Modular Current Converter Assembly for Scalable Power Capacity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current converters, such as inverters and DC/DC converters, face challenges in optimizing functionality and cost, particularly in electric drive devices of motor vehicles.
Innovation Solution
A scalable current converter design comprising functional base modules with sub-half-bridges and semiconductor switches, enclosed in a mechanical unit, allowing for modular construction and flexible scaling of power/current carrying capacity, with individual control and monitoring of semiconductor switches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional current converter design is used, then the device can perform basic current conversion functions, but the device complexity and manufacturing cost increase when scalability and flexibility are required
Solution Approach 1:
The current converter is divided into multiple identical functional base modules, each containing a sub-half-bridge with semiconductor switches. These modular units can be independently manufactured and then assembled in different quantities to achieve the desired power rating and configuration, enabling scalable design without proportionally increasing overall system complexity
Solution Approach 2:
The functional base modules are designed as universal building blocks that can be used in various configurations (e.g., different numbers of modules per bridge, different bridge topologies) to create current converters with different power ratings and performance characteristics, allowing a single module design to serve multiple application requirements
2Power
If more semiconductor switches are integrated to increase power capacity, then the power carrying capacity increases, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
Instead of manufacturing large power modules with many switches in a single complex process, the design segments the system into multiple identical functional base modules, each with a manageable number of semiconductor switches. This allows standardization of manufacturing processes for each module, reducing per-unit costs while enabling power scaling through simple replication
Solution Approach 2:
The power carrying capacity is adjusted by changing the number of functional base modules rather than redesigning the entire power module. This parameter-based scaling approach allows cost-effective customization for different power requirements using the same base module design, avoiding the need for expensive custom manufacturing for each power level
3Reliability
If functional base modules are electrically insulated from each other, then the reliability and safety improve, but the manufacturing and assembly process becomes more complex
Solution Approach 1:
Multiple functional base modules are mechanically assembled within a single housing that provides common electrical insulation for all modules. This merging approach consolidates the insulation function at the housing level rather than requiring individual insulation measures for each module, reducing assembly complexity while maintaining the reliability benefits of electrical insulation between modules
Data Source
AI summary
The invention relates to a current converter (IV), having:a plurality of functional base modules (FB), which each form a sub-half-bridge with a positive-voltage-side semiconductor switch (T1) and a negative-voltage-side semiconductor switch (T2) and which each have a plurality of external current terminals (H+, H−, P);a number of power base modules (LB2, LB3), which each have a plurality of the functional base modules (FB) and an enclosure unit (MM), wherein the enclosure unit (MM) of the respective power base modules (LB2, LB3) mechanically connects together the respective corresponding functional base modules (FB) and encloses them apart from their respective current terminals (H+, H−, P), wherein the functional base modules (FB) of the respective power base modules (LB2, LB3) are electrically insulated from one another within the respective corresponding enclosure unit (MM);a current converter power module (LM), which has the power base modules (LB2, LB3) and a plurality of current connections (GV, PV), wherein the current connections (GV, PV) electrically connect together the respective corresponding current terminals (H+, H−, P) of the respective functional base modules (FB) of the respective power base modules (LB2, LB3).The invention also relates to an electric drive device having a said current converter, and to a method for manufacturing a current converter.