Layered Busbar Connector for Voltage Fluctuation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing converter systems experience fluctuations in intermediate circuit voltage due to limitations in current carrying capacity of flexible cables and inadequate insulation, leading to safety risks and inefficiencies.
Innovation Solution
A connector adapter with a stack of busbars surrounded by an electrically insulating sheath, featuring insulating layers and tab-like sections for parallel busbars at the same potential, reduces electrical conduction resistance and inductance, while providing safe insulation and increased capacitance without additional capacitors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flexible cables are used to connect intermediate circuits, then the system is simple to implement, but the current carrying capacity is limited and voltage fluctuations occur
Solution Approach 1:
The connector divides the current path into multiple parallel busbars instead of using a single flexible cable. Each busbar carries a portion of the total current, thereby increasing the overall current carrying capacity while maintaining a simple connection structure through modular parallel arrangement.
Solution Approach 2:
The invention transitions from one-dimensional flexible cable connections to a multi-dimensional busbar stack structure. The busbars are arranged in parallel layers with insulating material between them, creating a three-dimensional current distribution that significantly increases current capacity without proportionally increasing connection complexity.
2Reliability
If busbars are placed close together to reduce inductance, then path inductance decreases, but electrical insulation and safety are compromised
Solution Approach 1:
The connector uses a composite structure combining conductive busbars with insulating material layers. The insulating material is positioned between adjacent busbars, allowing them to be placed close together for low inductance while the insulating layers prevent electrical breakdown and maintain safety.
Solution Approach 2:
The insulating material acts as an intermediary substance between the busbars carrying different potentials. This intermediary layer enables the busbars to be in close proximity for low inductance while preventing direct electrical contact, thus resolving the conflict between inductance reduction and insulation requirements.
3Reliability
If additional capacitors are added to increase intermediate circuit capacitance, then voltage fluctuations are reduced, but device complexity and cost increase
Solution Approach 1:
The busbar stack structure serves multiple functions simultaneously: it provides current conduction paths, increases intermediate circuit capacitance through its physical structure, reduces inductance through parallel arrangement, and provides mechanical support. This multi-functionality eliminates the need for separate capacitor components.
Solution Approach 2:
The invention merges the functions of current conduction and capacitance provision into a single integrated busbar stack structure. The busbars and insulating material together form both the current path and the capacitive elements, combining what would traditionally require separate components.
4Loss of energy
If busbar cross-section is enlarged to reduce ohmic resistance, then resistance and losses decrease, but the connector size and complexity increase
Solution Approach 1:
Instead of using a single large cross-section busbar, the invention segments the current path into multiple smaller busbars arranged in parallel. Each busbar has a manageable cross-section, but collectively they provide the equivalent or greater current carrying capacity with reduced overall resistance.
Solution Approach 2:
The solution transitions from increasing cross-sectional area in two dimensions to utilizing three-dimensional parallel arrangement. Multiple busbars are stacked with insulating material between them, effectively increasing the current carrying capacity through the third dimension (vertical stacking) rather than enlarging individual cross-sections.
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 effectively reduces intermediate circuit voltage fluctuations, enhances safety by minimizing contact risks, and shifts resonant frequencies to higher ranges, achieving lower ohmic resistance and reduced losses through improved heat dissipation and insulation.
Implementation Method 1
the stack having insulating layers arranged between the busbars
Implementation Method 2
the layered structure enables the lowest possible electrical conduction resistance
Implementation Method 3
enlarging the conductor rail, acting like a heat sink, so that the ohmic resistance and the losses associated therewith can be reduced
Implementation Method 4
The layered structure reduces the inductance of the adapter by means of the busbars, which are widened like plates, and thus shifts the resonant frequencies
Implementation Method 5
the insulating means surrounding the housing forms at least one shrink tube... after insertion the shrink tubing can be heated so that it contracts around the conductor rail arrangement
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An adaptor for electrically connecting in particular intermediate circuits, and converter arrangement having an adaptor, wherein the adaptor has a layered structure, wherein an insulating medium, in particular an insulating film, is arranged between busbars, in particular of different potential, wherein the adaptor is surrounded by at least one insulating medium so as to form a housing.