Power Converter Assembly with Normal Terminals
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Solution Overview
Problem
Conventional power converters require multiple assembly steps to connect semiconductor modules and capacitors to a control circuit board, increasing complexity and production time.
Innovation Solution
A power converter design where voltage measuring terminals and control terminals extend normally to the control circuit board, allowing simultaneous connection and reducing the number of assembly steps, with a capacitor configuration that minimizes bus bar length and integrates voltage measuring terminals as two discrete parts for easier alignment and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the smoothing capacitor is connected to the control circuit board through wires and connectors, then the capacitor can be electrically connected to the control circuit, but the number of assembly steps increases and production complexity increases
Solution Approach 1:
The patent combines the voltage measuring terminals with the capacitor body into an integrated structure. The voltage measuring terminals are directly formed on the capacitor casing, eliminating the need for separate wire connections and connectors. This merging of functions reduces assembly steps while maintaining reliable electrical connection between the capacitor and control circuit board.
Solution Approach 2:
The capacitor casing serves multiple functions: it provides mechanical protection for the capacitor, provides mounting structure for voltage measuring terminals, and acts as an electrical connection interface with the control circuit board. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly process.
2Reliability
If the voltage measuring terminals are connected through separate wires, then the capacitor can be electrically connected to the voltage detector, but the assembly requires additional discrete steps and increases production time
Solution Approach 1:
The voltage measuring terminals are pre-integrated into the capacitor casing during capacitor manufacturing. This preliminary action ensures that the electrical connection path is already established before the capacitor is installed on the control circuit board, eliminating the need for separate connection steps during final assembly and improving productivity.
3Reliability
If long bus bars are used to connect the capacitor to the semiconductor modules, then the components can be connected electrically, but the overall device size increases and mechanical stability decreases
Solution Approach 1:
The patent optimizes the spatial arrangement by positioning the capacitor in close proximity to the semiconductor modules and routing the bus bars along the shortest possible paths in three-dimensional space. The control circuit board is positioned to allow direct connection to both components, reducing the need for long bus bar extensions and minimizing the overall device volume.
Data Source
AI summary
An easy-to-assemble structure of a power converter includes a control circuit board, semiconductor modules with power terminals and control terminals extending therefrom, and a capacitor to smooth voltage to be applied to the semiconductor modules. The capacitor includes capacitor devices coupled to the power terminals and voltage measuring terminals joined to electrodes of the capacitor devices. The control terminals and the voltage measuring terminals extend in a direction normal to the surface of the control circuit board. This permits the connections of the voltage measuring terminals and the control terminals with the control circuit board to be achieved simultaneously by bringing them close to the control circuit board from the normal direction.