DC-Voltage Busbar Clamping for Low Inductance Power Electronics
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Solution Overview
Problem
Existing power-electronic circuits face challenges in achieving a low-inductance configuration for power components and DC-voltage busbars without narrowing line cross-sections at connection points, which affects current-carrying capacity and increases leakage inductance.
Innovation Solution
The arrangement features flat DC-voltage connection conductors and partial busbars with clamping sections that form a force-fitting connection using screws, ensuring direct contact surfaces without reducing current-carrying capacity and maintaining low leakage inductance by maintaining uniform cross-sectional areas and using insulation for electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the DC-voltage connection conductors and partial busbars are connected using conventional methods, then the connection is electrically conductive, but the line cross sections are narrowed at connection points reducing current-carrying capacity and increasing leakage inductance
Solution Approach 1:
The connection structure is segmented into distinct functional zones: the contact section maintains the original line cross-section for current conduction, while the clamping section provides the connection interface. This segmentation allows the contact section to preserve current-carrying capacity without narrowing, while the clamping section handles the mechanical and electrical connection through force-fitting with the connector.
Solution Approach 2:
Different sections of the DC-voltage connection conductors and partial busbars are given different local properties: the contact section is designed to maintain full cross-sectional area and direct surface contact for optimal current flow, while the clamping section is designed with geometry suitable for force-fitting connection. This local differentiation resolves the contradiction by optimizing each section for its specific function.
2Reliability
If the DC-voltage connection conductors and partial busbars are arranged closely adjacent to minimize leakage inductance, then leakage inductance is reduced, but electrical insulation between the conductors must be ensured
Solution Approach 1:
An insulating means is introduced as an intermediary element between the closely adjacent DC-voltage connection conductors of different polarities. This insulating means allows the conductors to be arranged at minimal distance for low leakage inductance while preventing electrical breakdown between opposite polarities, thus resolving the contradiction between compact arrangement and insulation requirements.
3Reliability
If the contact sections lie directly flat on one another with force-fitting connection, then electrical contact resistance is minimized, but mechanical strength of the connection must be sufficient
Solution Approach 1:
The electrical and mechanical connection functions are merged into a single force-fitting connection mechanism. The connector applies mechanical force to press the contact sections of the DC-voltage connection conductors against the contact sections of the partial busbars, simultaneously achieving low contact resistance through direct surface contact and adequate mechanical strength through the clamping force. This merging eliminates the need for separate electrical and mechanical connection elements.
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 maintains high current-carrying capacity and minimizes leakage inductance by ensuring that the cross-sectional areas and contact surfaces are not restricted, while the closely adjacent design with insulation ensures effective electrical insulation.
Implementation Method 1
the clamping section of the DC-voltage connection conductor being connected to that clamping section of the partial busbars in a flat and force-fitting manner above one another by means of a connector
Implementation Method 2
The DC-voltage connection conductors are arranged closely adjacent to one another in this course in the direction of their respective normal vector there
Data Source
AI summary
An arrangement having a DC-voltage busbar and a power component. The power component has two flat DC-voltage connection conductors, each with a contact section and arranged closely adjacent to one another. Each connection conductor has a clamping section beside the respective contact section in the direction of current flow. The busbar has two partial busbars, each with a contact section and arranged closely adjacent to one another. Each partial busbar has a clamping section beside the respective contact section in the direction of current flow. The contact section of at least one connection conductor is electrically connected to the contact section of the associated partial busbar by connecting the clamping sections of the connection conductor to the clamping section of the partial busbars in a flat and force-fitting manner above one another and the respective contact sections therefore lying directly flat on one another.