to as plastic, resin, PET (PET; polyethylene terephthalate) or PVC (polyvinyl chloride) and rubber.

[0051] It should be noted that a coating such as a natural oxide layer on Aluminum may also be considered a filling material. As such layer is created on the outer perimeter of an Aluminum conductor by contact with Oxygen, Aluminum conductors may in some situations be preferred over Copper conductors.

[0052] According to an embodiment of the invention, the at least one electromagnetic field control element separates the outer perimeter of the electric current conductor into a plurality of conductor branches.

[0053] By separating the outer perimeter in branches, a conductor is provided that facilitates separating the total current into current fractions conducted by thesebranches. Thereby, the current fractions’ way through the conductor can be controlled by design of the electromagnetic field control elements and thereby indirectly of the branches.

[0054] According to an embodiment of the invention, the impedance of the plurality of conductor branches are predetermined.

[0055] According to an embodiment of the invention, the plurality of conductor branches has the same impedance to electric current.

[0056] It should also be understood that voltage across such impedance's are dependent of the type of impedance and signal. As example, resistive impedance have voltage drops in phase with current, inductive impedance have voltage drops leading the current of same conductor for self-inductance and voltage drop leading current of other conductor for mutual inductive impedance

[0057] By designing the electromagnetic field control elements and thereby designing the branches, the resistivity of the individual branches is controlled. The main branch related design elements are length of the branches, hight (depth of electromagnetic field control elements) and width. By controlling the branches according to these design parameters, it is possible to design branches which carries an equal fraction of the total current.

[0058] It should be noted that when referred to “the same” and “equal fraction” in this document, 100% similarity is difficult to reach and thus this should be understood as referred to ±5%. Hence, if 4 branches are provided, these are designed to each conductor 25% of the total current. This is considered achieved if ±5% of these 25% is conducted in each of the branches.

[0059] According to an embodiment of the invention, the depth of at least one of the plurality of electromagnetic field control element is between 5% and 125% of the skin depth of the current conducted by the electric current conductor.

[0060] A groove depth between 25% and 125%, such as between 30% and 100%, such as between 35%-50% of the skin depth may be sufficient to control the most of the current through the conductor by controlling the branch through the conductor.

[0061] Note that perimeter and circumference are both ways of referring to the outer distance around a conductor. Circumference is typically used when the conductor is spherics and perimeter is typically used when the conductor has a geometry that is different from spherics.

[0062] The current has a tendency to be conducted towards the outer perimeter of the conductor due to the effect of the electromagnetic field referred to as skin effect. The depth into the conductor where the current is conducted is referred to as the skin depth and depend mainly on the frequency of the current. Hence, a DC current is distributed equally in a conductor and as frequency increases i.e. if an AC current is conducted, the closer to the outer perimeter the current is conducted. Thus, the higher frequency, the smaller skin depth.

[0063] A conductor having 4 electromagnetic field control elements having a depth over 100% of the skin depth would facilitate separating the total current into four current fractions, and if no other electromagnetic fields impact the conductor, e.g. 60% of the total current is guided in the four current fractions. If not the depth of the electromagnetic field control elements equals the material thickness of the conductor, the last 40% of the total current will be conducted in the conductor material between the bottoms of the electromagnetic field control elements and an inner perimeter / center of the conductor.

[0064] The skin effect is caused by currents induced by the changing electromagnetic field resulting from the alternating current conducted by a conductor. The skin effect results in a tendency for the current conducted by the conductor to seek towards the outer edge of the conductor. Most current is conducted closest to the perimeter of the conductor and thus, the smaller skin depth. Hence, as the distance increases from the perimeter towards the center of the conductor, the current density decreases.

[0065] For standard AC power distribution systems operating at 50Hz or 60Hz, the skin depth in copper is approximately 8-9mm and in aluminum approximately 10-11mm. For systems with higher frequency components, such as systems comprising semiconductor switches, reactors, or power converters, the effective frequency may be higher and thus the skin depth may be smaller. The skilled person may determine the appropriate skin depth based on the operating frequency of the system and the resistivity of the conductor material using the equation provided below (EQI). In systems where multiple frequency components are present, the groove depth may be designed based on the dominant frequency or the highest frequency component that carries significant current. Hence, the design of the electromagnetic field control elements may be adapted to the specific operating conditions of the electric current distribution system in which the conductor is to be used.

[0066] According to an embodiment of the invention, at least one of the plurality of electromagnetic field control element only partly extends between the first end and the second end of the electric conductor.

[0067] According to an embodiment of the invention, the electromagnetic field control element follows a perimeter track between two spatial points that is longer than the direct distance along the perimeter between the two spatial points.

[0068] Direct distance should be understood as the shortest distance between the two spatial points. Hence, the perimeter track, such as a helix groove, between the two spatial points is longer than the shortest distance therebetween.

[0069] According to an embodiment of the invention, the distance between a first end and a second end of the electromagnetic field control element is at least 2.5 times the diameter of the conductor.

[0070] Diameter refers to tubular conductors or cylindrical conductors. For other geometries, such as rectangular, the distance between ends of a groove / electromagnetic field control element could be 2.5 times the height or width of the conductor.

[0071] The electromagnetic field control element should have a certain length such as longer than 20cm, 25cm, 30cm, 35cm and up for the effect of the electromagnetic field control element correspond to the additional costs related to providing it.

[0072] As the establishing of the groove increases the current path through the conductor, the relationship between the length of the conductor and the diameter of the conductor and thus the perimeter of the conductor should be considered before implementing spiral / helix grooves. Below, the benefit of the spiral groove may be present but may not be significant enough compared to the added DC resistance added by extending the current path to implement the spiral groove thus, this need to be considered.

[0073] According to an embodiment of the invention, at least one of the plurality of electromagnetic field control element travel around the outer perimeter of the electric current conductor, thereby forming the plurality of conductor branches as helix branches.

[0074] A conductor with helix branches is advantageous in that it has the effect, that the current conducted in the individual of the plurality of branches travels around the conductor perimeter. This is particularly relevant in AC multi-phase systems and in AC multi -conductor systems where an electromagnetic field is created around the individual conductor. An electromagnetic coupling effect, in this context referred to as proximity effect, is associated with the electromagnetic field, an effect that impact the current conducted in a neighboring conductor. The closer the two conductors are, the higher impact. Hence, due to the proximity effect, the current is either dragged towards or pushed away from the neighboring conductor. If no helix was established, this would cause the current to run in undesirable patterns, such as in loops or concentrated in one side of the conductor and thus not use the material in the other side of the conductor for current conduction. By providing helix branches, the current is forced around the perimeter of the conductor and thus material around the conductor perimeter is used for current conduction.

[0075] The proximity effect is caused by the presence of electromagnetic fields generated by alternating currents conducted by nearby conductors. The proximity effect results in a tendency for the current conducted in two nearby conductors to flow in other undesirable patterns, such as loops or concentrated distributions e.g. in the side, of the two nearby conductors, facing each other or is facing away from each other.

[0076] According to an embodiment of the invention, at least one of the plurality of electromagnetic field control element is traveling between 90 degrees and 360 degrees around the outer perimeter of the electric current conductor.

[0077] The closer to 360 degrees an electromagnetic field control element travel around the conductor, the better with respect to improved usage of material for current conduction. However, effects may occur also if an electromagnetic field control element only travel 90 degrees or less. Hence, it is preferred, that an electromagnetic field control element travel between 90 degrees and 360 degrees. Note that over 360 degrees i.e. more than one turn could also have effect.

[0078] It should be noted that one turn of the groove may be sufficient to sufficiently eliminate the consequence of the proximity effect. In some designs of the conductor, one continuous groove of one turn is not possible and thus one or more than one turn may be provided by one or more groove parts. However, it should be noted that the longer groove, the longer current path and thus higher resistance to the current through the conductor. Accordingly, the number of turns of the helix should not be increased without considering this aspect.

[0079] According to an embodiment of the invention, a plurality of the conductor branches is electrically connected at least once between the first end and the second end.

[0080] Connecting two or more branches provides mechanical strength to the conductor. The connection may be a monolithic connection. If the connection is towards one of the ends of the conductor such connection can be used as base for connecting an end terminal piece.

[0081] Along the length of the branches, two or more branches may be connected. Such connection may be where an open voltage potential difference between two branches is 0V. An open voltage potential should be understood as the voltage difference between two branches that are not electrically connected. Once connected, the voltage difference therebetween becomes 0.

[0082] Along the length of the branches (longitudinal axis), two or more branches may be connected. In case mechanical strength are prioritized higher than impact from the proximity effect. In this situation, a so-called short area may be provided where three or more branches are forming a belt around the perimeter of the conductor (substantially perpendicular to the longitudinal axis of the conductor). A belt where the outer perimeter of the conductor is not cut through or only cut through by a limited number of electromagnetic field control elements. The so-called pattern / implementation of the belt does not have to connect all branches and does not have to connect two neighboring branches to fall under the definition of a belt.

[0083] If one or more of the branches meets towards at least one of the first end and the second ends of the conductor, mechanical stability is added to the conductor that may otherwise be too flexible due to the grooves. This is especially true as the depth of the grooves gets close to or equal to the distance between the inner and outer perimeter of a hollow conductor and between the two opposing perimeter points of a massive conductor. As an example, where it is especially true is if more than half, such as all of the grooves, are having a depth that is equal to the distance between the inner and outer perimeter.

[0084] This is furthermore advantageous in that the total current conducted by the conductor is not restricted by grooves and thus can flow freely in the entire cross-sectional area of the conductor before it is divided into the branches formed by the grooves. It is preferred that an area of the conductor not having grooves is an area which do not have a neighboring conductor and thus not exposed to the proximity effect.

[0085] It should be noted that the meeting of the branches may also be implemented in an end piece in which the branches are mounted e.g. for commonly being connected to an electric component.

[0086] According to an embodiment of the invention, the electric current conductor is a modular electric current conductor comprising a plurality of conductor modules.

[0087] A modular electric current conductor is advantageous in that it has the effect that when used in an electric system, the electric system is made by a plurality of standard conductor modules. The use of standard conductor modules is advantageous in that the cost of production of the electric conductors of the electric system can be reduced in that a reduced number or no customized electric conductors may be needed.

[0088] In the context of this document, the term "conductor" should be understood as an electric current conductor that electrically connects two terminal sets and may e.g. be monolithic. A monolithic conductor is a single continuous piece extending between its ends without intermediate connections. A conductor may be produced, designed or in other ways provided in a predetermined way. In this situation, the conductor may be referred to as a “conductor module”. Hence, a conductor with e.g. a 90degrees bending portion or of a certain length may be a referred to as a conductor module. Similarly, an interface module and a terminal adapter may also be referred to as conductor modules. Also, assemblies with more than one conductor module such as an interface module and a conductor module may together be referred to as a conductor module. Thus, a "conductor module" should be understood as a segment or building block of a modular electric current conductor.

[0089] When multiple conductor modules are connected together, for example via interface modules or by connecting their interface areas, together they may be referred to as a modular conductor or modular electric current conductor. Hence, a conductor module is a constituent part of a modular conductor, whereas a conductor refers to the current path between two conductor ends.

[0090] Using standard conductor modules is especially advantageous when an electric conductor in an electric system is changing orientation in space such asrequiring a bend to be able to connect a first electric component located at (X, Y, Z) to a second component located at (X’, Y’, Z’). Such bend can be made with one standard conductor module i.e. without having to connect a plurality of conductor parts such as two or more rectangular busbars with bolt and nuts as known in the art. Thereby a lower ohmic resistance is obtained in the connection leading to a reduced electric loss in the electric system.

[0091] According to an embodiment of the invention, at least two of the plurality of conductor modules have a non-identical geometry.

[0092] A non-identical / different geometry among conductor modules should be understood e.g. as straight or linear conductor modules, angled conductor modules and / or interface modules. Conductor modules having a different geometry is advantageous in that it has the effect that a conductor layout in an electric system can be made by selecting between / connecting a few different types of standard conductor modules.

[0093] According to an embodiment of the invention, at least one of the plurality of conductor modules is selected from the list comprising a: 45 degrees bend, 90 degrees bend, T-module and Y-module.

[0094] Conductor modules of different geometries having different angles or different branching off are advantageous in that it has the effect that a flexible modular electric current conductor can be made from standard conductor modules. The flexibility includes branching off a current path either in a Y-shaped conductor module or in a T-shaped conductor module.

[0095] According to an embodiment of the invention, each of the first and second ends of a conductor module comprises an interface area.

[0096] The end of a conductor module such as a cross-sectional area of the current conducting part may be referred to as an interface area. Hence, when providing two such interface areas against each other two, often planer, cross-sectional areas are facing each other. When pushed against each other the two interface areas may befixed against each other e.g. by means of welding or bolt / nut connections. Such welding is advantageous in that it has the effect that only one joint is made between the two conductor modules. A conductor module may also be referred to a conductor assembly where a conductor and a interface module may be monolithically connected

[0097] According to an embodiment of the invention, one or more of the interface areas of the conductor modules is configured to be connected with an interface module.

