Modular Converter Segmentation for Repairable Power Electronics
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Solution Overview
Problem
Existing electrical converters for industrial installations require complex adjustments and increased safety risks during component replacement, particularly with power semiconductor switches, due to the need for re-evaluation of safety functions and hardware configurations.
Innovation Solution
A modular converter design with separate housings for the control and power elements, incorporating a safety control circuit that allows independent replacement and standardization of components, reducing the need for complex adjustments and enhancing safety through integrated safety functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the converter uses a integrated design where the control element and power element are combined in a single housing, then the device complexity is reduced, but the ease of repair deteriorates because component replacement requires re-adjustment of safety functions and hardware configurations
Solution Approach 1:
The converter is divided into two separate modular units: a control element housed in a first housing and a power element housed in a second housing. This segmentation allows the power element to be replaced independently without affecting the control element or requiring re-adjustment of safety functions, thereby improving ease of repair while maintaining manageable device complexity through standardized interfaces.
2Reliability
If the converter integrates safety control functions within the control element, then the reliability is improved, but the ease of operation deteriorates during replacement because adjustment of safety functions is required
Solution Approach 1:
The safety control circuit is extracted from the control element and integrated into the power element housing. This extraction allows the safety control circuit to remain permanently associated with the power element, eliminating the need for re-adjustment during replacement operations. The safety functions are thus maintained with high reliability while significantly improving ease of operation during maintenance activities.
3Power
If the converter uses high voltage and high current power semiconductor switches, then the power is improved, but the object-affected harmful factors worsen due to increased electromagnetic interference and stricter insulation requirements
Solution Approach 1:
The second housing containing the power semiconductor switch is provided with localized electromagnetic shielding and enhanced insulation specifically at the high voltage and high current regions. This local quality enhancement contains electromagnetic interference to the power element compartment, preventing it from affecting the control element in the first housing, thereby enabling high power operation while controlling harmful electromagnetic effects.
Data Source
AI summary
A converter has a control element with a motion control function and a power element with a power semiconductor switch. The power element is provided with a safety control circuit that provides for a safety function.