Multi-phase Converter Housing with Integrated Current Sensor Rings
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Solution Overview
Problem
The existing multi-phase three-phase converters face challenges in efficient and simple assembly, particularly with the installation of current sensors, which requires significant effort and storage of individual components during final assembly.
Innovation Solution
The converter features a housing section made of insulating injection-molded material that encapsulates power current connections, with current sensor rings integrated into the injection molding material, allowing for pre-assembly and reduced component handling, and a control circuit board can be easily inserted with sensor elements positioned for magnetic flux detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If busbars and current sensors are installed as individual components during final assembly, then the converter can be assembled with separate components, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the housing section, power current connections, and current sensors into a single integrated assembly. The housing section is designed as one piece that incorporates both the power current connection passages and the current sensor cores, eliminating the need to assemble these components separately and significantly simplifying the manufacturing process.
Solution Approach 2:
The current sensor cores are pre-installed into the housing section during its manufacturing process, before the final converter assembly. This preliminary action ensures that the sensor elements are already in position and properly integrated, eliminating the need for separate installation steps during final assembly.
2Productivity
If multiple individual components are stored and handled during assembly, then component flexibility is maintained, but storage space and handling effort increase
Solution Approach 1:
The patent merges multiple individual components (housing, power current connections, current sensor cores) into a single integrated housing section. This reduces the quantity of separate components that need to be stored and handled, thereby improving productivity by eliminating multiple storage locations and handling steps.
3Reliability
If sensor elements are soldered or glued on additional control circuit boards, then electrical connections are established, but assembly complexity and time increase
Solution Approach 1:
The sensor elements are pre-installed into the current sensor cores during the housing section manufacturing process, before the final converter assembly. This preliminary action eliminates the need for time-consuming soldering or gluing operations during final assembly, significantly reducing assembly time while maintaining reliable electrical connections.
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 approach simplifies assembly, reduces costs and time, enhances sealing, and allows for better space utilization, enabling efficient and straightforward integration of current sensors within the converter housing.
Implementation Method 1
Current sensor cores are known which, as a soft magnetic material, for example laminated cores, enclose the current conductor and have a gap. A magnetic sensor, in particular a Hall sensor, is then arranged in this gap, via which the flowing currents can be detected indirectly via the magnetic fields that are formed.
Implementation Method 2
A magnetic sensor, in particular a Hall sensor, is then arranged in this gap, via which the flowing currents can be detected indirectly via the magnetic fields that are formed.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
In a converter, in particular a multi-phase three-phase converter, with a DC link, power outputs and at least one power semiconductor, wherein power current connections (5) of the DC link and the power outputs are led out of a housing section (1) of the converter, the housing section (1) consists of insulating injection molded material and the power current connections (5) are overmolded by the injection molded material in the feedthrough and are firmly connected to it, wherein a current sensor ring (9) is arranged at least partially in the injection molded material surrounding at least one of the power current connections (5).