[0098] Connecting an interface module to an interface area of a conductor module is advantageous in that it increases the number of possible ways two conductor modules can be connected. This is achieved with a standard interface area that is similar at most of or all of the conductor modules. The geometry of interface modules may take many shapes and thus with a standard conductor e.g. ending in a straight 90 degrees cut, by mounting an interface module various different bends and connection of the modular electric current conductor can be made.

[0099] According to an embodiment of the invention, the interface module is monolithic with a conductor module.

[0100] If possible, it is advantageous to produce the conductor module with a monolithic interface module. In this way the total number of connections or joints in the modular electric current conductor can be reduced leading to a reduction in electric losses associated with the connections.

[0101] According to an embodiment of the invention, the interface module comprises a first side and a second side, wherein an angle between the first side and the second side is between 10 degrees and 100 degrees.

[0102] According to an embodiment of the invention, the angle is 15 degrees, 30 degrees, 45 degrees or 90 degrees.

[0103] By connecting two conductor modules with e.g. an angle of 15 degrees and an angle of 30 degrees respectively, a 45 degrees bend is provided between the two conductor modules. Establishing a modular conductor by means of interface modulesis advantageous in that it has the effect, that the bending radius is reduced compared to a cable that needs to bend.

[0104] According to an embodiment of the invention, at least part of the plurality of conductor modules has an interface area defined in a plane which is provided with a 90 degrees angle to a longitudinal axis of the at least part of the plurality of conductor modules.

[0105] Providing conductor modules with 90 degrees interface areas is advantageous in that it has the effect, that the different conductor modules can be made very little diversity. In one extreme all conductor modules can be made as linear conductor modules and then a layout of the modular electric conductor in the electric system can break away from a linear layout by connection of interface modules having different angles.

[0106] It should be mentioned that interface areas with other angles than 90 degrees such as between 15 degrees and 90 degrees may be advantageous.

[0107] According to an embodiment of the invention, the interface module comprises a divergent portion.

[0108] A divergent portion is advantageous if it matches divergent portions of another component such as an interface module of another conductor or of an electric component. If matching divergent parts are provided, the connection between the two interface modules is enchanced from an electric point of view.

[0109] According to an embodiment of the invention, the interface module comprises a poka yoke element.

[0110] A poka yoke element is advantageous in that it has the effect, that it facilitates that the interface module can only be mounted in one way i.e. the correct way. A poka yoke element may require a matching or opposite poka yoke element or structure on the interface that it has to be connected to. Also, a poka yoke element may facilitate a certain turn or twist of two interface modules / areas relative to each other.

[0111] A poka yoke element may be implemented as an irregular part of a structure such as an irregularity of a divergent surface, a cut corner, interrupted recess or protrusion, etc. that has a matching element on the part to which the interface module with poka yoke element is to be connected.

[0112] According to an embodiment of the invention, the interface module extends outside the outer perimeter of the conductor module.

[0113] Outside should be understood as the interface module is having an area that is larger than the area of the conductor module defined by its outer perimeter. This is advantageous in that it has the effect, that it is possible to mount two second sides of two interface module together, and thereby two conductor modules together. Such mounting can easily be made by bolts and nut provided in holes or recesses in the part of the interface modules that is outside the outer perimeter of the interface module.

[0114] According to an embodiment of the invention, at least one of the plurality of conductor modules comprises inner fastening means.

[0115] According to an embodiment of the invention, the inner fastening means are threaded parts configured for receiving bolts.

[0116] Inner fastening means e.g. implemented as a threaded part such as a bolt or thread for receiving a bolt is advantageous in that it has the effect that the amount of material used for the connection of two conductor modules that is not used for current conduction is reduced. Inner fastening means may require that the conductor module has a hollow interior space for access to the bolts.

[0117] According to an embodiment of the invention, an interface area of two conductor modules is connected forming a modular electric current conductor.

[0118] According to an embodiment of the invention, the connection of interface areas is provided by bolts, welding or soldering.

[0119] It should be noted that two conductor modules may be connected in various ways. One way is to reduce or increase the outer perimeter at one end of a conductormodule thereby allowing an overlapping area of the two conductor modules. This overlapping area may be fixated by parts going through both conductor modules such as bolts. Alternatively, such overlapping area may be fixed by a hose clamp forcing the outer conductor module into contact with the inner conductor module.

[0120] Alternative methods of connecting two conductor modules may comprise a push and click lock system, twist and lock systems, threaded parts in inner perimeter of the conductor and outer perimeter of a terminal rod facilitating screwing the two parts together, dowel, tongue and groove, the connection may be provided by heating and e.g. also with cold, etc.

[0121] If possible, it is advantageous to let a groove from one conductor pass on through interface modules to a second conductor. However, for practical reasons it is often necessary to short the grooves in relation to connecting an interface module to a conductor.

[0122] When connecting modules with grooves, it is advantageous if it is possible to continue a groove from one module to another. This may not be possible and if it is not possible it reduces the effect of the groove. One way of mitigating this risk is to ensure that a groove has taken a complete 360 degrees turn before the conductor module stops and should be continued in another module. Then the reduction of effect is minimized. Thus, connections between modules where the connections are with continued or discontinued grooves / branches. Discontinued grooves / branches are continued into or out from a short area.

[0123] According to an embodiment of the invention, the electric current conductor is a pipe-in-pipe conductor comprising an inner conductor and an outer conductor, and a transition module connecting the inner and outer conductors.

[0124] The pipe-in-pipe conductor comprising two interface modules and the transition module is an alternative way of controlling current through a conductor and thereby ensure the same amount of current in the inner and outer conductor. Such balancing is obtained because the transition module is located in the middle of the length between the two interface modules.

[0125] In an embodiment, at least one of the electromagnetic field control elements is asymmetric.

[0126] Asymmetric electromagnetic field control elements are advantageous in that they allow the conductor to be tailored to its specific location and function within the distribution system. When a conductor is impacted by electromagnetic fields from multiple other conductors at varying distances or with different current magnitudes, asymmetric grooves enable optimized current control and thereby may cause a reduction of losses compared to conductors with no grooves or with symmetric grooves. The varying slope along the length of the conductor allows control of both the electric path length and the mechanical strength at different portions of the conductor. The varying depth allows the conductor to have different flexibility and mechanical stability along its length, which may be beneficial where the conductor needs to bend or where mechanical stability is prioritized over current control. Furthermore, asymmetric groove designs enable the conductor to adapt to systemspecific requirements, such as situations where a conductor has neighboring conductors for only part of its length.

[0127] Asymmetry may be understood by at least one of: a varying slope along the length of the electric current conductor, a varying depth along the length of the electric current conductor, a varying width along the length of the electric current conductor, and a non-uniform spacing between adjacent electromagnetic field control elements.

[0128] In an embodiment, the electric current distribution system comprises at least two neighboring electric current conductors, and wherein the electromagnetic field control elements of the at least two neighboring electric current conductors have a corresponding symmetry.

[0129] Corresponding symmetry may be defined by at least one of: a matching slope between the electromagnetic field control elements of the neighboring conductors, a matching depth between the electromagnetic field control elements of the neighboring conductors, and a matching angular position of the electromagnetic field control elements around the outer perimeter of the neighboring conductors.

[0130] Corresponding symmetry between the electromagnetic field control elements of neighboring conductors is advantageous in that branches of both conductors may experience the same or closer to the same average electromagnetic field from each other. When the grooves of neighboring conductors have matching slope, matching depth, and / or matching angular position around the outer perimeter, the induced voltages in all branches of both conductors may equal out, thereby eliminating the possibility of electromagnetic fields driving eddy currents between the branches. This may optimize current distribution in both conductors and minimizes electric losses caused by the proximity effect. Furthermore, corresponding symmetry between neighboring conductors facilitates that the mutual location of the control elements may be more precise relative to each other, which may be relevant for obtaining the maximum effect of the control elements.

[0131] In some embodiments, corresponding symmetry between neighboring conductors may be achieved by designing the electromagnetic field control elements with identical or substantially identical parameters. As an example, two parallel neighboring conductors of the same length may each have grooves that complete one 360-degree turn over the same conductor length, resulting in matching helix slopes. In this example, if both conductors have a length of 100cm and a diameter of 5cm, the grooves of both conductors may be designed with a slope that results in one complete turn over the 100cm length, thereby achieving corresponding symmetry with respect to slope.

[0132] In another example, corresponding symmetry with respect to angular position may be achieved by aligning the groove starting points of neighboring conductors at the same angular position around the outer perimeter. For instance, if a first conductor has a groove starting at the "12 o'clock" position when viewed from one end, a neighboring second conductor may also have its groove starting at the "12 o'clock" position when viewed from the same direction. This alignment of angular positions may facilitate that the branches of both conductors experience the same average electromagnetic field from each other.

[0133] In some cases, when two conductors are parallel and positioned equidistant from each other along their length, corresponding symmetry may be achieved by using identical groove parameters for both conductors, including the same slope, the same depth, and the same angular starting position. The digital layout and simulation process described elsewhere in this document may be used to verify that the symmetry relationships achieve the desired effect of equalizing induced voltages in all branches of both conductors. In situations where the neighboring conductors have the same length, diameter, and material, corresponding symmetry may be achieved by manufacturing the conductors with identical electromagnetic field control element designs.

[0134] In an embodiment, the electric current distribution system comprises at least two neighboring electric current conductors, and wherein the electromagnetic field control elements of the at least two neighboring electric current conductors have a noncorresponding symmetry.

[0135] Non-corresponding asymmetry may be defined by at least one of: a different slope between the electromagnetic field control elements of the neighboring conductors, a different depth between the electromagnetic field control elements of the neighboring conductors, and a different angular position of the electromagnetic field control elements around the outer perimeter of the neighboring conductors.

[0136] Non-corresponding symmetry between the electromagnetic field control elements of neighboring conductors is advantageous in situations where the two conductors have different operating conditions or are positioned differently relative to other conductors in the system. When a conductor is impacted by electromagnetic fields from multiple other conductors, the groove design may be specifically tailored to the location of each conductor among the other conductors to control the current through each conductor causing lowest losses. Hence, when two neighboring conductors are each impacted differently by surrounding conductors or components, non-corresponding groove designs allow each conductor to be individually optimized for its specific electromagnetic environment. Different impact may occur if one conductor is an outer conductor in a row of three conductors and the another conductoris middle in a row of three conductors. Furthermore, non-corresponding symmetry may be advantageous when the two neighboring conductors have different lengths, different current magnitudes, or different routing paths. In such situations, forcing corresponding symmetry between the conductors may compromise the optimization of at least one of the conductors. By allowing non-corresponding symmetry, each conductor can have its groove slope, depth, and angular position independently optimized based on its own length, diameter, and proximity to other conductors, thereby achieving the lowest possible electric losses for the system as a whole.

[0137] In some embodiments, non-corresponding symmetry between neighboring conductors may be determined based on each conductor's specific electromagnetic environment. As an example, in a row of three parallel conductors where a first conductor is positioned at one end of the row and a second conductor is positioned in the middle of the row, the first conductor is impacted by electromagnetic fields from only one neighboring conductor, while the second conductor is impacted by electromagnetic fields from two neighboring conductors. In this situation, the groove design of the first conductor may have a different slope or depth than the groove design of the second conductor to account for the different electromagnetic environments.

[0138] In another example, non-corresponding symmetry may arise when two neighboring conductors have different lengths. If a first conductor has a length of 80cm and a second neighboring conductor has a length of 120cm, and both conductors are designed to have grooves that complete one 360-degree turn, the helix slope of the first conductor will be steeper than the helix slope of the second conductor. This results in non-corresponding symmetry with respect to slope, which may be acceptable or even advantageous when each conductor is individually optimized for its specific length and electromagnetic environment.

[0139] In some cases, non-corresponding symmetry may be intentionally designed when the two neighboring conductors carry different current magnitudes or have different routing paths. The design criteria for non-corresponding symmetry may include determining the groove parameters for each conductor independently based on factors such as the conductor's length, diameter, proximity to other conductors, and themagnitude of current to be conducted. The digital layout and simulation process may be used to optimize each conductor's groove design for its specific location in the electric current distribution system, resulting in non-corresponding symmetry between neighboring conductors that achieves the lowest possible electric losses for the system as a whole.

[0140] In an embodiment, the electric current distribution system further comprises a conductor assembly, wherein the conductor assembly comprises a tubular conductor and at least two conductor terminals welded to the tubular conductor.

[0141] Such conductor assembly is advantageous in that mounting is fast as only one part is to be mounted even when branching off current is needed. The reduced mounting parts also reduces losses as these occur when two parts are connected. Such assembly, having tubular conductors without grooves, may be used when the conductor assembly connects two terminals having a routing distance below 100cm, such as below 75cm, such as below 50cm.

[0142] In an embodiment, the at least one bend portion has a bending radius of at least 2 times, such as at least 3 times the outer diameter of the electric current conductor.

[0143] Even though a larger bending radius makes the bend portion longer and thus results in a larger footprint of the conductor, it may be desired to optimize the current flow path through the conductor. A larger bending radius is advantageous in that it provides a smoother transition of the current path through the bend portion, which may reduce turbulence in the current flow and thereby reduce losses in the bend portion. Furthermore, a larger bending radius reduces mechanical stress in the conductor material at the bend, which may improve the lifetime of the conductor and reduce the risk of fatigue failure. A larger bending radius also facilitates that any electromagnetic field control elements can be continued through the bend portion with a more uniform geometry, thereby maintaining the effect of the electromagnetic field control elements in the bend portion.

