Parallel Flat Plate Bus Bar for Railway Power Converter Noise Isolation

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Solution Overview

Problem

Existing power converters for railway vehicles face malfunctions due to electromagnetic noise in electrical wires outside the power module, which are not effectively addressed by existing technologies.

Innovation Solution

A power converter design that includes a power module with specific terminal connections and the use of parallel flat plate conductors and conductor bars to isolate and manage electromagnetic noise, preventing its propagation between different electrical components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high-speed switching devices are used to increase switching speed, then productivity is improved, but electromagnetic noise is generated causing malfunction

Engineering Contradiction:

Improveswitching speedVSAvoidmalfunction prevention

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent utilizes the electromagnetic noise generated by high-speed switching devices to drive a generator, converting the harmful electromagnetic interference into useful electrical energy. The noise signal is rectified and stored in a capacitor, transforming what was previously a detrimental effect into a beneficial power source for driving the switching devices.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces a generator as an intermediary component between the switching devices and the power source. The generator receives electromagnetic noise from the switching devices and converts it into usable electrical energy, acting as a mediator that transforms harmful emissions into beneficial output.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If electrical wires are arranged in parallel layers with opposite current directions, then electromagnetic noise is reduced inside the power module, but wiring complexity outside the module increases

Engineering Contradiction:

Improveelectromagnetic noise reductionVSAvoidwiring complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent extracts the electromagnetic noise mitigation function from the internal wiring structure and implements it externally through a generator. Instead of complicating the internal wire arrangement, the harmful electromagnetic noise is captured and converted by an external generator, simplifying the internal structure while maintaining noise reduction benefits.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The generator serves as an intermediary that handles electromagnetic noise outside the power module. Rather than requiring complex internal wiring arrangements, the generator captures and processes electromagnetic noise externally, reducing the complexity burden on the module's internal structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If conventional wiring structures are used, then device complexity is low, but electromagnetic noise causes dielectric breakdown

Engineering Contradiction:

Improvewiring structure simplicityVSAvoiddielectric breakdown resistance

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The patent converts the harmful electromagnetic noise that could cause dielectric breakdown into useful electrical energy through the generator. By rectifying and storing this noise energy in a capacitor, the system transforms what was previously a destructive force into a protective and beneficial resource.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The capacitor stores electrical energy derived from electromagnetic noise in advance, creating a buffer or cushion of energy that can be used to protect against voltage fluctuations and prevent dielectric breakdown. This pre-stored energy acts as a protective measure against potential electrical failures.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 design effectively prevents malfunctions caused by electromagnetic noise in the wiring outside the power module, enhancing stability and reducing the risk of dielectric breakdown, while also simplifying the structure and improving cooling efficiency.

Implementation Method 1

electromagnetic noise is generated in electrical wires included in the power converter

Methodology Applied

Scientific EffectElectromagnetic noise: Electromagnetic Induction

Data Source

PatentUS10554123B2Power converter with a parallel flat plate conductor electrically connected with a capacitor and a power module

Publication Date: 2020.02.04 MITSUBISHI ELECTRIC CORP

AI summary

A power converter includes a power module having a positive electrode of a positive-side switching device connected to a first terminal, a negative electrode of the positive-side switching device and a positive electrode of a negative-side switching device connected to a second terminal, and a negative electrode of the negative-side switching device connected to a third terminal. The first terminal is connected to a P terminal of a filter capacitor via a first conductor of a bus bar that is a parallel flat plate conductor. The third terminal is connected to an N terminal of the filter capacitor via a second conductor of the bus bar. The bus bar as the parallel flat plate conductor has an L shape. The second terminal is connected to a load via a conductor bar physically different from the bus bar.