Three-Stage DC Power Filter Layout for Low Insertion Loss
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Solution Overview
Problem
Existing filters for direct-current power supplies in high-voltage and high-power density electric drive controllers face issues with stray inductance, high insertion loss, and inflexible volume structures, leading to electromagnetic interference and high maintenance costs, which hinder their widespread application.
Innovation Solution
A filter design comprising a base with integrated power charging, positive, and negative copper bars, along with three stages of filter components, including magnetic rings and capacitors, that are electrically connected to provide power and filtering functions, achieving high resistance to insertion loss and meeting strict filtering requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional filter structures are used in high-voltage and high-power density electric drive controllers, then the filtering function is provided, but stray inductance increases and insertion loss becomes high
Solution Approach 1:
The filter is divided into three stages with filter components distributed at different positions along the copper bars. This segmentation reduces the stray inductance by breaking up the current path into smaller segments with lower individual inductances, while maintaining the filtering function across multiple frequency ranges.
Solution Approach 2:
The patent transitions from a planar layout to a three-dimensional structure by stacking copper bars vertically and distributing filter components across multiple height levels. This spatial arrangement reduces parasitic inductance and allows for optimized current paths, thereby reducing insertion loss while maintaining filtering effectiveness.
2Reliability
If traditional filter designs are used, then filtering is provided, but the volume structure is inflexible and maintenance costs are high
Solution Approach 1:
The filter assembly is segmented into modular units with copper bars and filter components that can be independently assembled and replaced. This modularity provides flexible volume configuration and simplifies maintenance, as individual stages can be serviced without dismantling the entire filter structure.
Solution Approach 2:
The copper bars serve multiple functions: they provide electrical connection, structural support, and mounting surfaces for filter components. This multi-functionality reduces the need for additional structural elements, increasing design flexibility while reducing overall complexity.
3Volume of moving object
If compact filter design is implemented, then volume is reduced, but electromagnetic interference may increase
Solution Approach 1:
By utilizing the third dimension (vertical stacking of copper bars and filter components), the patent achieves compact horizontal footprint while maintaining adequate spacing between components. This vertical arrangement reduces electromagnetic interference through increased separation distance while keeping the overall volume small.
Solution Approach 2:
Filter components are strategically positioned at specific locations along the copper bars where electromagnetic interference is most problematic. The three-stage distribution optimizes the local filtering effect at critical points, effectively suppressing EMI within a compact volume.
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
The design achieves stable and reliable signal transmission with low maintenance costs, high integration, compact layout, and small volume, effectively addressing electromagnetic interference and meeting stringent filtering needs.
Implementation Method 1
at least three stages of filter components, where the at least three stages of filter components are assembled to the base, and are electrically connected to the power charging copper bar, the power positive copper bar, and the power negative copper bar
Implementation Method 2
including magnetic rings and capacitors, that are electrically connected to provide power and filtering functions
Data Source
AI summary
Disclosed in the present application are a filter of a direct-current power source, and an electric drive controller and a vehicle. The filter of a direct-current power source comprises a base, a power source charging copper bar, a power source positive copper bar, a power source negative copper bar and at least three stages of filtering assemblies. The power source charging copper bar, the power source positive copper bar, the power source negative copper bar, and the at least three stages of filtering assemblies are all assembled on the base, and the at least three stages of filtering assemblies are electrically connected to the power source charging copper bar, the power source positive copper bar and the power source negative copper bar, respectively.