[0144] In an embodiment, the electric current conductor is self-supporting between the first terminal set and the second terminal set, and wherein the middle section comprises at least one bend portion.

[0145] A self-supporting electric current conductor with at least one bend portion is advantageous in that no support brackets or similar support elements are needed between the conductor and other system elements such as the electric cabinet or frame structure. This has the effect that mounting of the conductor is simplified as only the connections at the terminal sets need to be established. Furthermore, the absence of support brackets reduces the number of mechanical interfaces between the conductor and the system, which may reduce the risk of unintended electrical contact or grounding. A self-supporting conductor with at least one bend portion is also advantageous in that the routing path of the conductor can follow a three-dimensional path between the terminal sets without requiring intermediate support, thereby enabling a compact system layout. The combination of self-supporting and at least one bend portion further facilitates that the conductor can be manufactured as a monolithic piece and mounted in a single operation, reducing mounting time and the risk of human errors during installation.

[0146] In an embodiment, the electric current conductor is monolithic between the first end and the second end, self-supporting between the first terminal set and the second terminal set, and wherein the middle section comprises at least two bend portions.

[0147] The combination of a monolithic, self-supporting conductor with at least two bend portions is advantageous in that the conductor can be manufactured as a single piece that follows a three-dimensional routing path between two terminal sets without requiring any intermediate connections or support elements. By providing a monolithic conductor with at least two bend portions, no bolt and nut connections, weldings, or similar joints are needed between the terminal sets, thereby eliminating ohmic losses and heat generation associated with such connections. The combination of these features facilitates that the conductor can be mounted in a single operation byconnecting its two ends to the respective terminal sets, thereby significantly reducing mounting time and the risk of human errors during installation.

[0148] In an embodiment, the at least one bend portion extends between a first bend portion point and a second bend portion point, wherein the at least one bend portion has an asymmetric bend profile, wherein the main angular change of the bend portion is concentrated in a first part of the bend portion, the first part being less than half of the routing length between the first and second bend portion points.

[0149] A conductor may have more than one bend, and one of these bends may have an asymmetric bend profile. An asymmetric bend profile is advantageous in that it facilitates the possibility of optimal conditions for current conduction i.e. layout or routing of the conductor in the electric system taking into account available space and optimal flow path for current in the conductor. By concentrating the main angular change in a first part of the bend portion, the remaining part of the bend portion may have a more gradual transition, which may be beneficial for maintaining the effect of electromagnetic field control elements through the bend portion. Furthermore, an asymmetric bend profile may enable the conductor to be routed around obstacles or other components in the electric system while maintaining a smooth current flow path in the portions of the conductor where the current density is most sensitive to changes in direction. The first part of the bend portion may alternatively be less than a third, such as less than a fourth of the routing length between the first and second bend portion points, thereby further concentrating the angular change and providing a longer gradual transition portion.

[0150] In an embodiment, the at least one bend portion extends between a first bend portion point and a second bend portion point, wherein the at least one bend portion has a continuous bend along the routing length between the first and second bend portion points.

[0151] In an embodiment, the routing length between the first bend portion point and the second bend portion point is at least 2 times the outer diameter of the electriccurrent conductor, such as at least 3 times, such as at least 5 times the outer diameter of the electric current conductor.

[0152] Even though a longer routing length between the bend portion points makes the bend portion longer and thereby results in a larger footprint of the conductor, it may be desired to optimize the current flow path through the conductor. A longer routing length through the bend portion is advantageous in that it provides a more gradual change of direction of the conductor, which may reduce the disturbance of the current flow through the bend portion. This is particularly relevant for conductors with electromagnetic field control elements, as a more gradual bend facilitates that the helix grooves can be continued through the bend portion with a more uniform geometry, thereby maintaining the effect of the electromagnetic field control elements. Furthermore, a longer routing length through the bend portion reduces the mechanical stress concentration in the conductor material, which may improve the lifetime of the conductor and reduce the risk of fatigue failure. A routing length of at least 2 times the outer diameter also distinguishes the bend portion from sharp angular connections known in the art, where two straight conductor segments are connected at a point, and instead provides a smooth transition that is integral with the conductor.The drawingsFig. la illustrates an electric system with conductors having bending portions,Fig. lb and 1c illustrates an electric system seen from different angles according to an embodiment of the invention,Fig. Id illustrates an electric system having a different type of electric conductor compared to the electric conductors of fig. lb and 1c,Fig. le illustrates a further example of an electric system,Fig. If illustrates examples of an electric conductor of an electric system and conductor terminals used for implementing the electric conductor in the electric system,Fig. 2 illustrates prior art electric conductors,Fig. 3 illustrates a cross-sectional view of an electric conductor used in an electric system according to the invention,Fig. 4 and Fig. 5 illustrate cross-sectional views of an electric conductor used in an electric system according to the invention,Fig. 6a-6c illustrates an example of a conductor with grooves covered and partly covered,Fig. 7 illustrates a modular conductor comprising conductor modules and interface modules,Fig. 8a-8c illustrates examples interface modules,Fig. 9a-9c illustrates examples connection between conductor modules and electric components,Fig. lOa-lOc illustrates different variants of conductor modules,Fig. Ila illustrates a transition module, andFig. 1 lb illustrates a pipe-in-pipe modular conductor.Detailed description

[0153] Fig. la illustrates an electric current distribution system ECS comprising two circuit breakers CB representing electric components EC, each having a first terminal set ITS with three first terminals IT for phases LI, L2 and L3, and three busbars BB forming a second terminal set 2TS with three second terminals 2T. The illustrated system is a three phased AC system. In case of a DC system, only a negative and positive potential electric current conductor C is needed. In fig. la, the three conductors are electrically connected between the first and second terminal sets ITS, 2TS. Each conductor C comprises a middle section MS provided between a first end IE connected to a first terminal IT of a circuit breaker CB and a second end 2E connected to a second terminal 2T of a busbar BB. The middle section MS of eachconductor C comprises at least one bend portion BP enabling the conductor to follow a routing path between the circuit breaker CB and the busbar BB, which are located at different spatial coordinates within an electric cabinet ECA.

[0154] Fig. lb illustrates an electric current distribution system ECS according to an embodiment of the invention. The illustrated system comprises five electric components EC, two circuit breakers CB and three busbars BB, connected by electric current conductors C. The conductors each comprises two bend portions BP.

[0155] Each of the two circuit breakers CB comprise a first terminal set ITS. Because the circuit breakers are three phased, the first terminal sets ITS each comprises three first terminals IT one for each of the phases LI, L2 and L3.

[0156] The busbars BB are illustrated as rectangular busbars one for each of the three phases LI, L2 and L3. The individual terminals of these busbars are referred to as second terminals 2T and together these three second terminals 2T are referred to as a second terminal set 2TS.

[0157] The first and second terminals IT and 2T in this embodiment are connected by conductors C having electromagnetic field control elements G, also referred to as electromagnetic field control elements G. The first terminal IT being connected to a first end IE and the second terminal 2T being connected to the second end 2E with the middle section MS therebetween. The middle section may be defined as the conductor part comprising grooves and / or as the part of the conductor that is not directly in contact / mounted to a conductor terminal CT. As illustrated, the control elements G are implemented in the individual conductors G as one helix track. This track may also be referred to / implemented as a groove or protrusion that can have various geometries as explained elsewhere in this document. Such track e.g. in the form of a groove could also be referred to as a control element for current through the conductor and thereby controlling consequences of electromagnetic phenomenon's occurring in the electric conductor or from a neighboring electric conductor.

[0158] On fig. la two circuit breakers CB are illustrated as electric components EC. Each of these circuit breakers is connected to a first end IE of one conductor C foreach of the phases LI, L2 and L3. The second end 2E of these conductors C are connected to one busbar BB for each phase LI, L2, L3. Hence, the first end IE of two LI phase conductors, one from each of the circuit breakers CB, are connected to the same LI busbar BB at their second ends 2E. The same applies for the L2 and L3 phase conductors.

[0159] Thus, the lengths and bending radii of the two LI conductors are different. The first ends IE in this embodiment have the same Y and Z coordinates, but have different X coordinates. In the same way, the second ends 2E in this embodiment have the same X and Z coordinates but have different Y values. Accordingly, the conductors C travel through different third spatial points between their first and second ends. The start at displaces locations in the YX plane and terminates at displaced locations in the YZ plane. Hence, when referring to X, Y, Z coordinates this may be one single point or several points of the ends.

[0160] The conductors C are connected to the circuit breakers CB via conductor terminals CT at their first ends IE. The conductor terminals CT comprise holes aligned with holes in the first terminals IT of the circuit breakers CB, allowing bolts to pass through and establish a mechanical and electrical connection.

[0161] At the second ends 2E, the conductors C are connected to the busbars BB via terminal adapters TA. The terminal adapters TA are necessary because the busbars BB have a terminal plane in the XY plane while the conductor terminals CT have a terminal plane in the Y Z plane. The terminal adapter TA bridges between these two terminal planes, with holes on one side aligned with holes in the busbar BB and holes on the other side aligned with holes in the conductor terminal CT.

[0162] The conductors C illustrated in fig. la are tubular conductors, also referred to as power tubes, comprising electromagnetic field control elements G in the form of helix grooves. The helix grooves travel around the outer perimeter OP of the conductors C, forming branches B that guide the current through the conductors. As the two LI phase conductors have different lengths, the slope of the helix grooves inthese conductors may be different to ensure that the grooves complete a predetermined number of turns around the outer perimeter.

[0163] The design of the electromagnetic field control elements G, including their slope, depth and number, is determined based on the specific location of the conductor in the electric current distribution system ECS. When a conductor is impacted by electromagnetic fields from multiple other conductors, the groove design may be specifically tailored to the location of the conductor among the other conductors to control the current through this conductor causing lowest losses. With this said, it should be noted that a conductor with grooves, even though not specifically designed to the particular location, may be better from an electric loss point of view than a tubular or rectangular conductor without grooves.

[0164] The slope of the helix groove is determined based on the length of the conductor and the desired number of turns around the outer perimeter. For optimal mitigation of the proximity effect, the groove should complete at least one full 360 degrees turn around the outer perimeter. However, the slope must be balanced against the increased current path length, which increases the DC resistance of the conductor. Hence, the slope is a design parameter that is optimized for each conductor based on its length, diameter, and the proximity to neighboring conductors.

[0165] The depth of the groove is determined based on the skin depth of the current conducted by the conductor. As mentioned, a groove depth between 25% and 125% of the skin depth may be sufficient to control most of the current through the conductor. If the groove extends all the way through the current conducting material, full control of the current is achieved as no free-flowing current remains in the center part of the conductor. However, grooves that do not extend all the way through may be preferred in situations where mechanical stability is prioritized.

[0166] The number of grooves is determined based on the desired number of branches and the current capacity requirements. More grooves result in more branches, which can provide finer control of the current distribution. However, more grooves also result in more material removed from the conductor, which may reduce the currentcarrying capacity. Typically, between 2 and 8 grooves are provided, such as 4 grooves as illustrated in fig. 3 and 4.

[0167] In situations where a conductor is located between two or more other conductors, the electromagnetic field impact from each of the neighboring conductors may be considered when designing the grooves. The groove design may be asymmetric to account for different distances to the neighboring conductors or different current magnitudes in the neighboring conductors. Alternatively, a symmetric groove design with sufficient turns around the perimeter may be used to average out the electromagnetic field impact from all neighboring conductors. It should be noted that the mentioned asymmetry may be found along the length of one or more grooves on a conductor and between one or more grooves of different conductors.

[0168] In general the system may first be established as a digital layout, for example using 3D CAD software, used as basis for simulations of the electromagnetic field effects. Such simulations may be performed using electromagnetic field simulation tools, such as finite element analysis (FEA) software, to model the skin effect and proximity effect in the conductors. The simulation may calculate current density distribution, induced voltages in the branches, and electric losses for a given conductor geometry and groove design. Optimization criteria may include minimizing electric losses in the conductors, achieving uniform current distribution across the branches, and ensuring that induced voltages in all branches equal out to eliminate eddy currents between branches. Adjustments of one or more grooves of one or more conductors may be made based on the simulation results to optimize the effect thereof. Such adjustments may include modifying the groove slope, depth, width, or number of grooves. The skilled person would be familiar with electromagnetic simulation tools and methods for modeling current distribution in conductors, and may use such tools to iteratively refine the groove design until the optimization criteria are met. Thereby, leading to predictable and optimized performance of the electric current distribution system.

[0169] As illustrated, each conductor C in fig. lb comprises two bend portions BP. The two bend portions BP of each conductor are different in that they may have different bending radii and / or different angles. The first bend portion may displace the routing of the conductor along one or more of the X, Y and Z axes, and the second bend portion may displace the routing of the conductor along one or more different axes. In this way, the conductor is able to follow a three-dimensional routing path between the first terminal set ITS and the second terminal set 2TS.

