Electric Power Conversion Device Bus Bar Layout Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multiphase power converters face challenges in minimizing power loss in the power line without increasing the size and weight of the bus bar, which is typically achieved by maximizing the cross-section of the bus bar, leading to increased size and weight.
Innovation Solution
The electric power conversion device is designed with a case that includes a mounting portion and side walls, featuring primary and secondary side connection portions strategically arranged to minimize the length of the negative bus bar, thereby reducing power loss. This is achieved by positioning the reactors and switching units in a manner that shortens the lengths of the positive and negative bus bars, optimizing the layout to reduce power loss without increasing the size or weight of the bus bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the cross section of the bus bar is increased to minimize power loss, then power loss is reduced, but the size and weight of the bus bar are increased
Solution Approach 1:
The patent transitions from a two-dimensional layout to a three-dimensional arrangement by stacking reactors and switching devices in vertical layers within the case. This spatial reorganization shortens the current path length of the bus bar, reducing power loss without requiring increased bus bar cross-section, thereby avoiding increased weight.
Solution Approach 2:
The connection portions are strategically positioned on the case to minimize the length of the negative bus bar before the bus bar is even installed. This preliminary optimization of the layout ensures that the bus bar operates at minimal length, reducing power loss without needing to increase its cross-sectional area.
2Loss of energy
If the cross section of the bus bar is increased to minimize power loss, then power loss is reduced, but the size of the bus bar is increased
Solution Approach 1:
The patent utilizes vertical stacking in the third dimension to reduce the horizontal spread of components. By arranging reactors and switching devices in multiple layers, the current path length is shortened, which reduces power loss without increasing the bus bar's cross-sectional area or overall device footprint.
Solution Approach 2:
The connection portions are pre-positioned on the case to optimize the bus bar routing and minimize its length before installation. This preliminary layout optimization ensures that the bus bar operates at minimal length, reducing power loss without requiring increased size.
3Loss of energy
If the length of the negative bus bar is minimized to reduce power loss, then power loss is reduced, but the layout complexity increases
Solution Approach 1:
The device is segmented into distinct functional modules (reactors, switching devices, connection portions) that are independently positioned and then integrated. This modular segmentation allows each component to be optimized for its specific function while maintaining an overall compact layout, reducing power loss without excessive complexity.
Solution Approach 2:
The case structure serves multiple functions: it houses the components, provides mechanical support, and positions the connection portions to optimize bus bar routing. This multi-functionality reduces the need for additional structural elements, maintaining layout simplicity while achieving short bus bar lengths.
Data Source
AI summary
An electric power conversion device is provided with a case (60) including a mounting portion (61) extending along a plane defined by a first direction and a second direction that are orthogonal to each other, and a side wall (62) provided along a periphery of the mounting portion, a primary side connection portion (23) and a secondary side connection portion (27) provided on the case, a plurality of reactors arranged along the second direction in the case and connected in parallel to one another, and a switching unit including a plurality of switching devices positioned in the case on one side of the reactors in the first direction, arranged along the first direction, and respectively connected to the reactors.