Power Converter Current Sensor Mounting for Compact Layout
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Solution Overview
Problem
The existing power converters face challenges in downsizing due to the space required for current sensors, which enlarges the device in a particular direction, limiting their mountability in compact spaces such as vehicle engine compartments.
Innovation Solution
The current sensor is positioned on the bottom surface perpendicular to the mounting surface of the terminal block, allowing it to be placed alongside the terminal block without increasing the device's size in the direction of the power conversion section, thus enabling the power converter to be downsized without enlarging its body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the current sensor is mounted in the power converter, then the control accuracy is improved, but the size of the power converter increases in a particular direction
Solution Approach 1:
The current sensor is positioned on the bottom surface of the terminal block, utilizing the Z-axis dimension (height direction) rather than extending the device in the X-axis direction. This dimensional repositioning allows the sensor to be integrated without increasing the overall footprint of the power converter, thereby resolving the contradiction between measurement precision and device volume.
2Adaptability or versatility
If the current sensor is located between the power conversion section and terminal block, then the space for arrangement is secured, but the body of the power converter is enlarged
Solution Approach 1:
The current sensor is integrated with the terminal block structure, where the sensor is positioned on the bottom surface of the terminal block. This merging of functions allows the sensor to be accommodated within the existing terminal block volume without requiring additional space between the power conversion section and terminal block, thus preventing enlargement of the power converter body while maintaining adaptability.
3Volume of moving object
If the power converter is downsized, then the mountability in vehicle engine compartments is improved, but the space for current sensor arrangement is reduced
Solution Approach 1:
By positioning the current sensor on the bottom surface of the terminal block in the height direction (Z-axis), the design utilizes the vertical dimension for sensor arrangement. This allows the power converter to be downsized in the horizontal plane (X-axis) for improved mountability in vehicle engine compartments, while the sensor still has adequate space on the terminal block's bottom surface for proper arrangement and operation.
Data Source
AI summary
The power converter includes a power conversion section which configures a circuit for power conversion, a power bus bar extending from the power conversion section, a terminal block, and a current sensor measuring current flowing in the power bus bar. The terminal block includes a mounting surface to which a terminal portion of the power bus bar is mounted. The mounting surface faces a direction substantially perpendicular to an arrangement direction in which the power conversion section and the terminal block are arranged. The current sensor is located at a side of a bottom surface on the opposite side of the mounting surface in the terminal block. The power bus bar includes: a sensor-surrounded portion surrounded by the current sensor; and an outer surface faced portion located between the sensor-surrounded portion and the terminal portion along an outer surface on the opposite side of the power conversion section.