[0170] It should be noted that one helix grove, as illustrated, may not be sufficient to gain full potential of the electromagnetic field control elements G. The number of electromagnetic field control elements G, their implementation i.e. slope, width, depth and hight and their length is determined in dependence of the distribution systems ECS they are installed in. I.e. these design and modification parameters are determined case-by-case and a minimum version with respect to number of electromagnetic field control elements G is illustrated in fig. lb.

[0171] Fig. lb also illustrates a close to minimum version with respect to the slope of the helix of the electromagnetic field control elements G. The slope of the illustrated helix results in a 540 degrees helix i.e. a P / 2 turning around outer perimeter of the electromagnetic field control elements G. As can be seen from the two LI phase conductors, the conductor distance between the two terminal sets is different. As the track G of both phase conductors have a 540 degrees turn the slops of the helix groves of these conductors are different.

[0172] Effect of the electromagnetic fields control elements G may be achieved with a less steep slope, however often a slope turning more than 1 time, such as turning between 1 and 25 times may be implemented. It should be noted that only one turn may be sufficient to gain effect. However, due to design of the conductor a total of more than one turn may be established. As mentioned, the slope of the helix is a design parameter that is dependent on the current distribution system in which the conductor is installed. Thus, if the conductor is long, such as over 400cm, the design of the conductor may require a groove G or more groove parts that together may turn more than one turn of the helix. It should be noted that this may also be the case if theconductor is less than 400cm, 300cm, 200cm, 100cm and also in situations less than 50cm.

[0173] As illustrated, the phase current conducted by each of the busbars BB is divided in into two conductors C. This is because the phase current is high such as above 4000A and thus, to reduce cost of the circuit breakers CB, the current is divided so that standard circuit breakers can be used.

[0174] As illustrated, the conductors C are connected to the electrical components EC via different terminal design. The first terminal set ITS is designed with a planer surface (in the XY plane) comprising holes for receiving bolts. This is illustrated at the first terminal IT of the circuit breaker CB to the left in fig. lb to which the conductor of phase LI is connected. The illustrated connections of phases L2 and L3 are illustrated without a conductor terminal CT.

[0175] The conductor conducting phase LI is illustrated with a conductor terminal CT. As illustrated, this conductor terminal CT comprise holes through which bolts can pass through and in this way, via threaded parts of the holes in the first terminal IT, connect the conductor terminal CT, and thereby the conductors C, to the electric components CB.

[0176] The second terminal s 2T of the second terminal set 2T S are designed different than the first terminals of the first terminal set ITS. In fact, the second terminals 2T are merely implemented as holes in the busbars. These holes are adapted to receive a bolt that is also going through holes in a terminal adapter TA. This terminal adapter TA is at one side designed so that holes thereof are aligned with holes in the second terminals 2T (at the busbars) and at another side designed so that holes thereof are aligned with holes in a conductor terminal CT (at the conductor). In this way the same conductor terminal CT can be used in both ends of the conductor to connect the conductor to electric components EC having different types of terminal design.

[0177] It should be noted that the illustrated way of connecting conductors to electric components i.e. the design of the terminals IT, 2T and of the conductor terminals CT is only an example for explanation. Hence, the terminals can be designed in variousother ways such as with bolt part protruding from the first and second terminals IT, 2T, conductor terminals CT such as cable shoe like, etc. The terminal design is adapted to the design of the electric component as illustrated with the different terminal designs at the circuit breakers CB and busbars BB. In some cases, terminal adaptors may be needed i.e. to be able to establish a connection or to be able to use standard terminal either of the conductor or at the electric component.

[0178] The conductor C must be terminated to be able to be connected to an electric component. The termination, and such the conductor terminal, may in a simple form be holes, e.g. with a threaded part, in the conductor via which bolts can be used to mount the conductor to a terminal of an electric component. One example for explanation only could be that the electrical component to which the conductor is to be connected, comprises a terminal designed so that the conductor is allowed to be surrounded by the terminal or to surround the terminal. In this way, a bolt through the terminal and into the conductor or vice versa can be used to mount the conductor to the electric component or a pressing tool can be used. As indicated, the conductor may be a tubular or massive conductor.

[0179] In addition, or alternatively, the conductor terminal CT may comprise a conductor terminal part CTP that need to be mounted to the conductor i.e. which are not monolithic with the conductor. Such conductor terminal part CTP may be designed according to the conductor design i.e. if the conductor is hollow, massive, has one end or a plurality of branches at the one end, etc.

[0180] In case the conductor C is tubular i.e. having a hollow inner portion IPO, the conductor terminal CT may comprise a conductor terminal part CTP that is designed to be connected to the conductor via the conductor’s inner portion IPO. One way of doing this is illustrated in fig. If. Here two wedge formed conductor terminal parts CTP are illustrated. When tightened together e.g. by a bolt and nut / threaded part, these parts will displace relative to each other thereby making the outer perimeter of the two conductor terminal parts longer. This will provide a force between the two conductor terminal parts and the inner perimeter IP of the conductor C. A force whichwill ensure that the conductor and the conductor terminal parts are connected both mechanically and electrically.

[0181] In case the conductor is massive, cylindrical or square, a not illustrated conductor terminal part that is able to at least partly surround the conductor can be used to establish a terminal of the conductor. Two or more of the parts that surrounds the massive conductor may comprise holes for bolts that via nuts is able to, when tightened, clamp the conductor part to the conductor and thereby ensure that the conductor and the conductor terminal part(s) are connected both mechanically and electrically.

[0182] The above examples are only to exemplify that various ways of connecting a conductor terminal exists. Hence, other not specified examples may be used, such examples may include threaded parts of one of the busbars and the conductor terminal CT allowing screwing the two together, insert and turn / click systems, etc.

[0183] As illustrated at fig. lb, terminal adapters TA may be used to facilitate an optimal electric and or mechanic connection between the busbar and the electric components. Terminal adapters may be used to connect connectors and electric systems having contact surfaces in different plans. Again, with reference to fig. lb, the busbars have a terminal plane in the Y plane wherein the conductor terminal has a terminal plan in the Z plane. For the two terminal plans to meet, the terminal adapter is introduced therebetween.

[0184] Depending on the method of manufacturing the conductor, at least part of the conductor terminal can be made monolithic with the conductor / middle segment of the conductor.

[0185] To facilitate optimal electric connection, the terminal planes of all terminals that have to be connected together may have matching divergent portions of the surfaces that is to be connected. A divergent portion should be understood as a nonplaner structure. Matching divergent portions may be a pyramid or sawtooth pattern just to mention two. When both terminal portions are equipped matching divergent portions, the clamping force provided when tightening the two plans together isimpacting the other part via the plans of the pyramid / sawtooth in a direction that is not parallel to the clamping force. In this way an improved electric connection therebetween is established due to the engagement between these divergent portions.

[0186] An electric current distribution system ECS according to the invention should be understood as a high-power system that is configured for conducting one or more phase currents over 100A. Thus, a distribution system ECS may simply be a current path between two sets of terminals with conductors therebetween i.e. systems that only conduct current from one terminal to another. It may be a system that is able to break or cut the current such as illustrated in fig. lb by means of circuit breakers or switchgear. It may be a system that shapes voltage / current such as in a power converter or transforms voltage from one voltage potential to another, etc. In fact, the function or type of the system is not important, the conductors with electromagnetic field control elements G is advantages in systems where copper, aluminum or other alloys or electric conductive materials is used to conduct high currents over long distances thereby requiring a high current conducting cross-sectional area of the conductor.

[0187] Examples of embodiments where existing distributions systems could benefit from being implemented as a distribution system according to the present invention systems include systems where the currents are high such as over 100 A and up to several thousand amps such as 6.000A to 10.000A or even higher. Systems where routing distances are long such as over 35cm and up to several hundred meters such as 1 ,000m. In prior art systems where conductors typically are implemented as massive busbars having a rectangular geometry of current conducting material, such rectangular geometry may be of 10mm x 10mm x 100mm and up, a massive cylindrical geometry of current conducting material having a diameter 10mm and up, cross-sectional area of 5.000mm2 and up just to mention a few examples. It should be mentioned that these dimensions are valid at least with 50Hz and 60Hz. At higher frequencies the dimensions and magnitude of current are less than the above-mentioned

[0188] If the conducting material of the conductors is isolated or if the conductors are located in a safe space such as in a fenced area, the conductors can be severalmeters long. In such situation the electric system could be a utility grid substation, power-to-x system or the like. Conductors of a system ECS may be provided under ground level e.g. in ducts.

[0189] In fact, the electric current distribution system ECS may be part of the utility grid. Hence, the conductors with electromagnetic field control elements may be used as current conductors in the utility grid substituting known types of cables. This is especially true for minor local parts of the utility grid such as distribution panels, switch gear panels, junction boxes for transformers, motors, generators, etc. i.e. where the conductor length is less than 500m. With this said, there are no hindrance for the conductors having electromagnetic field control elements to substitute existing cables of the utility grid for distances measured in kilometers such as 1000m to 10.000m or even longer.

[0190] The terminal sets ITS, 2TS of the circuit breakers illustrated in fig. lb, are the outlet terminals, i.e. the terminal sets illustrated at the uppermost part of the circuit breakers are the inlet terminals. In this particular embodiment, the conductors connected to the inlet terminals may in their other ends be connected to power modules of a power converter or to other busbars which then is connected e.g. to power modules. The power through the two circuit breakers may be different such as in one circuit breaker the current may be 3000A and in the other 1500A. In this case, the conductors connected to the outlet terminals may not need to have the same current conducting cross-sectional area. As the phase current from both of the circuit breakers are connected in the busbar BB, the total phase current may be 4500A in the busbar BB.

[0191] Fig. 1c illustrates a frame of an electric cabinet ECA in which the circuit breakers CB and their electric connection of the system ECS are provided. The view is a perspective view which is different from the view of fig. lb. From this way it is easier to see all terminals of the two terminal set ITS, 2TS, the connection of the conductors C, which may in this embodiment be referred to as power tubes, to the busbar BB, which as mentioned is only an example for explanation.

[0192] The inlet terminals IT, i.e. the upper most terminals of the circuit breakers CB of the electric cabinet ECA, which is part of the electric distribution system ECS, is easier to see in the view of fig. 1c. As one might notice, the conductors C mounted to the inlet terminals IT are also different from known rectangular busbars and circular cables. Hence, these conductors C may also be of the power tube type as those connected to the outlet terminals ITS. What is noticed on the leftmost circuit breaker is that the inlet terminal conductors have two conductor terminals CT each. This enables the circuit breaker to be “supplied” from two parallel busbars similarly to the busbars BB that are “supplied” by two parallel power tubes C.

[0193] The inlet terminals IT illustrated in fig. 1c are tubular conductors that do not comprise electromagnetic field control elements. The inlet terminals IT may have two or three conductor terminals CT, one at each end and optionally one in the middle / therebetween for branching. The conductor terminals CT and the tubular conductors may be welded together, and together they may be referred to as a conductor assembly. Such conductor assembly with conductors without grooves may be used when the routing distance between two terminals is below e.g. 50cm, such as below 30cm. At such short distances, the negative effect of the proximity effect is limited and thus the benefit of providing electromagnetic field control elements may not outweigh the additional cost of providing them. However, it should be noted that even at short distances, conductors with electromagnetic field control elements may be beneficial in situations where the conductor is located very close to other current conducting elements. Accordingly, such conductor assembly may be used in an electric current distribution system e.g. on an inlet or outlet side of an electric component such as a circuit breaker independent of what is connected to the outer side of the electric component.

[0194] As illustrated the conductors connected to the inlet terminals of the circuit breakers are not identical. This indicate that they are not breaking the same magnitude of current. Further, the conductors C of the leftmost circuit breaker may be designed so that their impedance is balanced so that an equal share of current is conducted from the parallel busbars (not illustrated) through the conductors C to the circuit breaker.

[0195] Fig. Id is a closer view of the system of fig. lb and 1c. Fig. Id servers to illustrate that the conductors C can be implemented by different power tube designs than what is illustrate in fig. la. Hence, as illustrated a first and second power tube Cl, C2 are illustrated connected to the leftmost first terminal IT of the circuit breaker CB. The two power tubes Cl, C2 may be referred to as conductor modules. They are illustrated as spaced apart but may be connected by a connection piece (not illustrated) which may be referred to as an interface module modular or permanent fixation such as welding or soldering. As indicated the first conductor Cl has a different design of the electromagnetic field control elements G compared to the second conductor C2 and the rest of the illustrated conductors C. The design of the electromagnetic field control elements may be made according to location in the system of the conductors such as with respect neighboring conductors of magnetic material.

[0196] From the two additional conductors denoted C the bend portion BP between a first bend portion point 1BPP and a second bend portion 2BPP is illustrated. The bend portion BP is the part of the conductor where the routing direction changes. The first and second bend portion points 1BPP, 2BPP define the start and end of the bend portion along the routing length of the conductor. On the figures, these points are illustrated as perimeter lines. Hence, these lines only serve to illustrate where a bed portion start and stop and thus, where a straight linear conductor part is provided. As mentioned, the illustrated conductors may be monolithic (e.g. fig. Id) or may be established by mounting bend conductor modules and straight conductor modules.

