Modular Inverter Assembly for Scalable Motor Power and Lower Inductance
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Solution Overview
Problem
Existing inverters face challenges in flexibly responding to varying motor power requirements, necessitating the development of new components and rearrangement of components to handle medium or high power, which is inefficient and inflexible.
Innovation Solution
A modular inverter design featuring a capacitor unit with multiple capacitors, busbars, and power modules, along with a cooling unit, and a large-capacity inverter assembly that connects modular inverters using bus plates to reduce inductance and facilitate electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If new components are developed and components are rearranged to handle medium or high power inverters, then the inverter can respond to higher motor power requirements, but the development time and complexity increase significantly
Solution Approach 1:
The inverter is divided into modular units (power modules, capacitor units, cooling units) that can be independently configured and combined. Each module maintains standardized connection interfaces, allowing flexible assembly for different power levels without redesigning the entire system.
Solution Approach 2:
The patent creates a universal modular platform where the same basic components (power modules, capacitor units, busbars) can serve multiple power levels and applications. The standardized interfaces and configurations allow a single design to respond to various motor power requirements from low to high power.
2Power
If traditional inverter designs are used for medium or high power applications, then component capacity must be increased, but this requires developing new components from the power module
Solution Approach 1:
The capacitor unit is segmented into multiple individual capacitors that can be connected in parallel to increase capacity. This allows scaling up the inverter capacity by simply adding more capacitor units or increasing the number of capacitors per unit, rather than developing entirely new capacitor designs for higher power applications.
Solution Approach 2:
The system allows dynamic configuration of capacitor units and power modules to match different power requirements. The modular architecture enables the inverter capacity to be adjusted by reconfiguring the number and arrangement of standard components, providing flexibility without requiring new component development.
3Power
If components are rearranged according to component capacity, then the inverter can be optimized for specific power levels, but the product development process becomes time-consuming
Solution Approach 1:
The inverter system is segmented into standardized modules (power modules, capacitor units, cooling units, busbar assemblies) that can be quickly reconfigured for different power levels. This modular approach eliminates the need for time-consuming custom designs, as developers can simply select and arrange appropriate numbers of standard modules to meet specific power requirements.
Solution Approach 2:
The patent establishes preliminary standardized configurations for modules and their connection interfaces. By pre-defining the modular architecture, connection protocols, and standard component specifications, the system enables rapid deployment for different power levels without requiring time-consuming development and testing of new configurations.
4Adaptability or versatility
If a single inverter design is used for various power ranges, then flexibility is improved, but the inductance and connection complexity increase
Solution Approach 1:
The connection structure is segmented into modular busbar assemblies with standardized connection points. Each power module and capacitor unit has defined connection interfaces that simplify the overall connection architecture. This modular connection approach reduces inductance by minimizing current path lengths and simplifies the connection structure through standardized interfaces, even as the system scales to accommodate various power ranges.
Data Source
AI summary
A modular inverter including a capacitor unit including two or more capacitors arranged at a first side, a first capacitor busbar contacting a lower end of the capacitor unit and including a first capacitor connection portion including a first portion located on a second side of an upper end of the capacitor unit, a second capacitor busbar covering the upper end of the capacitor unit and including a second capacitor connection portion including a second portion extending outwardly to a third side of the upper end of the capacitor unit, a cooling unit disposed above the second capacitor busbar, and one or more power modules disposed above the cooling unit, the one or more power modules including a first power module busbar and a second power module busbar extending to the third side of the upper end of the capacitor unit and connected to the second capacitor connection portion.