Power Conversion Device Bus-Bar Housing Integration
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Solution Overview
Problem
Conventional power conversion devices for hybrid and electric/fuel-cell vehicles have a complex housing structure due to the inclusion of a high-voltage three-phase connector male part, which increases the number of vehicle parts and costs.
Innovation Solution
A power conversion device with a simplified housing structure that integrates the connector male part function into the housing, directly exposing a multi-phase output bus-bar for electrical connection, eliminating the need for a separate connector male part and using a plastic fixture to fix the bus-bar, ensuring insulation and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate connector male part is used for electrical connection, then reliable electrical connectivity is achieved, but the housing structure becomes complex and the number of parts increases
Solution Approach 1:
The patent integrates the connector male part functions directly into the housing structure. The housing includes a bus bar that serves both as a structural component and as the electrical connector, eliminating the need for a separate connector male part. The bus bar has connection portions that directly connect to the power module and output portions that extend outward for external connections, merging multiple functions into a single integrated structure.
Solution Approach 2:
The housing is designed to perform multiple functions: it provides mechanical protection, structural support, and electrical connection. The bus bar integrated into the housing serves as both a current conductor and a connector, while the housing itself acts as a mounting structure for the power module and a connector for external wiring, reducing the total number of components needed.
2Stability of the object's composition
If a separate connector male part with fastening bolts is used, then secure assembly is achieved, but the number of parts and assembly complexity increases
Solution Approach 1:
The fastening function is integrated into the housing structure itself. The housing includes recesses and protrusions that interlock to secure the power module and provide mechanical fastening without requiring separate bolts or connectors. The integrated bus bar structure provides both electrical connection and mechanical attachment in a single component.
3Reliability
If a connector male part is bolted to the housing, then reliable electrical connection is achieved, but the housing size and cost increase
Solution Approach 1:
The electrical connection function is merged into the housing structure through the integrated bus bar. The bus bar extends from within the housing and provides external connection points, eliminating the need for additional space required by separate connectors and their mounting hardware, thereby reducing the overall housing volume.
Data Source
AI summary
A power conversion device includes a housing in which a power module is mounted and a multi-phase output bus-bar. The multi-phase output bus bar has one end electrically connected to the power module and a remaining end penetrating the housing so as to be directly exposed to an outside.