Laminated Busbar Diagonal Terminal Layout for Inverter Stray Inductance
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Solution Overview
Problem
Typical connection systems for electrified vehicles introduce stray inductances that affect surge voltages and power device switching losses due to their design, which is not optimal for handling the high current requirements of hybrid-electric and electric vehicles.
Innovation Solution
A laminated busbar assembly with a lower and upper conductive layer, each featuring specific openings and tabs for terminal attachment, and an insulation layer in between, is designed to minimize stray inductance by arranging terminals of the same polarity diagonally opposite to each other, allowing for efficient current distribution and reduced switching losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If typical connection systems are used to connect devices in electrified vehicles, then the system can handle current requirements, but stray inductances are introduced that affect surge voltages and power device switching losses
Solution Approach 1:
The busbar is divided into multiple segments (first busbar, second busbar, third busbar) that are arranged in a specific spatial configuration. Each segment handles specific current paths, and their distributed arrangement reduces the overall loop area, thereby minimizing stray inductance while maintaining current handling capability
Solution Approach 2:
The invention transitions from a conventional planar or linear busbar arrangement to a three-dimensional spatial configuration where busbars are positioned at different heights and angles. The first and second busbars extend in opposite directions from a central point, while the third busbar connects them at an elevated position, creating a compact 3D structure that reduces current loop area and stray inductance
2Ease of manufacture
If conventional busbar designs are used, then assembly is straightforward, but stray inductance affects system performance
Solution Approach 1:
The busbar system is segmented into multiple independent components (first busbar, second busbar, third busbar) that can be manufactured separately and assembled by simply connecting them at designated joints. This segmentation maintains ease of manufacture while the specific spatial arrangement of segments minimizes switching losses by reducing stray inductance
Solution Approach 2:
The busbar configuration uses three-dimensional spatial arrangement with busbars positioned at different levels and angles. The third busbar connects the first and second busbars at an elevated position, creating a compact 3D structure that reduces current loop area and associated energy losses during switching operations
Data Source
AI summary
A power module includes one of more bus capacitors and one or more power switching modules. The bus capacitors and power switching modules have positive and negative terminals. The positive terminals of the bus capacitors are arranged diagonally opposite to the positive terminals of the power switching modules. The negative terminals of the bus capacitors are arranged diagonally opposite to the negative terminals of the power switching modules. A laminated busbar assembly connects a positive conducting layer to the positive terminals and a negative conducting layer to the negative terminals. The laminated busbar assembly includes sets of tabs arranged diagonally opposite one another to match the arrangement of the terminals.