Inverter Power Assembly Layout With Integrated Cooling Frame
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Solution Overview
Problem
Existing inverter power assemblies have an unreasonable arrangement of power modules and capacitors, leading to complex structures, bulky volumes, and limitations on capacitor size due to excessive connecting components.
Innovation Solution
The inverter power assembly features a mounting frame with branch-arms and cooling chambers, allowing for a simple and compact structure with efficient capacitor connection and cooling, utilizing partition plates and medium ports for serial cooling chamber connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power module and capacitor are arranged with more connecting components, then the electrical connection is achieved, but the structure becomes complex and the volume increases
Solution Approach 1:
The mounting frame integrates multiple functions: it provides mechanical support for both the power module and capacitor, establishes electrical connections through integrated conductive paths, and enables cooling through built-in cooling chambers. This merging of support, connection, and cooling functions into a single structure eliminates the need for separate connecting components, thereby reducing structural complexity while maintaining reliable electrical connections.
Solution Approach 2:
The mounting frame serves multiple purposes simultaneously: it acts as a mechanical mounting structure, an electrical connection medium through its conductive features, and a cooling system through integrated cooling chambers. This multi-functionality reduces the overall number of components needed in the inverter power assembly, simplifying the structure while achieving all necessary functions.
2Reliability
If the power module and capacitor are arranged with more connecting components, then the electrical connection is achieved, but the volume of the inverter power assembly increases
Solution Approach 1:
The mounting frame combines mechanical support and electrical connection functions into a single integrated structure, eliminating the need for separate mounting brackets and connection terminals. This integration reduces the overall volume required for these components while maintaining reliable electrical connections between the power module and capacitor.
Solution Approach 2:
The capacitor is positioned within the spatial envelope defined by the mounting frame and power module arrangement, utilizing the three-dimensional space efficiently. The cooling chambers are nested within the mounting frame structure itself, allowing the cooling function to be incorporated without adding external volume. This nested arrangement optimizes space utilization and reduces overall assembly volume.
3Quantity of substance
If the capacitor size is increased for larger specifications, then the energy storage capacity is improved, but the arrangement becomes unreasonable and the volume increases
Solution Approach 1:
The mounting frame and component arrangement utilize three-dimensional spatial optimization, allowing the capacitor to be positioned in available vertical and lateral spaces rather than only horizontal plane. This dimensional approach enables larger capacitor installations without proportionally increasing the overall assembly footprint, as the frame structure efficiently packs components in multiple dimensions.
4Temperature
If the cooling structure is mounted on the mounting frame together with the power module, then the cooling function is achieved, but the volume of the inverter power assembly increases
Solution Approach 1:
The cooling chambers are integrated directly into the mounting frame structure, merging the cooling system with the mechanical support structure. This integration eliminates the need for separate cooling housings or external cooling assemblies, thereby achieving effective cooling of the power module while minimizing the increase in overall assembly volume.
Solution Approach 2:
The mounting frame serves dual purposes: it provides mechanical support for the power module and simultaneously houses the cooling chambers for thermal management. This multi-functionality allows the cooling system to be incorporated without requiring additional dedicated space, as the frame structure itself is utilized for both support and cooling functions.
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
This design results in a more compact and efficiently cooled inverter power assembly with improved capacitor integration and reduced bulk, enabling better thermal management and component compatibility.
Implementation Method 1
The mounting branch-arm and the mounting underframe are provided therein with cooling chambers in communication with each other
Implementation Method 2
a partition plate is arranged in the branch-arm cooling chamber, the partition plate divides the branch-arm cooling chamber into a branch-arm inlet chamber and a branch-arm outlet chamber
Data Source
AI summary
An inverter power assembly includes: a mounting frame; a power module mounted on the mounting frame; and a capacitor electrically connected to the power module. The inverter power assembly has the power module mounted on the mounting frame and the capacitor electrically connected to the power module, which leads to a simple and compact structure and a reasonable arrangement for the entire inverter power assembly.