Power Converter Bus Bar Structure for Perpendicular Capacitor Joining
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Solution Overview
Problem
Existing electric power converters face difficulties in closely aligning and easily joining the terminals of power modules with the capacitor, leading to challenges in efficient power conversion and stability.
Innovation Solution
The design includes a configuration where power modules are stacked along one direction, with the capacitor positioned perpendicular to both the modules and bus bars, allowing terminals to be aligned in a third direction, facilitating close proximity and easy connection using positive and negative bus bars with flanges extending away from the capacitor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the capacitor is arranged adjacent to the power modules in the stacking direction, then the connection between terminals and capacitor is simplified, but the space utilization and heat dissipation are compromised
Solution Approach 1:
The capacitor is arranged in the width direction (Y-direction) perpendicular to the stacking direction (X-direction) of the power modules, rather than adjacent in the stacking direction. This dimensional repositioning allows the terminals to extend in the stacking direction while the capacitor sits beside the modules in the width direction, optimizing both connection paths and spatial distribution for improved heat dissipation and space utilization.
2Ease of operation
If the terminals are extended in the stacking direction, then the connection to the capacitor is facilitated, but the alignment precision and joining difficulty increase
Solution Approach 1:
The terminals are designed with different extension directions for different functions: they extend in the stacking direction (X-direction) to facilitate connection with the capacitor arranged in the width direction, while their leading ends are positioned to align with the bus bar connection points. This localized directional design optimizes both capacitor connection and bus bar alignment without compromising manufacturing precision.
3Ease of manufacture
If the bus bar flanges extend away from the capacitor, then the joining process is simplified, but the device complexity increases
Solution Approach 1:
The bus bar is divided into two functional segments: the main body that connects to the capacitor and the flange portion that extends away from the capacitor to join with the terminals. This segmentation allows the flange to be positioned optimally for joining operations without interfering with the capacitor connection, simplifying the manufacturing process while maintaining reasonable structural complexity.
Data Source
AI summary
An electric power converter includes a plurality of power modules, a capacitor, a positive bus bar, and a negative bus bar. Each of the power modules includes a positive terminal and a negative terminal on a side facing the capacitor. Leading ends of the positive terminal and negative terminal are parallel to the side. The positive bus bar includes a positive/negative base plate joined to a positive/negative electrode of the capacitor and a positive/negative flange bent from the positive/negative base plate. The positive/negative flange is joined to the positive/negative terminals of the power modules. The positive flange and the negative flange extend in directions away from the capacitor.