Configurable Converter PCB Layout for Modular Control Interfaces
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Solution Overview
Problem
The wide variety of converter units due to specific design requirements leads to increased development, servicing, and production costs, as well as logistical challenges, as each unit requires customized components and documentation, resulting in inefficiencies and high storage costs.
Innovation Solution
A converter unit design where a single main printed circuit board can be used for different functionalities by adapting the functional module to use only the necessary control signals, allowing for identical boards to be used across various configurations, reducing the need for multiple designs and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If converter units are tailored specifically to each implementation with customized functional modules, then the functionality and performance requirements are met, but the variety of types increases leading to higher development, production, and servicing costs
Solution Approach 1:
The patent implements a universal main printed circuit board design that can be used across multiple converter unit types. The board includes standardized control connections and conductor paths that can accommodate different functional modules (rectifier units, inverter units, EMI filters) through mechanical connection at control connection regions. This allows a single board design to serve multiple functions and configurations, reducing the overall variety of converter unit types while maintaining the ability to meet specific functionality requirements through module selection and configuration.
2Reliability
If different embodiments are created for various functional units to meet specific voltage and current requirements, then the performance requirements are satisfied, but development effort and documentation updates increase significantly
Solution Approach 1:
The patent segments the converter unit into a standardized main printed circuit board and interchangeable functional modules. The board is divided into distinct regions including control connection regions where functional modules mechanically connect. This segmentation allows the control board to remain standardized while functional modules can be customized for specific voltage and current requirements. When performance requirements change, only the functional module needs to be updated rather than the entire converter unit design, significantly reducing development effort and documentation updates.
3Ease of manufacture
If a standardized main printed circuit board is used across different converter unit configurations, then production costs and logistics are reduced, but the board must be overdimensioned to accommodate all possible control signal connections
Solution Approach 1:
The patent implements a dynamic configuration approach where the standardized main printed circuit board includes all possible control signal conductor paths and connections, but individual converter unit configurations selectively activate only the needed connections. Functional modules mechanically connect at control connection regions and utilize only the conductor paths required for their specific function. Unused conductor paths remain inactive but are available for other configurations. This dynamic usage of the standardized board allows production efficiency and logistics benefits while managing design complexity through selective activation rather than requiring multiple specialized board designs.
Data Source
AI summary
A converter unit has a main printed circuit board (MPCB) on which at least one functional module is arranged. By the functional module, at least one AC voltage supplied to the functional module via first power connections of the functional module can be converted into at least two DC voltage potentials output via second power connections. The MPCB has conductor paths via which control signals can be supplied to control connections, and the MPCB has conductor paths which extend from a control unit to first and second control connections of the MPCB and via which the first and second control signals can be supplied to the first and second control connections. The functional module is at least mechanically connected to the MPCB at least in the region of the first and second control connections such that the functional module does not use the first and/or the second control signals.