Power Conversion Device Bus Bar Fastening and Capacitor Fixing
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Solution Overview
Problem
Conventional power conversion devices increase in size due to the need for space between the semiconductor module and the capacitor for tool access during bolt fixation, leading to increased volume and cost.
Innovation Solution
The semiconductor module and smoothing capacitor are arranged parallel to each other, with the capacitor fixed to the case at positions that avoid its corners, allowing for closer proximity and reducing the need for space between them, using bus bar fastening points that serve both as electrical connections and fixing points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the capacitor is fixed to the case by bolts at the four corners, then the capacitor is securely fixed, but the device volume increases due to the need for tool access space
Solution Approach 1:
The patent combines the capacitor fixing function with the bus bar electrical connection function into a single integrated structure. The bus bar is directly fixed to the capacitor, and both components are secured to the case together, eliminating the need for separate fixing operations and reducing the space required for tool access.
Solution Approach 2:
The bus bar structure serves multiple functions simultaneously: it provides electrical connection between the semiconductor module and capacitor, acts as a structural support element, and serves as the fixing point for securing the capacitor to the case. This multi-functionality eliminates the need for separate fixing mechanisms and reduces overall device volume.
2Volume of stationary object
If the semiconductor module and capacitor are positioned close to each other, then the device volume is reduced, but the bus bar length increases leading to higher cost
Solution Approach 1:
The bus bar is configured to extend in multiple spatial dimensions rather than a single straight line. It has a first extension direction from the semiconductor module to the capacitor, and a second extension direction perpendicular to the first, creating a three-dimensional path that optimizes both length and spatial utilization.
Solution Approach 2:
The bus bar cross-sectional area varies along its length, being larger at the semiconductor module end and smaller at the capacitor end. This non-uniform cross-section optimizes current carrying capacity where needed while reducing material usage where lower current flows, thereby reducing overall material quantity and cost.
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 configuration enables the downsizing of the power conversion device while maintaining strong capacitor fixation and reducing the length and cost of bus bars, improving durability and reliability of the high-voltage connection.
Implementation Method 1
The smoothing capacitor 5 is arranged parallel to the semiconductor module 4, is fixed to the case 30 by fixing bolts 54 and suppresses voltage fluctuations
Data Source
AI summary
A power conversion device includes a case, a power module, a smoothing capacitor and a high-voltage connection portion. The power module is housed in the case. The smoothing capacitor is fixed to the case by capacitor fixing bolt, and suppresses voltage fluctuations. In the high-voltage connection portion, the power module and the smoothing capacitor are electrically connected. The locations at which the smoothing capacitor is fixed to the case by the capacitor fixing bolts correspond to the capacitor fixing points. The capacitor fixing points are arranged at positions that avoid corner portions of the smoothing capacitor. The power module and the smoothing capacitor are disposed adjacent to each other at the high-voltage connection portion.