Segmented Power Electronics Busbar Topology for Leakage Inductance
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Solution Overview
Problem
Existing power electronics systems face challenges in achieving high power density, reliability, and efficient assembly in confined spaces with minimal leakage inductance and optimal connection technologies for electric vehicles.
Innovation Solution
A power electronics system with stacked busbars, where the upper busbar rests on an insulating film and lower busbar, featuring cut-outs and a bushing for easy connection, and an insulating part to minimize leakage inductance and maintain air gaps for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are stacked one above the other to reduce leakage inductance, then electrical performance is improved, but accessibility for connection operations deteriorates
Solution Approach 1:
The upper busbar is divided into two separate parts: a first busbar portion and a second busbar portion. The first portion is positioned above the power module for DC connection, while the second portion is positioned above the DC link capacitor for capacitor connection. This segmentation allows both connection points to be accessible from above, resolving the accessibility issue while maintaining the stacked configuration for low leakage inductance.
Solution Approach 2:
The patent transitions from a single vertically stacked busbar configuration to a two-part configuration where the second busbar portion extends laterally above the DC link capacitor. This dimensional change creates additional access paths from above, allowing connection operations on both the power module and capacitor without requiring lateral access.
2Productivity
If all connections are made from above to improve assembly efficiency, then productivity is improved, but connection reliability deteriorates due to limited access points
Solution Approach 1:
The upper busbar is segmented into two distinct portions positioned at different locations above the power electronics system. This allows multiple connection points to be accessible from above, enabling all connections to be made from a single direction while maintaining reliable access to each connection point.
Solution Approach 2:
The second busbar portion acts as an intermediary element that extends the electrical connection from the DC link capacitor upward to an accessible position above the capacitor. This intermediary structure enables top-down connection operations while maintaining reliable electrical connections to components that would otherwise require lateral access.
3Reliability
If busbars are positioned close together to reduce leakage inductance, then electrical performance is improved, but insulation requirements worsen
Solution Approach 1:
An insulating part is introduced as an intermediary element positioned between the upper busbar and the DC link capacitor. This insulating part provides the necessary electrical insulation to prevent flashover, allowing the busbars to be positioned close together for low leakage inductance while meeting insulation requirements through the added insulating component.
Data Source
AI summary
A power electronics system includes at least one power module which is connected to a direct-current source via an upper bus bar and a lower bus bar. The at least one power module has connection points for contact with the bus bars, and the upper bus bar rests on an insulating sheet and on the lower bus bar. The upper bus bar has a cut-out and the insulating sheet has a further cut-out, so that the lower bus bar is accessible from above.