Power Converter Busbar Layout for Faster Module-Capacitor Assembly
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Solution Overview
Problem
Conventional power converter assembly processes require separate steps for connecting power modules to busbars and smoothing capacitors to busbars, making it difficult to reduce assembly man-hours.
Innovation Solution
A power converter design that integrates a housing with capacitors, power conversion modules, and busbars, where the busbars are fixed to both the modules and the housing, allowing for simultaneous assembly and reducing the need for separate connection steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate steps are used for connecting power modules to busbars and smoothing capacitors to busbars, then connection reliability is improved, but assembly time increases
Solution Approach 1:
The patent combines the power module connection and smoothing capacitor connection into a single integrated assembly step. The busbar is designed with both power module connection portions and smoothing capacitor connection portions, allowing both connections to be established simultaneously in one assembly operation rather than separately, thus reducing assembly time while maintaining connection reliability through the integrated design
2Loss of time
If integrated assembly is used for power modules and smoothing capacitors, then assembly time is reduced, but assembly complexity increases
Solution Approach 1:
The busbar is segmented into distinct functional portions: power module connection portions with connection holes for power module attachment, and smoothing capacitor connection portions with connection terminals for capacitor attachment. This segmentation allows the integrated busbar to handle multiple connections simultaneously while maintaining clear functional separation, reducing assembly complexity despite the integrated approach
Data Source
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AI summary
A power converter that can reduce assembly man-hours is provided. The power converter includes a housing (50) that accommodates a capacitor, a first power conversion module (10) including a first positive electrode and a first negative electrode, the first power conversion module (10) being positioned on the second external surface of the housing (50), a second power conversion module (20) including a second positive electrode and a second negative electrode, the second power conversion module (20) being positioned on the third external surface of the housing (50), a first positive electrode busbar that connects a first electrode of the capacitor to the first positive electrode, a first negative electrode busbar that connects a second electrode of the capacitor to the second negative electrode, a second positive electrode busbar (80) that is fixed to the first positive electrode together with the first positive electrode busbar and that is fixed to the second positive electrode, and a second negative electrode busbar (90) that is fixed to the first negative electrode and that is fixed to the second negative electrode together with the first negative electrode busbar.