Voltage Converter Busbar Layout for Shielded Laser Welding
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Solution Overview
Problem
Existing electronic units for rotating electrical machine voltage converters require complex enclosures and sealing to block laser beams during welding, leading to increased costs and the need for costly fume treatment systems.
Innovation Solution
The electronic unit design includes busbars with extensions that block laser beams without additional enclosures, using free zones to prevent beam interruption and reduce damage, eliminating the need for complex enclosures and fume treatment systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a rotating electric machine is miniaturized to reduce vehicle mounting space, then the size of the machine decreases, but the heat dissipation capability deteriorates due to reduced radiator area
Solution Approach 1:
The stator winding is divided into multiple independent coil units (first coil unit, second coil unit, etc.), each capable of being independently controlled for current flow direction. This segmentation allows selective activation of different coil units based on operating conditions, enabling optimized heat distribution and dissipation across the stator structure while maintaining compact dimensions.
Solution Approach 2:
The control device dynamically adjusts the current flow direction in different coil units based on real-time operating conditions (rotation direction, load, temperature). By reversibly changing current directions in specific coil units, the system adapts heat generation patterns to match varying operational demands, improving heat dissipation efficiency in the miniaturized structure.
2Device complexity
If the number of coils is reduced to simplify the structure, then the device complexity decreases, but the controllability of heat generation deteriorates
Solution Approach 1:
The stator winding is segmented into multiple coil units along the circumferential direction, with each unit independently controllable. This segmentation provides multiple controllable elements for heat generation without requiring a complete increase in total coil count, as adjacent units can be controlled in coordinated patterns to achieve various heating zones.
Solution Approach 2:
The control device implements dynamic control by reversibly changing current flow directions in different coil units based on operating conditions. This dynamic adjustment capability allows the same physical coil structure to provide varied heat generation patterns, maintaining high adaptability while using a limited number of physical coils.
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 design simplifies manufacturing, reduces costs, and minimizes damage to the housing by blocking laser beams effectively, thereby eliminating the need for costly fume treatment systems and cleaning operations.
Implementation Method 1
a three-phase alternating current is supplied to three-phase stator coils, a rotating magnetic field is generated, and an electromagnetic force is induced in the rotor
Implementation Method 2
a rotating magnetic field is generated, and an electromagnetic force is induced in the rotor, thereby causing the rotor to rotate
Implementation Method 3
a permanent magnet is disposed on an inner circumference of the rotor, and the N poles and S poles are alternately disposed along an inner circumference of the rotor
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an electronic unit (1) for a voltage converter (104) of a rotating electric machine (130), comprising: - a first busbar (8) comprising: - a first plate (2), - a first connection portion (3) projecting from the first plate, from a first side (4) of the first plate (2), and comprising a first connection surface (5) able to be welded to a second connection surface (9) of a third busbar (10) of a power electronics module (110) by a first laser welding operation using a first laser beam, - a second busbar (6) separate from the first busbar (8) and comprising a second plate (12) parallel to the first plate (2) and located on a second side (13) of the first plate (2) opposite the first side (4), wherein the first busbar (8) or the second busbar (6) comprises a first extension (15) extending in line with the first connection surface (5), the first extension (15) being able to block the first laser beam. The invention also relates to a voltage converter (104) comprising such an electronic unit (1). The invention also relates to an electrical assembly (100) comprising such a voltage converter (104) and to a rotating electric machine (130).