Modular Voltage Converter Busbar Layout for EMC Adaptation
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Solution Overview
Problem
The existing voltage converters require frequent redesign of main positive and negative bus bars to adapt to different environments and electromagnetic compatibility requirements, leading to significant costs for research, development, and manufacturing tool configuration.
Innovation Solution
A voltage converter design that separates the main module from a terminal module, where only the terminal module needs to be redesigned for each new environment, incorporating auxiliary bus bars and optional capacitors and magnetic components to achieve desired electromagnetic compatibility without altering the main module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the main positive and negative bus bars are redesigned for each new environment, then the voltage converter adapts to different electromagnetic compatibility requirements, but the research and development costs and manufacturing tool configuration costs increase significantly
Solution Approach 1:
The voltage converter is divided into two independent modules: a main module containing the core power conversion circuitry and a terminal module containing the positive and negative terminals. This segmentation allows the terminal module to be redesigned for different environments without affecting the main module, thereby reducing R&D and manufacturing tool configuration costs while maintaining adaptability to different electromagnetic compatibility requirements.
2Reliability
If the main module is redesigned for each environment, then electromagnetic compatibility requirements are met, but the device complexity and development time increase
Solution Approach 1:
By separating the voltage converter into a main module and a terminal module, the design complexity is reduced. The main module with fixed architecture ensures consistent electromagnetic compatibility performance, while only the terminal module needs to be adapted for different environments, thereby meeting electromagnetic compatibility requirements without increasing overall device complexity.
3Adaptability or versatility
If the main bus bars are redesigned frequently, then different terminal configurations are achieved, but the manufacturing tool configuration costs increase
Solution Approach 1:
The terminal module is designed as an independent, replaceable unit containing the positive and negative terminals. This allows different terminal configurations to be achieved by simply changing the terminal module rather than redesigning the entire main module, thereby providing terminal configuration flexibility while reducing manufacturing tool configuration costs.
Solution Approach 2:
The main module is designed with a universal interface that can accommodate different terminal module configurations. This universality allows the same main module to work with various terminal modules designed for different environments, achieving terminal configuration flexibility without increasing manufacturing tool configuration costs.
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 approach reduces manufacturing costs by allowing the terminal module to be adapted for various environments while maintaining minimum electromagnetic compatibility, allowing for different electromagnetic compatibility classes without changing the main module's architecture.
Implementation Method 1
a first capacitor connected between the main positive bus bar and electrical ground, a second capacitor connected between the main negative bus bar and electrical ground
Implementation Method 2
the terminal block module further includes a magnetic core surrounding the auxiliary positive bus bar and the auxiliary positive bus bar
Data Source
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AI summary
The invention relates to a voltage converter (104) which comprises a main module (202) comprising a main positive busbar (206), a main negative busbar (208), at least one phase busbar (122) intended for being connected to a respective phase of an electrical machine (130), for each phase busbar (122), a top side switch (112) connected between the main positive busbar (206) and the phase busbar (122) and a bottom side switch (114) connected between the phase busbar (122) and the main negative busbar (208), an electrical ground, a first capacitor connected between the main positive busbar (206) and the electrical ground and a second capacitor connected between the main negative busbar (208) and the electrical ground, as well as a terminal block module (204) comprising an auxiliary positive busbar (210) having a positive terminal (212), the auxiliary positive busbar (210) being secured to the main positive busbar (206) and an auxiliary negative busbar (214) having a negative terminal (216), the auxiliary negative busbar (214) being secured to the main negative busbar (208).