Power Converter Busbar Layout for Compact Connector Assembly
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Solution Overview
Problem
Conventional power converters face challenges in reducing appearance size while maintaining workability due to the complex connection of multiple busbars, which often require large gaps and increased components, complicating assembly and increasing device size.
Innovation Solution
A power converter design with busbars routed to bypass the connection area, using offset connection points and longer coupling parts to facilitate easier assembly, while integrating the busbars with insulating material for handling as a single component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the gaps between busbars are narrowed to reduce appearance size, then the device size is reduced, but the connecting work becomes complicated and the number of components increases
Solution Approach 1:
The busbars are arranged in the depth direction of the case rather than the width direction, utilizing the third dimension (depth) to accommodate multiple busbars. This allows the busbars to be positioned at different depths while maintaining adequate spacing for connection work, thereby reducing the width (appearance size) without compromising connectability.
Solution Approach 2:
The busbars are positioned asymmetrically in the depth direction with different offsets from the side wall, rather than symmetrically in the width direction. This asymmetric arrangement in depth allows for compact width while providing sufficient access space for connection operations.
2Volume of moving object
If the gaps between busbars are narrowed while adopting conventional routing, then the device size is reduced, but the connecting work becomes more difficult requiring division of busbars into elements
Solution Approach 1:
The busbars extend in the depth direction of the case, utilizing the depth dimension for routing rather than the width dimension. This allows the busbars to be connected to the connector without requiring division into multiple elements, as the depth direction provides sufficient space for connection operations while reducing the overall width of the device.
3Volume of moving object
If the appearance size is reduced, then the occupancy space is narrowed, but the gaps between busbars must be maintained for connecting work
Solution Approach 1:
The necessary gap area for connecting work is relocated from the width direction to the depth direction. By positioning busbars at different depths and allowing them to extend in the depth direction, the patent maintains adequate connection space without increasing the width, thereby reducing the overall occupancy space while preserving manufacturing ease.
Data Source
AI summary
A power converter includes a power module part having n power modules and a connector part having n busbars and a connector. First and second busbars to first and second power modules respectively have first and second connecting parts to the connector, module-side connecting parts to the power modules, and first and second coupling parts coupling the connecting part to the module-side connecting part. The connector has connection points disposed in a plane intersecting a first direction. The connection points for the first and second connecting parts are first and second connection points, respectively, and are offset so that the first connection point is closer to the power module part in a second direction intersecting the first direction. The second coupling part is longer than the first coupling part, and is routed to bypass outside an area where the connection points are disposed, when seen in the first direction.