[0197] The bend portion BP may have various profiles depending on the requirements of the electric current distribution system. In one variant, the bend portion has a continuous bend along the routing length between the first and second bend portion points 1BPP, 2BPP. A continuous bend provides a uniform change of direction and may be selected when a smooth current flow path through the bend is prioritized, such as when the conductor comprises electromagnetic field control elements G that should continue through the bend with a uniform geometry.

[0198] In another variant, the bend portion has an asymmetric bend profile, wherein the main angular change is concentrated in a first part of the bend portion. Anasymmetric bend profile may be selected when the available space in the electric cabinet ECA requires the conductor to change direction quickly in one area and then follow a more gradual path in another area. This may be the case when the conductor needs to route around an obstacle such as another electric component EC or another conductor C.

[0199] The routing length between the first and second bend portion points 1BPP, 2BPP may vary e.g. depending on the outer diameter of the conductor or a desired bending radius. A longer routing length provides a more gradual bend, which may be selected when mechanical stress in the conductor material should be minimized or when the electromagnetic field control elements G should be maintained through the bend with minimal disturbance. A shorter routing length provides a more compact bend, which may be selected when the available space is limited. In general, the routing length between the bend portion points may be at least 2 times the outer diameter of the conductor, such as at least 3 times, such as at least 5 times the outer diameter.

[0200] The bend portion BP may have different bending angles depending on the routing requirements of the electric current distribution system. The bending angle of a bend portion may be e.g. 15 degrees, 30 degrees, 45 degrees, 90 degrees or any angle therebetween or above. A conductor may comprise two or more bend portions having different bending angles. As an example, a first bend portion may have a bending angle of 45 degrees and a second bend portion may have a bending angle of 90 degrees.

[0201] The conductors and electric components may be comprised by an enclosure in the form of an electric cabinet ECA. In such implementation, this cabinet may be referred to as an example of a distribution system according to the invention. In this way the high currents can be protected from the surroundings for safety for persons and animals and to mitigate the risk of short circuits which could develop very high short circuit currents that could be dangerous for nearby environment. Two or more cabinets may also be built together to form a distribution system according to the invention.

[0202] Fig. le illustrates an electric current distribution system ECS. The distribution system ECS is supplied with power by one or more, such as three phases, via one or more, such as three or six, supply cables SC. The supply cables SC are mechanically and electrically connected to circuit breakers CB, and e.g. via a reactor R to a power module PM and then to a main busbar MB. The main busbar connects to output cables OC (only two phases are illustrated).

[0203] From the main busbar MB electrical components EC are supplied with power via one or more transmission busbars TB. Conventionally, transition busbars are made of copper, are massive or braided conductors. The transition busbars TB of the present invention may be manufactured by additive manufacturing and thus the geometry may be tailor made to the footprint, available space, cooling capacity, current capacity, etc. that is limiting or required from the transition busbar TB.

[0204] In the distribution system ECS of the present invention, the transition busbars TB are connecting the main busbars MB with the components EC. Hence, from the supply cables SC to the components EC, current may be conducted by main busbars and transition busbars. The latter may comprise predefined air gaps thereby allowing the transition busbars to reduce weight, be flexible, be optimized for cooling and have auxiliary functions such as air guides, heat sink and cooling channels.

[0205] The electrical components EC are typically high-power components such as power modules PM and reactors R which are designed for switching and / or conducting more than 1000A such as up to 4000A or even more. Power modules PM may comprise semiconductor switches such as IGBTs and may together form a three-phased invertor or rectifier module. A reactor R may also be referred to as a filter, transformer or simply windings around a core.

[0206] As illustrated in fig. le, the power modules PM are connected to the reactors via cable CA (only one phase cable is illustrated). The output cables OC may be connected to loads such as the utility grid or Power-to-X systems via cables or busbars.

[0207] The electrical cabinet ECA enclosing the distribution system ECS comprise openings and a fan positioned in one of the openings. Hence, by controlling the fan,control of a flow of air through the cabinet is possible. In alternative or in addition to the air flow-based cooling of components in the cabinet ECA, the distribution system ECS may also comprise a liquid cooling system.

[0208] The electric systems in which conductors of the present invention may be beneficial, include distribution panels, converter panels, inverter panels, rectifier units, junction boxes for transformers / generators / motors and the like. They may be connected by conductors with electromagnetic field control elements as described in this document or without as illustrated in fig. la.

[0209] The conductor C with one or more electromagnetic field control elements G, also simply referred to as a conductor C or power tube, may be monolithic (made e.g. by extrusion) and self-supporting between the terminal sets ITS, 2TS.

[0210] An example hereof is illustrated e.g. in fig. la and lb where the conductors C are illustrated as power tubes C (one of several possible geometries of the conductor). The power tubes C have no support element such as brackets or the like that are supporting the conductors and thereby there are no mechanic connection between the power tubes C and the electric cabinet ECA. This is possible because the power tubes are designed sufficient rigid i.e. with sufficient cross-sectional area relative to the routing distance between the terminal sets.

[0211] The conductors and terminals of the system illustrated e.g. in fig. la and lb may be monolithic i.e. the conductors may have no connections between the two terminal sets ITS, 2TS. This is relevant especially with respect to electric losses and time spend on mounting power tubes between the terminal sets.

[0212] In each electric connection between two electric conductors ohmic losses in the form of heat occur. Obviously, for this reason avoiding electric connections is extremely beneficial. Not only for the electric efficiency but also, since no heat is generated, the temperature is reduced having positive effect on lifetime of the electric components and need for cooling is reduced leading to reduction in cost both OPEX and CAPEX.

[0213] Further, mounting one power tube that is design for a predetermined routing between the two terminal sets can be made very fast. In addition, as no conductor parts have to be mounted together, the precision of the location of the power tube in the system is very accurate. Only tolerances are needed in the connection at the terminals contrary to known conductor / busbar system where tolerances are needed at each of the at least two connections that are needed between terminal sets ITS, 2TS on fig. la and lb.

[0214] The mutual location of control elements of two neighboring conductors may be relevant for the effect of the control elements. Thus, in some embedment, to obtain most effect of the control elements, it is relevant that the control elements are located as precise as possible relative to each other i.e. as close to the digital layout which was used as basis for simulations of the effect.

[0215] Finally, with respect to mounting, the weight of a power tube i.e. a tubular conductor with electromagnetic field control elements, is significantly reduced compared to known massive busbars. Hence, if an assembly of known massive busbars are pre-mounted and should be mounted between the two terminal sets of fig. lb, the weight would be higher than what is allowed to handle for one or even for two persons.

[0216] The power tubes C illustrated in fig. lb are clearly not following a straight line between the two terminal sets ITS, 2TS. The first terminal set could be said to be positioned (such as having its center) in a set of first spatial coordinates (X, Y, Z) and similarly, the second terminal set in a set of second spatial coordinates (X’, Y’, Z’). In the example of fig. lb, none of the X, X’ or Y, Y’ or Z, Z’ coordinates are identical meaning that the two terminal sets are located spaced apart in a spatial Cartesian coordinate system. Accordingly, to connect terminal IT and 2T of the same phase of the two electric conductors, the power tube needs to have at least two bend portions. Thus, a power tube would in many implementations required a bending portion if connections of individual power tube parts should be avoided.

[0217] It should be noted that a conductor according to the invention may also include conductor connections. An example could be if the length of the conductor islonger than then what can be transported. Then two such conductors can be connected by a connection piece / modules specifically designed to the conductor geometry. Such connection piece / modules could simply be implemented as two conductor terminal CT that are connected.

[0218] An area of the surface of the conductor may be referred to as a contact surface. A contact surface should be understood as an area of the conductor that is configured for connection of additional conductors. Hence, a contact surface could simply be a flat area against which e.g. a conductor terminal can be electrically connected.

[0219] The electric conductor used in a distribution system of the present invention, comprises a first end, a second end and a middle section provided between the first end and the second end. An example of such middle section is illustrated in fig. 3 where four electromagnetic field control elements G are illustrated in the form of grooves. Hence, remembering that the electromagnetic field control element can be implemented in ways alternative to grooves, the description of fig. 3 uses the term groove. The electric conductor is a three-dimensional conductor illustrated as a power tube. The middle section MS extend between the two conductor ends IE, 2E. The grooves can extend all the way between the two conductor ends or the grooves can start and stop anywhere along the middle section. In this way the middle section may comprise one or more groove sections between the two conductor ends.

[0220] An electric conductor with one or more grooves is advantageous in that it has the effect, that the current through such conductor is divided into each of the plurality of branches B formed by these grooves. Hence, by design of these grooves it is possible to design / control how the current is conducted / guided through the part of the middle segment having grooves. Controlling where in the conductor the current is actually conducted can be done this way due to the electromagnetic phenomenon referred to as skin effect, that causes current to seek towards the perimeter of the conductor. Thus, when first the current has entered a branch, the current will stay in this branch. Accordingly, to gain full control of the current, the grooves should go all the way through the current conducting material as illustrated in fig. 3.

[0221] Effect may be achieved by providing grooves that do not go all the way through the current conducting material as illustrated in fig. 3b.

[0222] By this opportunity to design control elements in the form of a groove and thereby control where in the conductor the current is actually conducted, it is possible to design a conductor with an equal distribution of current (also referred to as current density) across the cross-sectional area of the conductor. In this way, the amount of material of the conductor that is actually used for conducting current can be optimized. Such optimization may e.g. lead to a reduction of the cross-sectional area of the conductor and / or to choice of material that has a higher volumetric resistivity alternatively it allows to conduct higher current with the same current conducting cross-sectional area.

[0223] No matter type of conductor material, it is obviously preferred to utilize the conductor material best possible. It is known that current conducted through a cable / conductor is influenced by electromagnetic fields. This influence can be divided into impact from electromagnetic field origin from the conductor (self-impedance) which in this document is referred to as an internal impact and, impact from electromagnetic filed origin from a nearby conductor (mutual impedance) which in this document is referred to as an external impact.

[0224] The internal impact from the self-impedance results in a tendency of the current that is conducted, to be conducted towards the perimeter of the conductor. The electromagnetic phenomenon causing this tendency is referred to as skin effect. The extend to which this tendency is dominant i.e. how deep into the conductor, from the outer perimeter towards the center of the conductor, the current is conducted (referred to as skin depth), is depending on the resistivity of the conductor and the frequency of the current.

[0225] The skin depth is calculated by equation 1 :£ J — — f ~ Frequencyp ~ Resistivity ™ 4?rx 10

[0226] EQ1: "

[0227] The skin effect is a fact in AC systems and is undesired in that it may cause heating in the conductor and uneven current density across the cross-sectional area of the conductor, leading to conductor material not being used for conducting current.

[0228] The external impact from the mutual impedance occurs to a first conductor when that conductor is located next to a second conductor or other current conducting elements that is conducting a current (AC).

[0229] If both of the first and second conductors are conducting an AC current, the external impact results in a tendency of the current that is conducted in the second conductor, to be pushed away from the first conductor or dragged towards the first conductor. Whether the current is pushed or dragged depends on the direction of the current in the first and or in the second conductor. The electromagnetic phenomenon causing this tendency is referred to as proximity effect. The extend to which this tendency is dominant i.e. how much the current is pushed or dragged is depending on the distance between the first and second conductors and the magnitude of the current. The higher current, the higher frequency and the closer distance the stronger proximity effect.

[0230] Summing up, when conducting an AC current in a conductor, the current will have a tendency to seek to the perimeter of the conductor leading to increased losses and unused material in the center of the conductor. Further, if the same conductor is located next to another current conducting element such as a conductor, the current in that conductor will have a tendency to displace the current towards one of the sides of the conductor.

[0231] To mitigate and / or control the impact of these electromagnetic field coupling effects, one or more grooves are provided in the conductors modules. As mentioned, agroove may be provided into the perimeter of the conductor module, may be added to the outer perimeter as a protrusion. If the conductor has a hollow center part, the grooves or protrusions may be provided into / onto the inner perimeter or in combination with grooves provided into / onto the outer perimeter. The preferred implementation to date is as a groove.

[0232] Fig. 2 illustrates a cross-sectional area of two massive prior art conductors C conducting a current CU that is influenced by both the skin effect and the proximity effect. As illustrated, the current is concentrated at the perimeter of the conductor and towards the side of the nearby conductor. It should be noted that current not conducted in the skin depth is neglected in fig. 2.

[0233] When the current conducted by the conductor as the one illustrated in fig. 3, is not influenced by the proximity effect and when the self-impedance (i.e. selfresistance + self-inductance) and resistivity in the branches B is the same, an equal share of the total current hot is conductor in the 4 branches. Assuming that all of the current was conductor in the branches (i.e. the conductor only comprises branches that are not electrically connected between the ends), each branch would conduct hot / 4 current.

[0234] If a conductor was positioned nearby, the current would displace in the cross-sectional view, e.g. as indicated in fig. 2 due to the proximity effect. To avoid this, the inventors modified the grooves G. The modification consists in letting the grooves G spin around the perimeter of the conductor as illustrated in fig. 3 forming a helix groove also referred to as a spiral in this document encircling the perimeter of the conductor. Optimally, with respect to proximity effect, each branch B would encircle the perimeter of the conductor once i.e., a 360 degrees encircling.

