Integrated EMC Filter Busbar for Compact Power Electronics
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Solution Overview
Problem
Existing EMC filter devices for power electronics in electric machines are not compact enough and require too many interfaces/contacts, making them difficult to integrate into limited installation spaces and increasing assembly effort.
Innovation Solution
A compact EMC filter device with a laminated busbar conductor structure, featuring multiple conducting layers insulated by an insulating film, integrated inductors, and additional electronic components such as capacitors, current sensors, and discharge resistors, which are materially bonded to the conductor structure for reduced complexity and installation space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional EMC filter devices are used, then electromagnetic compatibility is ensured, but the device occupies too much installation space and requires too many interfaces/contacts
Solution Approach 1:
The patent combines multiple separate components (EMC filter, current sensor, discharge resistor, capacitors) into a single integrated module with a common housing and shared conductor structure. This merging reduces the overall installation space required while maintaining all necessary functions including electromagnetic compatibility filtering.
Solution Approach 2:
The conductor structure serves multiple functions simultaneously: it acts as the EMC filter inductor support, provides current conduction paths, serves as the mounting base for capacitors and other components, and enables current sensing through integrated sensors. This multi-functionality reduces the number of separate components and interfaces needed.
2Object-affected harmful factors
If traditional EMC filter devices are used, then electromagnetic compatibility is ensured, but the number of interfaces/contacts increases assembly effort
Solution Approach 1:
By integrating multiple components into a single module with a common housing and shared conductor structure, the number of separate connections and interfaces required during assembly is significantly reduced. The module is installed as one unit rather than multiple separate components.
Solution Approach 2:
The conductor structure is pre-assembled with all electronic components (capacitors, current sensors, discharge resistors) and the EMC filter inductor before final installation. This preliminary assembly of sub-components into an integrated module simplifies the final installation process and reduces assembly effort.
3Adaptability or versatility
If components are separately mounted, then functionality is achieved, but the structure becomes less compact and more complex
Solution Approach 1:
The patent integrates the EMC filter inductor, capacitors, current sensors, and discharge resistors into a single structural unit with a common housing and shared conductor structure. This merging maintains all necessary functionalities while reducing structural complexity compared to separate mounting of each component.
Solution Approach 2:
The conductor structure is designed as a multi-layer laminated busbar structure with conducting layers arranged in specific patterns to provide both electrical conduction and magnetic filtering functions. This three-dimensional arrangement of conducting layers enables compact integration of multiple functions within a limited space.
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 solution allows for easier integration into existing spaces, reduces assembly effort, and enhances electromagnetic compatibility while maintaining a compact design, saving installation space and simplifying the power electronics module.
Implementation Method 1
The conducting layers are electrically insulated from one another
Implementation Method 2
at least one inductor interacting with the conductor structure
Data Source
AI summary
An EMC filter device for power electronics of an electric machine includes an electrical conductor structure having at least two separate conducting layers that are insulated from one another; an inductor that cooperates with the electrical conductor structure; and a plurality of additional electronic components fastened to the electrical conductor structure.