Multiphase Power Converter Module Stacking and Segmentation
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Solution Overview
Problem
Conventional power converter arrangements face challenges in space efficiency, weight reduction, and high maintenance and repair costs due to the spread of damage from one module to others, especially in space-restricting environments like ships, and the need for extensive cleaning and replacement of modules and busbar connections.
Innovation Solution
A multi-phase power converter arrangement with power converter modules arranged in horizontal rows within a cabinet, where each phase forms a module row, and rows of different phases are stacked vertically, using encapsulated modules in polycarbonate or polymethyl methacrylate cells to isolate damage, and employing bipolar transistors or diodes with shared control assemblies for efficient electrical connections and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If converter modules are arranged in a conventional layout, then the converter cabinet requires more space and has greater weight, but the arrangement of modules in horizontal rows stacked vertically enables more modules to be arranged in a smaller cabinet
Solution Approach 1:
The converter modules are arranged in a vertical stacking configuration where module rows are arranged horizontally one behind the other and stacked vertically one above the other. This three-dimensional arrangement optimizes space utilization within the cabinet, allowing more converter modules to be accommodated in a reduced cabinet volume compared to conventional layouts.
2Reliability
If converter modules are not encapsulated, then the structure is simpler, but damage from short circuits spreads to adjacent modules requiring extensive cleaning and replacement
Solution Approach 1:
Each converter module is encapsulated in an individual cell with a cell housing made of polycarbonate or polymethyl methacrylate. This segmentation isolates each module within its own protective enclosure, preventing damage such as short circuits from spreading to adjacent modules. The encapsulation creates independent compartments that contain harmful effects locally, significantly reducing maintenance and repair costs.
3Ease of repair
If busbar connections are not optimized for modular rows, then electrical connection is simpler, but maintenance and repair costs increase due to extensive cleaning and replacement requirements
Solution Approach 1:
The busbar connections are designed to correspond with the modular row structure of the converter modules. Each module row has dedicated busbar connections that facilitate easy electrical interconnection and isolation. This segmented busbar system allows for simplified maintenance and repair operations, where individual modules or rows can be disconnected and replaced without affecting the entire system, reducing both maintenance time and costs.
Data Source
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AI summary
The invention relates to a power converter arrangement (100) with a multiphase power converter (1) comprising several electrically interconnected power converter modules (3, 5) for each power converter phase, and with a power converter cabinet (23) in which the power converter (1) is arranged. Each power converter module (3, 5) has a heat sink (25) and at least one semiconductor device (7, 9) arranged on the heat sink (25). The power converter modules (3, 5) are arranged in the power converter cabinet (23) such that the power converter modules (3, 5) of each power converter phase form a module row (C1, C2, C3) of horizontally arranged power converter modules (3, 5) and the module rows (C1, C2, C3) of the different power converter phases are arranged vertically one above the other.