[0235] The skin effect causes the current to be conductor in the branches (even in a massive conductor). When the branches are turning in a helix around the perimeter of the conductor, the current in the branches on the opposite side of the conductor, with respect to the nearby conductor causing the proximity effect, cannot “flow out of the branch” and the proximity effect is thus eliminated. The reason why the helix aroundthe perimeter works is because in this way all branches experience the same average field from nearby conductor(s). Hence, induced voltages in all branches equal out, thereby eliminating the possibility of electromagnetic fields driving eddy currents in the branches.

[0236] In this way, contrary to the conductor illustrated in fig. 2, the material of the conductor on the opposite side of the nearby conductor, is also used for conducting current. Thereby, a conductor is provided, which when used in a current distribution system with more than one conductor, is optimized with respect to usage of conductor material.

[0237] The effect of the spiral grooves i.e. the optimized material usage may have the effect that the cross-sectional area of the conductor can be reduced. Hence, compared to copper conductors without spiral grooves, the current conducting cross-sectional area of a copper conductor with spiral grooves can be reduce with more than 50%. Simulations has shown that in large systems where five to six 10mm x 100mm copper conductors are used to conduct a phase current, a reduction of up to 70% of the copper material can be saved. If the frequency is higher e.g. in electric systems comprising reactors, semiconductor switches such as IGBT, the frequency is higher and thus the savins on material can be higher. In such systems the phase current conducted may be 1000 A to 6000 A.

[0238] As mentioned, the conductors illustrated in fig. 3 and 4 is a tubular conductor i.e. a conductor where the center part is removed and thus the cross-sectional area is defined between an outer perimeter OP and an inner perimeter IP. As indicated, the grooves can be implemented in massive conductors or in other not mentioned types of conductors having the effect describe in this document.

[0239] The interior space defined by the inner perimeter of a tubular conductor can be used for guiding of a cooling fluid. Hence, if a flow of air is directed through the interior space, heat from the conductor can be removed.

[0240] The grooves are formed as continuous grooves or as stepwise grooves in the outer perimeter of the conductor. Continuous grooves should be understood as theslope of the groove is continuous increasing or decreasing or the slope may be constant. The implementation of the groove is not important from an electric perspective. Most important is that the groove is provided and both with respect to production and current conduction a continuous groove with not too many changes of directions is preferred.

[0241] In general, the grooves may be defined by at least two design parameters one being the depth and one being the width and by a modification design parameter being the slope of the spiral / helix along the length of the conductor.

[0242] The branches defined by the grooves, should preferably have the same impedance / ohmic resistance to ensure an equal current density sharing between the branches.

[0243] The shape of the grooves can in principle have any geometry including V, U square formed geometries, etc. most important is that they are provided to establish branches that has a spiral shape. The shape of the groove may thus be determined by the method used to produce the conductor.

[0244] Fig. 4 illustrates a cross-sectional view of a tubular conductor having grooves G. As mentioned, the depth D can be determined by skin depth caused by the skin effect i.e. based on the percentage of current that is desired to be conducted in the branches and desired to be conducted in center part CP of the conductor. The center part CP is defined by a center perimeter CPE and the inner perimeter IP, where the center perimeter CPE being defined by a virtual line connecting the bottom BO of the grooves G. In the center part CP, the current is in principle free flowing and thus can be pushed or dragged by the proximity effect.

[0245] With reference to fig. 4, the cross-sectional area of the conductor material that is conducting current is defined between the inner and outer perimeter IP, OP illustrated as distance DIS. With respect to current conducting cross-sectional area, the outer perimeter is defined by what on fig. 4 is referred to as outer perimeter OP, first and second groove sides 1GS, 2GS and groove bottom BO. With respect to the footprint of the conductor the cross-sectional area is defined by what on fig. 4 isreferred to as outer perimeter OP. The outer perimeter in this context is defined by the outer perimeter of the conducting material and a virtual line over the grooves as illustrated by a stipulated line in fig 4.

[0246] The conductor may be designed giving priority to different aspects including flexibility and electric losses. The design of the conductor may be depending on the electric system in which the conductor is to be used, specifically if the conductor has neighbouring conductors or not.

[0247] As mentioned, the depth of the grooves may not need to be deeper than the skin depth to guide sufficient current to achieve the advantages of the present invention. In fact, the depth may be 50%, 60%, 70%, 80% or 90% of the skin dept and still control the current through the conductor sufficiently to achieve the advantages of the present invention. With this said, as no free flowing current is present in the conductor if the grooves cuts all the way through the conductor, this may be preferred if the effect of the grooves should be fully exploited.

[0248] Regarding flexibility, this can be added to the conductor by increasing the depth of the groove D. In one extreme, the depth of the groove D equals the distance DIS between inner and outer perimeter. In this situation, the branches B are completely separated by the grooves G and thus isolated from each other by air. In such embodiment the conductor could be extremely flexible and not considered selfsupported. A self-supported conductor would require a diameter of the branches of a certain size. This diameter would be determined e.g. based on length of the conductor, distance between conductor support, requirements in case of shot circuit, etc. Of cause this diameter increases with the length of the conductor. A high degree of flexibility may be critical with respect to short of the branches (two neighbouring branches may touch each other) and thereby uncontrolled flow of current between branches could occur which is not desired. Support may be effected by additional brackets and holders, which may provide a locking mechanism between branches.

[0249] To change between flexibility and optimized material usage, the depth of the grooves may change along the length of the conductor. The deeper groove, the more mechanically flexible conductor

[0250] Another way to control flexibility of the conductor is to start the grooves at different distance from an end or from a short area. In this way, wider branches may be divided into sub-branches which will lead to variable flexibility throughout the length of the conductor that could benefit bending and tolerances when connecting to brackets or terminals.

[0251] The length of the spiral groove between groove endpoints may be coincident with the length of the conductor between its two ends i.e. between its first and second ends. If however, the conductor is short relative to its diameter, a spiral grove less than 360 degrees may be provided. In an embodiment a lower limit for a conductor length where it is advantageous to include a spiral groove is a conductor length that is at least 2,5 or 3 times the diameter of the conductor. As an example, % (90 degrees) of a complete spiral may be provided in a conductor that has a diameter of 50mm if its length is 150mm. From this lower limit relationship of length and diameter, the spiral groove may increase towards a full spiral i.e. 360 degrees.

[0252] As the electric path through the conductor is increased with the spiral branch, the resistance of the electric path is increased. Thus, the advantage gained by reducing the consequence of the proximity effect has to be compared to the disadvantage of the longer electric path.

[0253] If for some reason it is desired to separate the branches completely in the longitudinal direction of conductor, the branches may be short, by connecting them with a branch connector, at predetermined locations along the length of the conductor to provide mechanical strength to the conductor. Alternatively, or in addition, so-called transversal short areas may be provided along the length of the conductor and / or at the ends IE, 2E of the conductor. It should be mentioned that short of branches may also be provided if a groove does not separate the branches completely.

[0254] Branch connectors may be provided between two branches thereby establishes a connection across a groove from the first groove side to the second groove side of the groove. A branch connector is preferably located where the open voltage potential is zero or close to zero voltage between the specific physical points of the two branches that are to be connected. In this way, as there is no or very limited voltage different between two branches, no current will flow therebetween. To reduce a current flow between two connected branches further, the diameter or cross-section area of the branch connector could be reduced to a minimum that still provide the required mechanic stability. The diameter of the branch connector is often below 10mm, such as below 5mm, preferably below 2mm.

[0255] An open voltage potential difference should be understood as the voltage difference between two branches that are not electrically connected. Once connected, the voltage difference becomes 0.

[0256] Branch connectors are advantageous in that they have the effect, that they add mechanical stability to the conductor. Especially, in the situation where the depth of the grooves forms individual air insulated branches or where the grooves are so deep that the branches are only connected / short towards the center of the conductor with less than e.g. 10mm of material.

[0257] If access through the center of a conductor is required only neighbouring branches should be connected with branch connectors. If mechanical stability is prioritized, all zero voltages locations between to branches are connected

[0258] The grooves may have a varying depth. A varying depth should be understood as a depth of the groove changing between 0mm and maximum, where maximum is all the way through the conductor in a crosse sectional view. Thus, an example of varying depth is a depth between 0mm and distance between outer and inner perimeter of a hollow tubular conductor.

[0259] A varying depth can be implanted in a system where two conductors are provided next to each other for e.g. 90cm and for a further 90cm the second conductor does not have any nearby conductors. In that situation, the grooves are provided in thetwo conductors during the first 90cm and not in the second conductor for the last 90cm. Further, it would be advantageous if the helix of the two conductors during the first 90cm takes one full turn around the conductor.

[0260] Further, varying depth is advantageous in that it has the effect that it can be used to determine the strength of the conductor such as the yield point between elastic and plastic deformation of the conductor. Accordingly, where mechanical stability of the conductor is prioritized over current control through the conductor the depth of the grooves can be reduced. In one extreme the reduction can lead to what is referred to as a virtual groove i.e. a groove that is not made into the perimeter of the conductor at least part of the way.

[0261] The grooves may form a varying slope. A varying slope of e.g. two grooves will shape the branch accordingly. Hence, a slope of 0 degrees is considered a straight slop whereas a slope of 90 degrees is considered a slop going perpendicular to the direction of the aforementioned straight slope. As mentioned above with respect to the depth of the groove the slope of the groove may also vary along the length of the conductor. The effect of a varying slope is that the length of the electric path along the conductor may be controlled and the mechanical structure / strength along the conductor may be controlled.

[0262] The width W of a groove is not important with respect to control the current in the branches. In principle, a groove can be as thin as possible to manufacture. However, in practice, to ensure that branches on each side of the groove do not short in case of movement of the conductor, the groove may be between 0,5mm and 5mm such as 1mm to 2mm.

[0263] A minimum width of an individual groove depends e.g. on the difference between the voltage measured over two neighbouring branches. The closer these voltages are, the smaller groove width is required. Small groove width, e.g. from 1mm going towards 0.05mm, is advantageous in that more of the perimeter of the conductor is available for current conduction. Lager groove width, e.g. from 1mm going towards6mm, is advantageous in that the conductor is able to be more flexible before edges of the grooves short due to e.g. bending of the conductor.

[0264] In principle, the width of the groove can be as small as allowed by method of producing the conductor with grooves / the grooves in the conductor.

[0265] In some cases, the conductor i.e. the outer perimeter as explained above may be provided with an isolating material. This is especially relevant if the conductor when mounted is able to flex so much that there is a risk of two branches could touch and thereby short. Insulation material may be applied to the conductor itself or it may be in the shape of a separate body / part being placed or adapted onto the conductor. Such part may be applied only into the groove to ensure separation of the branches during flexing of the conductor, while not isolating the rest of the outer perimeter.

[0266] As mentioned, the branches are defined by the grooves. Thus, when the grooves are spiral / helix grooves along the length of the conductor, the branches also become spiral / helix branches along the length of the conductor.

[0267] The grooves may design the branches with an equal resistance to ensure as uniform voltage over each branch as possible and thereby as equal current distribution between the branches as possible. In many cases an equal resistance / impedance would also result in a similar design or geometry. With this said, it may be relevant to design the branches with different geometry to ensure same resistance / impedance. This may be the situation e.g. if the conductor should bend. In such bend an outer branch is longer than an inner branch and the same applies for the outer perimeter compared the inner perimeter of bend branches. Hence, to compensate for this difference in current path, the geometry may be different to maintain the same resistance / impedance.

[0268] The width of a branch may be defined as the distance between two branches. This distance may e.g. be plus / minus 30% of the skin depth of the current conducted by the conductor.

[0269] Fig. 5 illustrates an embodiment of a conductor C for use in a distribution system where the electromagnetic field control elements G are implemented in theinner perimeter IP. This design is more or less an inverse implementation of the design illustrated in fig 4. Hence, in fig. 5 the outer perimeter is not broken by electromagnetic field control elements G and thus forming a conducting part CP between groove bottoms B and outer perimeter OP

[0270] Inner electromagnetic field control elements G has the same effect as outer electromagnetic field control elements G. In addition, inner grooves can be used to reduce the thickness of the outer perimeter, improve efficiency with a thin outer perimeter and increase mechanical stability.

[0271] It should be noted that conductors may also be equipped with electromagnetic field control elements G both in the inner and in the outer perimeter. This embodiment is however not illustrated.

[0272] The conductors of the system of the present invention may be produced in various ways. A step that typically would be common to each of the various ways of production is the step of establishing design parameter and / or modified design parameter and establish a digital representation of the conductor according to these design parameters the modification of these design parameters.

[0273] The geometry of the electromagnetic field control elements may be defined by the design parameter. An example hereof could be width, depth or hight (relative to the outer perimeter) of the electromagnetic field control element. Also, the geometry of the electromagnetic field control element i.e. the shape onto or into the conductor may be considered a design parameter. Hence, the design parameter may be visible in a cross-sectional view of the conductor.

[0274] A modified design parameter may be understood as parameters defining the electromagnetic field control element along the longitudinal direction of the conductor. An example hereof could be the slope of the turn i.e. the helix form of the electromagnetic field control element along the longitudinal direction of the conductor.

