Power Conversion Apparatus with Partitioned Metal Cover
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Solution Overview
Problem
Conventional power conversion apparatuses face challenges in reducing size and weight due to installation space restrictions, and maintaining reliability when a primary failure occurs, as additional components are needed to prevent secondary failures, increasing the number of parts and complicating size reduction.
Innovation Solution
A power conversion apparatus with a metal cover that includes protrusions to separate first and second power conversion sections, inhibiting failures from affecting each other, and utilizing a control circuit board and metal cover for efficient cooling and electromagnetic shielding, reducing the number of parts and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional members are disposed to prevent secondary failures from primary failures, then reliability is improved, but the number of parts is increased making it difficult to reduce size
Solution Approach 1:
The power conversion section is segmented into multiple independent modules (first power conversion section and second power conversion section) that are physically separated by a partition wall. This segmentation allows the system to maintain reliability through redundancy while avoiding the need for additional protective members, as each module can fail independently without affecting the other.
2Device complexity
If the number of parts is reduced to reduce size, then device complexity is reduced, but reliability may be compromised when primary failures occur
Solution Approach 1:
Multiple functions are merged into the partition wall structure: it serves as a physical separator between power conversion sections, a mounting surface for semiconductor devices, and an integrated part of the housing. This merging allows the system to achieve redundancy and reliability without increasing the number of separate components, thereby maintaining low device complexity.
3Volume of moving object
If power conversion sections are disposed close together to reduce size, then volume is reduced, but failures in one section may affect other sections
Solution Approach 1:
The partition wall creates distinct spatial segments for each power conversion section, ensuring that failures (such as semiconductor device breakage) are contained within one section and cannot propagate to other sections. This segmentation maintains reliability through failure isolation while allowing the overall apparatus to remain compact.
4Reliability
If redundant power conversion sections are added to prevent secondary failures, then reliability is improved, but weight is increased
Solution Approach 1:
The partition wall is integrated as part of the housing structure rather than being a separate component, and semiconductor devices are mounted directly on it. This merging eliminates the need for additional structural supports and mounting brackets, thereby reducing the overall weight increase that would normally accompany the addition of redundant power conversion sections.
Data Source
AI summary
Disclosed is a power conversion apparatus that improves the reliability of a redundant system therefor. The power conversion apparatus includes a motor having a cylindrical motor case, a multi-phase stator, and a rotor, a power conversion section that switches the supply of electrical power to the motor, a control circuit board that controls the power conversion section, and a cover made of metal on which the power conversion section and the control circuit board are mounted. The power conversion section includes a first power conversion section and a second power conversion section. The cover includes a protrusion that protrudes toward the motor from a surface substantially parallel to the radial direction of the motor. The protrusion is formed in such a manner as to separate the first and second power conversion sections from each other.