Configurable Power Converter Housing Casting Design
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Solution Overview
Problem
The high cost and time-consuming process of designing and tooling power converters for various applications in electric drivetrains, as each configuration requires unique housing designs and tooling, leading to significant engineering expenses and inefficiencies in production.
Innovation Solution
A flexible casting design for power converter housings that allows for adaptable mounting of components such as heat sinks, DC connection boxes, and accessory connectors on either side, enabling the same housing to accommodate different configurations with minimal component changes, including symmetric features for coolant and power module mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a new power converter design is created for each application, then the power converter can meet specific application requirements, but the design cost and tooling cost increase significantly
Solution Approach 1:
The housing casting is designed with symmetric features and interchangeable components that allow a single housing design to accommodate multiple power converter configurations. The casting includes symmetric mounting holes, connection locations, and heat sink orientations that can be adapted to different applications without requiring new tooling, thereby achieving multi-functionality while reducing manufacturing costs.
2Ease of manufacture
If a single housing design is used for different power converter designs, then tooling costs are reduced, but the ability to meet specific application requirements is limited
Solution Approach 1:
The power converter system is segmented into modular components including the housing casting, heat sink, connection boxes, and mounting brackets. These segmented components can be independently configured and assembled in different arrangements within the same housing, allowing adaptation to various applications while using a single standardized housing design and tooling.
Solution Approach 2:
The housing casting incorporates asymmetric mounting features and connection locations that can be selectively activated or deactivated depending on the application. By including optional asymmetric elements within a symmetric overall design, the housing can accommodate both symmetric and asymmetric power converter configurations without requiring different tooling.
3Ease of operation
If different connection locations are provided for different machine locations, then the power converter can be installed flexibly, but multiple housing designs are required
Solution Approach 1:
The housing casting includes universal mounting features and connection locations that can serve multiple installation configurations. Symmetric mounting holes and connection points are provided that allow the same housing to be installed in different orientations and locations, eliminating the need for multiple specialized housing designs while maintaining installation flexibility.
Data Source
AI summary
A casting for a housing for a flexible, configurable power converter is disclosed. The housing includes a power compartment that is configured to accept a heat sink in either of two orientations. The configurable nature of the power converter allows the same power convertible package to be used in a number of applications without having to incur the cost of developing a new power converter package.