[0275] A digital representation of the conductor with these parameters is advantageous in that it has the effect, that a 3D visualisation of the electric conductorcan be established. Further, it is advantageous in that it becomes possible to simulate the effect of controlling the internal and external electromagnetic effects i.e. the skin and proximity effects. Further it is advantageous in that it becomes possible to provide an apparatus for producing the electric conductor with 3D information of the electromagnetic field control elements based on which the apparatus can produce or partly produced the conductor with desired electromagnetic field control element.

[0276] Summing up, a designer may be designing a digital representation of the system including conductor(s) according to electrical, mechanical, structural, etc. requirements in e.g. a 3D CAD software such as Solidworks. Files (digital representation) from such 3D developing tool is exported to the machinery used for production of the conductors.

[0277] A conductor, according to the invention may be produced comprising an electromagnetic field control element in the form of a groove and / or protrusion may be produced according to the following steps. 1) establishing a design parameter such as depth of groove that meet requirements for controlling an internal occurring electromagnetic effect in the form of skin effect, the internal occurring electromagnetic effect being caused by currents induced by changing electromagnetic field in the electric conductor, wherein the changing electromagnetic field is caused by an alternating current conducted by the electric conductor. 2) establishing a modification design parameter defining a slope of the helix being required for modifying the electromagnetic field control element, for the helix electromagnetic field control element to be able to control an external occurring electromagnetic effect in the form of proximity effect, the proximity effect being caused by an external electromagnetic field from a nearby conductor, wherein the external occurring electromagnetic field is caused by an alternating current conducted by the nearby electric conductor. 3) establish a digital version of the conductor and / or electric distribution system based on the above-mentioned parameters and additional system information. 4) validate or simulate the effect of the conductors in the system. 5) amend or update the digital version of the conductor. 6) repeat step 4) and 5) until a satisfying conductor / system is reached. 7) establish the electric conductor with the electromagnetic field controlelement according to the design parameter and according to the modified design parameter. The establishing of the conductor may be done by one of the mentioned production methods. 8) post treatment of the conductor to establish the produced conductor. 9) installing the conductor in the electric current distribution system.

[0278] It should be noted that some steps may be repeated and that some steps may not always be necessary. Also, the sequence of some of the steps may be in another order than what is provided above.

[0279] The electric conductor with electromagnetic field control element may be produced by extrusion. Extrusion is advantageous in that it has the effect that it is a fast, cheap and a proven method of establishing electric conductors. The electromagnetic field control element can be provided in the perimeter by protrusions or recesses at the extrusion outlet.

[0280] It should be noted that the length of such protrusions / recesses may vary to establish variable depth / height of the electromagnetic field control elements along the length of the conductor. It should further be noted that such protrusions / recesses may rotate to establish helix electromagnetic field control element along the length of the conductor. Rotation to form the electromagnetic field control element along the length of the conductor may be performed during extrusion by twisting the extruded element or the outlet with protrusion / recesses.

[0281] Alternative methods of producing the conductor may include casting, milling, casting, and additive manufacturing, the latter being most relevant for reduced size components. Some of the mentioned methods would require post treatment e.g. in the form of shaping such as bending, rotating or establishing of the electromagnetic field control element.

[0282] Post treatment can be cutting into the conductor with a laser cutter. The laser cutter may be positioned on a robot arm so that it is able to make the electromagnetic field control element. Alternatively, the conductor is rotated relative to the laser cutter. The cutting could also be done with alternatives to laser cutting. Post treatment could also include adding material to the outer perimeter of the conductor.

[0283] Post treatment could also include milling the surface. Hence, if the electromagnetic field control elements are to go all the way through the current conducting material, then to keep the branches in place relative to each other, a groove cover GC is left after the extrusion over the electromagnetic field control element see fig. 6a, 6b. The post milling process could then be applied to remove at least part of this groove cover GC as illustrated in fig. 6c Only sufficient material is left to ensure required stability of the conductor. The material left could be referred to as what is also referred to as branch connectors i.e. this is one way of providing a conductor with branch connectors. The groove covers GC may be provided if inner grooves are extruded. The groove covers are provided directly on top of such inner grooves. In the process of extruding, the mold rotates while the conductor is pushed through. This results in a cross-sectional area as illustrated in fig. 6b. The raw conductor could look like the one illustrated in fig. 6a and after the post processing, in this case milling part of the groove covers away, the conductor can look like the illustrated conductor in fig.6c.

[0284] Figures 7-1 lb illustrates various conductor modules which can be connected to establish the conductor illustrated e.g. in fig. la and lb.

[0285] Fig. 7 illustrates a modular conductor MC according to an embodiment of the invention. The modular conductor MC comprises two tubular conductor modules CM1, CM2 each having interface modules IM1, IM2 via which the two conductor modules CM are connected. When connected, the two conductor modules CM form a 90 degrees bend of the modular conductor MC. At each end of the conductor modules, i.e. their first end IE and second end 2E, the conductor modules CM have an interface area IA. Between the interface areas IA, a groove G is provided into the outer perimeter OP of the conductor module CM, extending all the way through the current conducting material between the inner and outer perimeters IP, OP of the tubular conductor module CM. The groove G takes one or more 360 degrees turn around the outer perimeter of the conductor module. The groove G defines a branch B which turns with the same slope around the perimeter of the conductor module CM.

[0286] Fig. 8a illustrates an interface module IM having a first side IS defining a first plane and a second side 2S defining a second plane. Between the two planes an angle A is provided. The first side IS of the interface module IM comprises holes H. The location of these holes H is determined so that when bolts are pushed through these holes, the bolts can engage with interior threaded part TP of the conductor module (see fig. 7) or nuts and thereby facilitate a releasable connection of these two modules.

[0287] Fig. 8b illustrates the interface module IM from the back side, with the first side IS / first plane partly visible. One hole H and parts of two other holes provided in the first side IS are illustrated. From this view it is possible to see where bolts can be pushed through to engage with the threaded part TP of the conductor module. The first and second sides IS, 2S interfacing another part may be provided with divergent portions DP for optimal electric connection. The clamping force provided when tightening the two planes together impacts the other part via the planes of a pyramid or sawtooth pattern in a direction that is not parallel to the clamping force, establishing an improved electric connection through engagement between the divergent portions.

[0288] Fig. 8c illustrates an interface module IM having a design different from the embodiment illustrated in fig. 8a and 8b. This embodiment comprises two wedge-like parts which are connectable via a bolt BOL. When the bolt is tightened, the two parts are forced together and the diameter defined by the two parts is expanded, creating a force outward from the center axis of the interface module. This force clamps the interface module towards an inner perimeter IP of the conductor module CM. The engaging parts of the two wedge-like parts may comprise divergent portions DP for optimal electric connection to the inner perimeter of the conductor module. The interface module illustrated in fig. 8c is advantageous when mounting to a conductor module that does not have internal threaded parts.

[0289] Fig. 9a illustrates a connection between an interface module IM, a conductor and an electric component EC. The interface module provides a planar surface, which may include divergent portions on its surface, adapted to interface a corresponding terminal on the electric component EC. The terminal of the electriccomponent EC and of the conductor module CM is in this embodiment connected via bolts in the terminal holes TH. The end of the conductor module illustrated in fig. 9a could be a first end IE of a modular conductor.

[0290] Fig. 9b illustrates conductors, interface module and terminal adaptor together forming the conductor module illustrated in fig. 9c. Hence, fig. 9b illustrates a connection between a conductor module CM and a busbar serving as an electric component EC (here stipulated busbar), seen from a first angle. The busbar terminals are implemented as holes in the busbars. The terminal holes TH are adapted to receive a bolt that also goes through holes in a terminal adapter TA. The busbars have a terminal plane in the Z plane, while the interface module has a terminal plane in the Y plane. The terminal adapter TA is introduced therebetween to allow the two terminal planes to meet. The end of the conductor module illustrated could be a second end 2E of a modular conductor illustrated in fig. 9a.

[0291] Fig. 9c illustrates the same connection as fig. 9b seen from a different angle and assembled, showing the conductor module CM connected to a busbar BB. From this angle, the arrangement of the terminal holes TH and the terminal adapter TA bridging between the busbar terminal plane and the interface module terminal plane is visible. The terminal adapter TA is designed so that holes on one side are aligned with holes in the busbar and on the other side aligned with holes in the interface module / conductor, allowing the same interface module to be used at both ends of the conductor module to connect to electric components EC having different terminal designs.

[0292] Fig. 10a illustrates a linear / straight conductor module CM comprising a plurality of grooves G extending all the way through the current conducting cross-sectional area, thereby forming a plurality of branches B. Towards one end there are no grooves to ensure mechanical stability of the conductor module and facilitate mounting of interface modules. From the interior of the conductor module, the inner perimeter comprises divergent portions DP adapted for connection with an interface module illustrated in fig. 8c. The linear conductor module may be produced in standard lengths and cut to the desired length on site of mounting.

[0293] Fig. 10b illustrates a conductor module CM that has a pre-bend shape / angle. This serves to illustrate that a conductor referred to as a conductor module CM of the present invention may be produced in various desired geometries with or without grooves. The bend module of fig. 10b could, as other illustrated conductors / conductor modules, be massive or hollow such as tubular. No grooves are illustrated in this embodiment.

[0294] Fig. 10c illustrates part of a modular conductor MC. The illustrated part comprises a plurality of conductor modules CM. Some modules are linear conductors whereas other modules have bends. The groove G is in this modular conductor continued from one conductor module to another which is preferred but not mandatory. The interface areas of the modules i.e. where the modules are connected, may be designed as threaded bushings. In this way, the modules can be screwed together. Alternatively, the modules may be connected by welding. Alternatively, the conductor modules may comprise aligned holes when the interface area of two conductor modules are overlapping. Via the holes the conductor modules can be connected by bolts and nuts.

[0295] Fig. Ila illustrates a transition module TM for a modular conductor MC. The transition module TM is designed to connect an inner conductor module CM and an outer conductor CM in a pipe-in-pipe configuration. The transition module TM is used in the pipe-in-pipe modular conductor illustrated in fig. 1 lb and provides an alternative way of controlling current through a modular conductor by ensuring the same amount of current flows in the inner and outer conductors.

[0296] Fig. 11b illustrates a pipe-in-pipe modular conductor MC comprising two interface modules IM, two conductor modules CM and a transition module TM. The transition module TM is located in the middle of the length between the two interface modules IM. This configuration provides an alternative way of controlling current through a modular conductor and thereby ensures the same amount of current in the inner and outer conductor. Such balancing is obtained because the transition module is located in the middle of the length between the two interface modules.

[0297] For the conductor to comply with requirements of the distribution system of the present invention it can be produced according to various principles.

[0298] In case a power tube is extruded as a straight tubular conductor and that conductor need to bend the center part of the power tube may be temporary filled. The filling may be a material that can support the inner perimeter of the power tube while a bending force is applied and removed when the power tube has been bend in the right angle. The material may be introduced and subsequently solidified or it may be a spring type of material that is flexible and can bend with the power tube and be pulled out after the bend has been made.

[0299] Independent of how a tubular conductor is manufactured, the electromagnetic field control elements can be provided to the power tube in various ways. One way is to fixate the power tube and let e.g. a robotic arm cut or apply the electromagnetic field control elements. Alternatively, the cutting or applying tool is fixed and the power tube is moved relative thereto. Alternatively, both the cutting or applying tool and the power tube is moved relative to each other.

[0300] It should be mentioned that the electromagnetic field control elements may be applied to the tubular connector after it is shaped into the desired design e.g. by a robotic arm.

[0301] According to the above, the invention relates to an electric current distribution system comprising one or more conductors having electromagnetic field control elements. Such conductor may be used in high power / high current systems where currents above 100A, such as above 500A, such as above 1000A are used. Further, to obtain full benefit of conductors of the present invention, the physical distances in such system should exceed 30cm i.e. a conductor of at least 30cm (routing distance) should be needed to connect two components of the system. Alternatively, or in addition, the routing distance from a terminal to a component in such system should be at least 30cm. This 30cm limit is not fixed, it is an example of a relationship between length and diameter of the conductor. Hence, a typical minimum length for a conductor ofthe present invention could be a length of three times the diameter of the current conducting diameter of the conductor.

[0302] As mentioned, the electromagnetic field control element may, from the outer perimeter of the conductor, extend in a range from 0% or close to 0% to 100% of the cross-section of the current conducting material (with reference to fig. 4, this crosssection is defined as the distance DIS).

[0303] Examples of systems requiring conducting e.g. +1000 A over a routing distance of + 30cm include electric systems such as power converter, reactors, switchgear, power distribution systems, etc. Also power supply to e.g. electrolysis stacks that need high power to produce hydrogen may be supplied at least partly from conductors according to the present invention.

