AC Carrier Busbar Assembly With Integrated EMI Damping Core
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Solution Overview
Problem
Current busbar designs for three-phase electric motors and inverters face performance limitations due to electromagnetic interference (EMI) and varying levels of magnetic flux, requiring different sizes of common mode chokes and flux concentrators for different applications.
Innovation Solution
The proposed interface includes an AC carrier assembly with a core that surrounds the busbars to dampen EMI and flux concentrators disposed in sub-housings to manage magnetic flux, allowing for adaptable use with various motor and inverter combinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a common mode choke is used to address EMI, then electromagnetic interference is reduced, but the device complexity and number of components increase
Solution Approach 1:
The patent integrates the common mode choke functionality directly into the busbar structure by forming a core with an aperture through which the busbars extend. This merging of the choke core and busbar assembly eliminates the need for separate EMI filtering components while maintaining EMI reduction capabilities.
Solution Approach 2:
The busbar assembly serves multiple functions simultaneously: it provides electrical connection between motor terminals and inverter, structurally supports the EMI filtering function through the integrated core, and manages magnetic flux through incorporated flux concentrators. This multi-functionality reduces overall device complexity.
2Reliability
If different sizes of common mode choke and flux concentrators are used for different motor-inverter combinations, then performance requirements are met, but inventory complexity and manufacturing costs increase
Solution Approach 1:
The patent designs the core and flux concentrators with adjustable positioning capabilities within the busbar assembly. The core can be positioned at different locations along the busbars, and flux concentrators can be adjusted to different orientations and positions, allowing the same component design to adapt to various EMI and flux requirements across different motor-inverter combinations.
Solution Approach 2:
The invention allows modification of geometric parameters such as core aperture size, core material properties, and flux concentrator dimensions while maintaining the same basic component design. This enables adaptation to different current and voltage levels without requiring entirely different component designs.
3Power
If flux concentrators are used to intensity magnetic flux, then motor performance is improved, but the device complexity and component count increase
Solution Approach 1:
The flux concentrators are integrated into the busbar assembly structure itself rather than being separate components. The concentrators are positioned within cavities formed as part of the busbar housing, merging the flux management function with the existing structural elements of the connection assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively reduces EMI and manages magnetic flux, enabling the AC carrier assembly to be used with different electric motor and inverter applications while maintaining performance and reducing the need for multiple components.
Implementation Method 1
a core at least partially disposed in the receptacle, the core surrounding the busbars to dampen electromagnetic interference
Implementation Method 2
a plurality of flux concentrators, where each of the flux concentrators is disposed in a corresponding one of the sub-housings
Data Source
AI summary
An AC carrier assembly, which includes a housing, a receptacle integrally formed as part of the housing, a plurality of busbars extending through the housing, a core at least partially disposed in the receptacle, the core surrounding the busbars to dampen electromagnetic interference. A plurality of sub-housings are integrally formed as part of the housing, and each of a plurality of flux concentrators, is disposed in a corresponding one of the sub-housings. The AC carrier assembly also includes a cover attached to the housing, and a plurality of conductors. Each of the conductors is connected one of the busbars, and each of the flux concentrators surrounds a corresponding one of the busbars. Each sub-housing includes a cavity, and one of the flux concentrators is at least partially disposed in the cavity of the sub-housing. Each sub-housing may be overmolded around the flux concentrators.