Current-Shaping Bus Bar Connector for Balanced Switch Currents
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Solution Overview
Problem
Power converters in locomotive and OHV applications face challenges in maintaining electrical and thermal balance among semiconductor power switches, leading to uneven current distribution, resistive and inductive losses, and potential thermal stress-related failures.
Innovation Solution
The design of bus bars with strategically reshaped supply and load terminal connectors, featuring discrete current paths and optimized mutual inductances, ensures balanced electrical and thermal conditions across all terminals, minimizing stray inductance and resistive losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional terminal connectors are used to connect semiconductor power switches, then the device structure is simple, but uneven current distribution and thermal stress occur leading to reliability issues
Solution Approach 1:
The terminal connector is segmented into multiple conductive regions (first conductive region, second conductive region, third conductive region) with distinct functions. Each region handles specific current paths, dividing the current distribution task to achieve uniform current flow and reduce thermal stress concentration, thereby improving reliability without excessive complexity
Solution Approach 2:
Different regions of the terminal connector are designed with different properties: the first conductive region connects to DC link buses, the second region connects to switch terminals, and the third region provides isolation. This local differentiation optimizes current distribution and thermal management in each specific area, enhancing overall reliability
2Loss of energy
If terminal connectors without discrete current paths are used, then the device complexity is low, but resistive and inductive losses increase reducing efficiency
Solution Approach 1:
The terminal connector segments current paths into distinct conductive regions, creating discrete current paths that minimize resistive losses by optimizing conductor geometry and reducing inductive losses through strategic placement of conductive regions, thereby reducing energy losses without excessive complexity
Solution Approach 2:
The terminal connector utilizes three-dimensional spatial arrangement of conductive regions (first, second, and third conductive regions at different positions and orientations) to optimize current paths. This dimensional approach allows simultaneous reduction of both resistive and inductive losses through optimized geometry and positioning
3Productivity
If terminal connectors with optimized current paths are implemented, then switching heat loss and response time improve, but the manufacturing complexity increases
Solution Approach 1:
The terminal connector is segmented into standardized conductive regions that can be manufactured using conventional processes. Each region (first, second, third conductive regions) represents a manufacturable unit with defined geometry and connection points, enabling optimized current paths to be achieved through modular assembly rather than complex monolithic manufacturing
Solution Approach 2:
The terminal connector design provides multi-functionality: it connects DC link buses, connects to switch terminals, provides electrical isolation, and optimizes current paths. This universal design achieves multiple performance improvements (reduced heat loss, improved response time) through a single integrated component that can be manufactured using standard processes
Data Source
AI summary
A bus bar includes a load terminal connector comprising a conductive plate that extends from a first edge to an opposite second edge and extends from a third edge to an opposite fourth edge. The third and fourth edges extend from the first edge to the second edge. The plate includes a window opening located between the first and second edges and between the third and fourth edges. The plate also includes a slot extending into the plate from the first edge to the window opening. The plate includes first and second sets of openings configured to receive connections with first and second power terminals of switch packages. The first set of openings and the second set of openings are located on opposite sides of the slot.