Phase Module Busbar Geometry for Uniform Current Distribution
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Solution Overview
Problem
The current phase modules with semiconductor modules arranged in parallel face issues with uneven current distribution due to differences in inductance along current paths, leading to inefficient performance and utilization of semiconductor modules, especially at high switching frequencies.
Innovation Solution
The arrangement of busbars is optimized by placing the first and second busbars close to each other, with a distance less than half the distance between AC and DC voltage connections, and incorporating webs to connect busbars to voltage connections, ensuring identical inductance paths and reducing inductive coupling, thereby achieving uniform current distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If semiconductor modules are arranged in parallel to increase electrical performance, then the total current capacity is improved, but uneven current distribution occurs due to inductance differences
Solution Approach 1:
The patent combines the first and second busbars into a single integrated component with a specific geometric configuration. The busbar features a first section connected to AC voltage terminals and a second section connected to DC voltage terminals, with the sections arranged to minimize the enclosed area of current paths. This merging eliminates the need for separate busbar components and their associated connection inductances, thereby achieving uniform current distribution across parallel semiconductor modules while maintaining high total current capacity.
2Loss of substance
If busbar cross-section is optimized to reduce material costs, then copper usage is reduced, but inductance increases leading to worsened current distribution
Solution Approach 1:
The patent employs a curved or bent busbar configuration where the first and second sections are arranged in a compact geometry that minimizes the enclosed area. This curved arrangement allows the busbar to achieve low inductance with reduced cross-sectional area, as the inductance is primarily determined by the loop area rather than the conductor cross-section. The optimized shape enables cost-effective copper usage while maintaining uniform current distribution.
3Manufacturing precision
If distance between busbars is reduced to minimize inductance, then inductive voltage influence is reduced, but insulation requirements become more stringent
Solution Approach 1:
The patent introduces an insulating structure as an intermediary element between the first and second sections of the busbar. This insulating structure serves multiple functions: it provides electrical insulation between sections with different potentials, maintains the compact geometric configuration that minimizes inductance, and allows the busbar sections to be positioned close together without compromising insulation. The insulating structure enables the busbar to achieve low inductance while meeting insulation requirements.
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 configuration minimizes inductive voltage influences on module currents, leading to a more even current distribution and improved utilization of semiconductor modules, reducing the need for complex control measures and allowing independent operation of semiconductor modules.
Implementation Method 1
the first busbar being connected to AC voltage terminals of the semiconductor modules, the second busbar being connected to DC voltage terminals of the semiconductor modules
Implementation Method 2
minimizes inductive voltage influences on module currents, leading to a more even current distribution
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a phase module (1) for a power converter (3) comprising a first busbar (11), a second busbar (12) and at least two semiconductor modules (4), wherein the first busbar (11) is connected to AC voltage connections (41) of the semiconductor modules (4), wherein the second busbar (12) is connected to DC voltage connections (42) of the semiconductor modules (4). In order to improve the operating behaviour of a phase module (1) having parallel semiconductor modules (4), according to the invention, at least sections of the first and the second busbars (11, 12) are to be arranged at a distance to one another, the value of which is less than half the value of the distance between the AC voltage connection (41) and the DC voltage connection (42) of one of the semiconductor modules (4), wherein the first and/or the second busbar (11, 12) has at least one separator (15) which is arranged at a right angle on the remaining part of the busbar (11, 12) and connects the busbar (11, 12) to at least one of the DC voltage connections (42) or one of the AC voltage connections (41) of one of the semiconductor modules (4), wherein the separator (15) is arranged along a surface of the one semiconductor module (4). The invention also relates to a power converter (3) comprising at least two phase modules (1) of this type, wherein the AC voltage connections (41) of the phase modules (1) form the phase connections of the power converter (3). The invention further relates to a method for operating a phase module (1) of this type or a power converter (3) of this type, wherein the controlling of the parallel semiconductor modules (4) occurs independently of the module current (i1,i2,i3) through each semiconductor module (4).