Detachable Sensor Integration in Power Modules for Fast Fault Detection
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Solution Overview
Problem
In electric vehicle inverters, sensors outside the power module often have long reaction times, leading to issues like short circuits and current overloads due to integration with current sensors that measure current values.
Innovation Solution
A power module design with a detachable sensing component that can be easily replaced, allowing for different sensitivity ranges and measures, and can stop operation to prevent short circuits and current overloads by detecting abnormal current or voltage values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the sensor is disposed outside the power module, then the power module structure is simpler, but the reaction time is too long causing short circuits and current overloads
Solution Approach 1:
The sensing component is integrated within the power module housing, merging the sensing function with the power module structure. The housing cover part includes a sensing component receiving structure that accommodates the sensing component, enabling it to be positioned close to the power components while maintaining structural integration. This resolves the contradiction by achieving both structural simplicity and fast reaction time through functional merging.
2Reliability
If the sensing component is fixed inside the power module, then the reaction time is fast, but the sensing component cannot be easily replaced when abnormal or when different measurement ranges are needed
Solution Approach 1:
The sensing component is designed as a detachable, modular unit that can be independently removed from the power module. The housing cover part includes a sensing component receiving structure with opening and closing directions, allowing the sensing component to be segmented from the main assembly. This enables fast reaction time when installed while facilitating easy replacement when abnormal or when different measurement ranges are needed.
Solution Approach 2:
The sensing component receiving structure is designed with dynamic characteristics, allowing the sensing component to be installed in a closed state for optimal sensing performance and opened for replacement. The structure transitions between closed (for fast reaction) and open (for easy replacement) states, resolving the contradiction between fixed installation benefits and replacement needs.
3Device complexity
If the sensing component has fixed measurement range and sensitivity, then the design is simpler, but it cannot adapt to different measurement requirements or abnormal conditions
Solution Approach 1:
The sensing component receiving structure is designed as a universal interface that can accommodate different types of sensing components with varying measurement ranges and sensitivities. The standardized receiving structure allows multiple sensing components to be installed in the same position, enabling the system to adapt to different measurement requirements without redesigning the housing structure.
Data Source
AI summary
A power module with detachable function is provided. The power module includes a housing box part, a power component, a housing cover part, and a sensing component. The sensing component is configured to measure parameters of the power component and detachably installed on the housing cover part and the housing box part. When the housing cover part is mounted on the housing box part, the housing cover part and the housing box part can restrict the movement of the sensing component. Thus, a tight fit can be achieved.