Vehicle Inverter Module Layout for EMI and Cooling Density
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Solution Overview
Problem
Existing control apparatuses for DC/AC inverters in motor vehicles face issues with high interference emissions due to high current switching, leading to increased costs and reduced power density, as well as limited attachment of power modules to coolers.
Innovation Solution
A control apparatus design featuring a combined control and driver board with a flexible interconnect section, where power modules are attached to a cooler with minimal interference input, allowing for increased power density without additional filtering and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If combined control and driver boards (CCDB) are used to reduce production costs, then manufacturing cost is reduced, but high interference emissions are generated due to high current switching
Solution Approach 1:
The interconnect device is divided into a first section for driver activation and a second section for control, connected by a flexible third section. This segmentation allows spatial separation of high-current power signals from sensitive control signals, reducing electromagnetic interference while maintaining the cost benefits of a combined board design.
Solution Approach 2:
The flexible third section acts as an intermediary between the driver section and control section, providing physical and electromagnetic isolation. This intermediate element allows the two functional sections to be connected electrically while minimizing interference coupling, solving the contradiction between integration and interference reduction.
2Object-generated harmful factors
If additional filtering is added to reduce interference emissions, then interference is reduced, but device complexity and production costs increase
Solution Approach 1:
The interference reduction function is extracted from the control circuitry and implemented through the physical layout and flexible connection structure of the interconnect device itself. This eliminates the need for additional filtering components in the control path, maintaining simplicity while reducing interference.
Solution Approach 2:
The flexible third section, which could be seen as a potential source of interference due to its nature, is instead used as the solution by providing inherent electromagnetic isolation. The flexibility allows for optimized routing that minimizes interference coupling, converting a potential problem into a benefit.
3Power
If the number of power modules attached to the cooler is increased to improve power density, then power density is improved, but the attachment capability is limited
Solution Approach 1:
The interconnect device extends in multiple spatial dimensions with the first section, second section, and flexible third section arranged to accommodate multiple power modules on the cooler. This multi-dimensional layout allows increased power module attachment capability without compromising the interference reduction benefits.
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 effectively reduces interference emissions, eliminates the need for additional filtering, and increases the number of power modules that can be cooled, enhancing the power density and reducing production costs of the control apparatus.
Implementation Method 1
a cooler, and an interconnect device... power modules that can be attached to the cooler
Implementation Method 2
cooler therebetween... allowing for increased power density without additional filtering
Data Source
AI summary
A control apparatus for operating an electric drive for a vehicle may include one or more of the following: a plurality of power module, which has one or more power semiconductors; an intermediate circuit capacitor, which is connected in parallel to the power module; a cooler for dissipating heat generated by the power module; an interconnect device for obtaining electrical contact to the power module, where the interconnect device has a first section and a second section at an angle to the first section, and where the first section and the second section are each perpendicular to a main plane of the power module.