Power Converter AC Busbar Current Sensor Mounting
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Solution Overview
Problem
Existing power converters for AC-DC power conversion lack easy integration of current sensors for measuring alternating currents to AC loads, complicating their fabrication and maintenance.
Innovation Solution
The power converter design includes AC busbars with a current sensor attached to a terminal holder, allowing easy installation and improved fabricability, with the current sensor having through-holes to fit the AC busbars, enhancing space efficiency and ease of replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a current sensor is integrated into the power converter for measuring alternating currents to AC loads, then measurement capability is improved, but device complexity and fabrication difficulty increase
Solution Approach 1:
The power converter is divided into modular components: stacked converter units containing semiconductor modules and refrigerant paths, separate busbar assemblies, and independently attachable current sensors. This segmentation allows each component to be manufactured and tested separately, then assembled together, reducing overall fabrication complexity while maintaining measurement capability.
Solution Approach 2:
The busbar serves as an intermediary element between the semiconductor modules and the current sensor. The current sensor is attached to the busbar rather than directly integrated into the stacked converter unit, providing a convenient intermediate mounting point that simplifies both fabrication and maintenance while enabling accurate current measurement.
2Reliability
If the current sensor is permanently integrated into the power converter structure, then measurement reliability is improved, but ease of repair and replacement deteriorates
Solution Approach 1:
The current sensor is segmented from the main power converter structure and mounted on the removable busbar assembly. This allows the sensor to be easily detached and replaced by simply removing the busbar from the stacked converter unit, maintaining measurement reliability through proper mounting while dramatically improving repair ease.
Solution Approach 2:
The mounting structure allows the busbar with attached current sensor to be dynamically removable and reattachable. The busbar can be easily detached from the stacked converter unit and reattached after sensor replacement, providing the flexibility needed for maintenance while ensuring reliable electrical connections during operation.
3Volume of moving object
If the current sensor is attached to the AC busbars during fabrication, then space efficiency is improved, but fabrication complexity increases
Solution Approach 1:
The current sensor is preliminarily attached to the busbar during busbar fabrication, creating a pre-assembled busbar-sensor subassembly. This preliminary action allows the sensor to be positioned optimally for space efficiency while the modular nature of the subassembly keeps fabrication steps manageable and separable.
Solution Approach 2:
The busbar and current sensor are merged into a single functional assembly that is then integrated with the stacked converter unit. This merging achieves space efficiency by consolidating current-carrying and measurement functions in one compact unit, while the modular assembly process keeps fabrication complexity manageable.
Data Source
AI summary
In a power converter, a plurality of AC busbars are electrically connected to an AC load. An insulating support surrounds at least part of a stacked converter unit of semiconductor modules and refrigerant paths. The set of busbars are fixedly mounted on the insulating support. A terminal holder has a mount surface on which one end of each of the plurality of AC busbars is mounted as a terminal. A current sensor has a through-hole and measures a current flowing through at least part of at least one of the plurality of AC busbars. The current sensor is attached to the terminal holder with the at least part of the at least one of the plurality of AC busbars being fitted in the through-hole of the current sensor.