[0304] The conductor of the present invention may, as indicated above, have one or more middle sections with spiral grooves. As mentioned, it is optimal if the spiral takes one 360 degrees turn over a predetermined distance, however as also mentioned, less (or more) can do. With knowledge of the system in which the conductor of the present invention is to be used, it is possible to design the different parts of the conductor with 90, 180, 360 or whatever degree turn of the spiral branches / groves over a given length of the conductor / middle section. The location of the conductor in the system is determining for the design of the branches. Hence, if two conductors are within a range of e.g. 1cm to 100cm such as within 70cm, 60cm, 50cm, 40cm, 30c, 20cm or 10cm of each other, the spiral grooves may have effect. Also, the length the two conductors are having this mutual distance is determining for the design of the branches. Hence, if one conductor turns and thus have no immediate neighbor, the branches may not be needed.

[0305] It should be noted that the individual branches may be terminated individually or in groups of two or more individual branches. Such termination could be similar to what has been described above.

[0306] Different methods of manufacturing a conductor with grooves according to the present invention exists. One would be extrusion, another one would be laser orwaterjet cutting and yet another would be milling. Grooves may be applied to a tube or to a sheet material, which is then formed into a tube by e.g. rolling and welding. Additive manufacturing is of course a possibility however, it is not the preferred due to the length of the conductor.

[0307] In an embodiment, the invention related to an electric current distribution system ECS comprising: first terminal set (ITS) comprising one or more first terminals (IT), a second terminal set (2TS) comprising one or more second terminals (2T), and at least one electric current conductor (C) electrically connected between the terminals (IT, 2T) of the first and second terminal sets (ITS, 2TS), herein the at least one electric current conductor (C) comprises a middle section (MS) provided between a first end (IE) and a second end (2E) of the at least one electric current conductor (C), and wherein the middle section (MS) comprises a plurality of electromagnetic field control elements (G).ListECS Electric Current distribution SystemITS, 2TS First Terminal Set, Second Terminal SetIT, 2T First Terminal, Second TerminalC Electric Current conductor1C First electric current conductor2C Second electric current conductor... etc.MS Middle SectionIE, 2E First End, Second EndG Electromagnetic field control element such as a groove EC Electric ComponentECA Electric CabinetOP Outer PerimeterB BranchesD DepthDIS DistanceCB Circuit Breaker (example of electric component) BB BusbarCT Conductor TerminalTA Terminal AdaptorCTP Conductor Terminal PartIPO Inner PortionR ReactorPM Power ModuleMB Main BusbarOC Output CableSC Supply CableTB Transmission BusbarCU CurrentIP Inner PerimeterCPE Center perimeterBO BottomCP Center Part1GS, 2GS First Groove Side, Second Groove SideCA CableIT Inlet terminalsW WidthGC Groove CoverBOL BoltCM Conductor ModuleIM Interface ModuleIA Interface Area1 S, 2S First Side (of interface module), Second Side (of interface module) A Angle (between first and second side of interface module)TM Transition ModuleMC Modular ConductorTP Threaded PartTH Terminal HolesH HolesS Side

Claims

Patent claims1. An electric current distribution system (ECS) comprising:• a first terminal set (ITS) comprising one or more first terminals (IT),• a second terminal set (2TS) comprising one or more second terminals (2T), and• at least two electric current conductors (C) electrically connected between the terminals (IT, 2T) of the first and second terminal sets (ITS, 2TS),wherein the at least two electric current conductors (C) comprises a middle section (MS) provided between a first end (IE) and a second end (2E) of the at least two electric current conductors (C), and wherein the middle section (MS) comprises at least one bend portion.

2. An electric current distribution system according to claim 1, wherein the first terminal set (ITS) and / or the second terminal set (2TS) is comprised by an electric component (EC), and wherein the first terminal set (ITS) and / or the second terminal set (2TS) is electrically connecting the electric current conductor (C) and the electric component (EC).

3. An electric current distribution system according to any one of claims 1 and 2, wherein the electric current conductor (C) is a tubular conductor.

4. An electric current distribution system according to any of the preceding claims, wherein a first end (IE) of the electric current conductor (C) is configured for being connected to the first terminal set (ITS) in a first spatial point (X, Y, Z), wherein a second end (2E) of the electric current conductor (C) is configured for being connected to the second terminal set (2TS) in a second spatial point (X’, Y’, Z’), wherein the first and second spatial points are different, and wherein at least one of the X, Y and Z coordinates of the second spatial point is different from the corresponding X, Y or Z coordinates of the first spatial points.

5. An electric current distribution system according to claim 4, wherein the electric current conductor (C), between the first and second spatial points, travels through a third spatial point (X”, Y”, Z”) wherein all of the X, Y and Z coordinates of the third spatial points are different from all of the X, Y and Z coordinates of the first and second spatial points.

6. An electric current distribution system according to any one of claims 4 and 5, wherein the electric conductor (C) between the first and second spatial points is monolithic.

7. An electric current distribution system according to any of the preceding claims, wherein the electric current conductor (C) is monolithic between a conductor terminal (CT) of a first end (IE) of the electric current conductor (C) and a conductor terminal (CT) of a second end (2E) of the electric current conductor (C).

8. An electric current distribution system according to any of the preceding claims, wherein the electric current conductor (C) is self-supporting.

9. An electric current distribution system according to any of the preceding claims, wherein the electric current conductor comprises at least one electromagnetic field control elements (G).

10. An electric current distribution system according to any of the preceding claims, wherein the middle section (MS) is comprised by an electric cabinet (ECA).

11. An electric current distribution system according to any of the preceding claims, wherein the length of the middle section (MS) at least 200cm, such as at least 400cm such as between 100cm and 20.000cm.

12. An electric current distribution system according to any of the preceding claims, wherein the middle section (MS) has an outer perimeter length (OP) of at least 4cm.

13. An electric current distribution system according to any of the preceding claims, wherein the electric current conductor follows a path between two spatial points that is longer than the direct distance between the two spatial points.

14. An electric current distribution system according to any of the preceding claims, wherein the electric current conductor (C) comprises a contact surface.

15. An electric current distribution system according to any of the preceding claims, wherein the middle section (MS) comprises a contact surface.

16. An electric current distribution system according to any one of claims 14 and 15, wherein a part of the contact surface comprises a divergent portion17. An electric current distribution system according to any of the preceding claims, wherein the electric current conductor has an internal cooling channel.

18. An electric current distribution system according to any of the preceding claims, wherein the at least one electromagnetic field control element (G) is non-electric conductive.

19. An electric current distribution system according to any of the preceding claims, wherein the at least one electromagnetic field control element (G) is implemented in the electric current conductor (C) as air gaps in the perimeter of the electric current conductor (C).

20. An electric current distribution system according to any of the preceding claims, wherein air gaps can be filled with a material of the list of materials comprising: ceramics, glass, polymer and paper.

21. An electric current distribution system according to any of the preceding claims, wherein the at least one electromagnetic field control element (G) separates the outer perimeter (OP) of the electric current conductor (C) into a plurality of conductor branches (B).

22. An electric current distribution system according to claim 21, wherein the impedance of the plurality of conductor branches (B) are predetermined.

23. An electric current distribution system according to claim 22, wherein the plurality of conductor branches (B) has the same impedance to electric current.

24. An electric current distribution system according to any of the preceding claims, wherein the depth (D) of at least one of the at least one electromagnetic field control element (G) is between 5% and 125% of the skin depth of the current conducted by the electric current conductor (C).

25. An electric current distribution system according to any of the preceding claims, wherein at least one of the at least one electromagnetic field control element (G) only partly extends between the first end (IE) and the second end (2E) of the electric conductor (C).

26. An electric current distribution system according to any of the preceding claims, wherein the electromagnetic field control element (G) follows a perimeter track between two spatial points that is longer than the direct distance along the perimeter between the two spatial points.

27. An electric current distribution system according to any of the preceding claims, wherein the distance between a first end and a second end of the electromagnetic field control element (G) is at least 2.5 times the diameter of the conductor.

28. An electric current distribution system according to any of the preceding claims, wherein at least one of the at least one electromagnetic field control element (G) travel around the outer perimeter (OP) of the electric current conductor (C), thereby forming the plurality of conductor branches (B) as helix branches.

29. An electric current distribution system according to any of the preceding claims, wherein at least one of the at least one electromagnetic field control element (G) is traveling between 90 degrees and 360 degrees around the outer perimeter (OP) of the electric current conductor (C).

30. An electric current distribution system according to any of the preceding claims, wherein a plurality of the conductor branches is electrically connected at least once between the first end (IE) and the second end (2E).

31. An electric current distribution system according to any of the preceding claims, wherein the electric current conductor (C) is a modular electric current conductor (MC) comprising a plurality of conductor modules (CM).

32. An electric current distribution system according to claim 31, wherein at least two of the plurality of conductor modules (CM) have a non-identical geometry.

33. An electric current distribution system according to any one of claims 31 and 32, wherein at least one of the plurality of conductor modules is selected from the list comprising a: 45 degrees bend, 90 degrees bend, T-module and Y-module.

34. An electric current distribution system according to any one of claims 31-33, wherein each of the first and second ends (IE, 2E) of a conductor module (CM) comprises an interface area (IA).

35. An electric current distribution system according to claim 34, wherein one or more of the interface areas (IA) of the conductor modules (CM) is configured to be connected with an interface module (IM).

36. An electric current distribution system according to claim 35, wherein the interface module (IM) is monolithic with a conductor module (CM).

37. An electric current distribution system according to any one of claims 35 and 36, wherein the interface module (IM) comprises a first side (IS) and a second side (2S), wherein an angle (A) between the first side and the second side is between 10 degrees and 100 degrees.

38. An electric current distribution system according to claim 37, wherein the angle (A) is 15 degrees, 30 degrees, 45 degrees or 90 degrees.

39. An electric current distribution system according to any one of claims 35-38, wherein at least part of the plurality of conductor modules (CM) has an interface area (IA) defined in a plane which is provided with a 90 degrees angle to a longitudinal axis of the at least part of the plurality of conductor modules.

40. An electric current distribution system according to any one of claims 35-39, wherein the interface module (IM) comprises a divergent portion (DP).

41. An electric current distribution system according to any one of claims 35-40, wherein the interface module (IM) comprises a poka yoke element.

42. An electric current distribution system according to any one of claims 35-41, wherein the interface module (IM) extends outside an outer perimeter (OP) of the conductor module (CM).

43. An electric current distribution system according to any one of claims 31-42, wherein at least one of the plurality of conductor modules (CM) comprises inner fastening means.

44. An electric current distribution system according to claim 43, wherein the inner fastening means are threaded parts (TP) configured for receiving bolts.

45. An electric current distribution system according to any one of claims 34-44, wherein an interface area (IA) of two conductor modules is connected forming a modular electric current conductor (MC).

46. An electric current distribution system according to claim 45, wherein the connection of interface areas (IA) is provided by bolts, welding or soldering.

47. An electric current distribution system according to any of the preceding claims, wherein the electric current conductor (C) is a pipe-in-pipe conductor comprising an inner conductor and an outer conductor, and a transition module (TM) connecting the inner and outer conductors.

48. An electric current distribution system according to any of the preceding claims, wherein at least one of the electromagnetic field control elements (G) is asymmetric.

49. An electric current distribution system according to any of the preceding claims, wherein the electric current distribution system comprises at least two neighboring electric current conductors (C), and wherein the electromagnetic field control elements(G) of the at least two neighboring electric current conductors have a corresponding symmetry.

50. An electric current distribution system according to any of the preceding claims, wherein the electric current distribution system comprises at least two neighboring electric current conductors (C), and wherein the electromagnetic field control elements (G) of the at least two neighboring electric current conductors have a noncorresponding symmetry.

51. An electric current distribution system according to any of the preceding claims, wherein the electric current distribution system further comprises a conductor assembly, wherein the conductor assembly comprises a tubular conductor and at least two conductor terminals (CT) welded to the tubular conductor.

52. An electric current distribution system according to any of the preceding claims, wherein the at least one bend portion has a bending radius of at least 2 times, such as at least 3 times the outer diameter of the electric current conductor (C).

53. An electric current distribution system according to any of the preceding claims, wherein the electric current conductor (C) is self-supporting between the first terminal set (ITS) and the second terminal set (2TS), and wherein the middle section (MS) comprises at least one bend portion.

54. An electric current distribution system according to claim 53, wherein the electric current conductor (C) is monolithic between the first end (IE) and the second end (2E), self-supporting between the first terminal set (ITS) and the second terminal set (2TS), and wherein the middle section (MS) comprises at least two bend portions.

55. An electric current distribution system according to any of the preceding claims, wherein the at least one bend portion (BP) extends between a first bend portion point (1BPP) and a second bend portion point (2BPP), wherein the at least one bend portion (BP) has an asymmetric bend profile, wherein the main angular change of the bend portion (BP) is concentrated in a first part of the bend portion, the first part being less than half of the routing length between the first and second bend portion points.

56. An electric current distribution system according to any of the preceding claims, wherein the at least one bend portion extends between a first bend portion point (1BPP) and a second bend portion point (2BPP), wherein the at least one bend portion has a continuous bend along the routing length between the first and second bend portion points.

57. An electric current distribution system according to claim 56, wherein the routing length between the first bend portion point (1BPP) and the second bend portion point (2BPP) is at least 2 times the outer diameter of the electric current conductor (C), such as at least 3 times, such as at least 5 times the outer diameter of the electric current conductor (C).

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