Dual-Inverter Busbar Layout for Balanced High-Power Electric Drives
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric drive systems face issues with uneven current distribution among power modules, leading to reliability and stability problems, and dual-inverter structures fail to output high power and high currents.
Innovation Solution
A modular design for inverter assemblies with alternating-current busbar assemblies and internal connection circuits, allowing for parallel dual-power modules to supply high drive power to both three-phase and six-phase motors, with electromagnetic shielding and symmetrical arrangements to enhance current distribution and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If numerous power modules are connected in parallel to output three-phase alternating-current, then the power level of the electric drive assembly is improved, but uneven current distribution occurs among the power modules, reducing reliability and stability
Solution Approach 1:
The patent divides the power output into two separate three-phase systems (dual three-phase solution), with each power module group independently controlling one set of three-phase outputs. This segmentation prevents current distribution imbalance by avoiding parallel connection of multiple power modules for the same three-phase output, thereby maintaining reliability while achieving high power through the combined capability of multiple independent modules.
Solution Approach 2:
The patent introduces a dual-inverter structure as an intermediary between the power modules and the motor. Each inverter independently processes three-phase currents from its associated power modules, acting as a mediator that balances and distributes current evenly. This intermediary structure eliminates the direct parallel connection problem while still achieving high current output capability.
2Power
If dual three-phase solution is adopted to achieve high power, then the power output is improved, but a brand-new control system and complicated control algorithms are required
Solution Approach 1:
The patent designs the dual-inverter control system to perform multiple functions: it independently controls two separate three-phase motor windings, manages power distribution from multiple power modules, and provides fault tolerance capabilities. By making the control system universal and multi-functional, the patent reduces the need for entirely new control algorithms while achieving high power output through the dual-three-phase configuration.
Solution Approach 2:
The patent merges the control of two three-phase systems into a unified dual-inverter control architecture. Instead of requiring completely separate control systems, the patent combines the control functions to share common processing resources and algorithms, thereby reducing overall control system complexity while maintaining the high power capability of the dual three-phase configuration.
3Reliability
If inverter assemblies are designed with symmetrical arrangements and electromagnetic shielding, then current distribution and cooling efficiency are improved, but the device structure becomes more complex
Solution Approach 1:
The patent employs asymmetrical layout strategies within the symmetrical dual-inverter framework. By strategically positioning electromagnetic shielding elements and cooling channels in asymmetric patterns where needed, the patent optimizes current distribution and thermal management without requiring complete symmetrical duplication of all structural elements, thereby reducing overall structural complexity while maintaining performance.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to the technical field of high-power electric drive system arrangement, and discloses an electric drive system and a vehicle. The electric drive system includes: an inverter assembly, the inverter assembly includes two power modules, and each power module is arranged with three power output ends; the inverter assembly further includes a first alternating-current busbar assembly, the first alternating-current busbar assembly includes three first output terminals, the two power modules are connected in parallel through the first alternating-current busbar assembly, and the three first output terminals are connected with the three power output ends respectively; or the inverter assembly further includes two second alternating-current busbar assemblies, each second alternating-current busbar assembly includes three second alternating-current busbars and three second output terminals, and one power module corresponds to one second alternating-current busbar assembly; a motor assembly, the motor assembly; and a reducer assembly, the reducer assembly includes an adapter seat, the adapter seat is connected with the three first output terminals and the three-phase motor, and the adapter seat is connected with six second output terminals and the six-phase motor.