Power Converter Busbar Routing for Compact Connector Assembly
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Solution Overview
Problem
Conventional power converters face challenges in compactly disposing busbars due to the need for large gaps, which complicates the connecting work and increases the number of components, making it difficult to reduce the appearance size while maintaining workability.
Innovation Solution
The power converter design includes busbars with connecting and coupling parts that bypass the connector's connection area, allowing for reduced gaps between module-side connecting parts and coupling parts, enhancing workability and reducing device size by routing the busbars such that the coupling parts bypass the connector's connection area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the gaps between busbars are narrowed to reduce device size, then the appearance size is reduced, but the connecting work becomes complicated and requires additional components
Solution Approach 1:
The busbars are arranged in the width direction (lateral dimension) rather than only in the depth direction, allowing multiple busbars to be disposed side-by-side with reduced gaps while maintaining accessibility for connection work
Solution Approach 2:
The connector is positioned asymmetrically relative to the busbar arrangement, with connection points disposed at different positions in the width direction, allowing optimized spacing and routing for both compactness and workability
2Ease of operation
If the gaps between busbars are maintained for easy connection work, then workability is secured, but the appearance size cannot be reduced
Solution Approach 1:
By utilizing the width direction for busbar arrangement instead of only the depth direction, the design achieves compact depth dimensions while maintaining adequate spacing in the width direction for connection work accessibility
Solution Approach 2:
The connection points are segmented and disposed at different positions in the width direction, allowing different busbars to be connected at different lateral positions, improving accessibility while reducing overall device dimensions
Data Source
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AI summary
A power converter includes a power module part having n power modules and a connector part having n busbars and a connector. First and second busbars to first and second power modules respectively have first and second connecting parts to the connector, module-side connecting parts to the power modules, and first and second coupling parts coupling the connecting part to the module-side connecting part. The connector has connection points disposed in a plane intersecting a first direction. The connection points for the first and second connecting parts are first and second connection points, respectively, and are offset so that the first connection point is closer to the power module part in a second direction intersecting the first direction. The second coupling part is longer than the first coupling part, and is routed to bypass outside an area where the connection points are disposed, when seen in the first direction.