Shielded Power Converter Assembly With Isolated Busbar Connections
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Solution Overview
Problem
Existing power converter assemblies in working machines and vehicles face challenges with electromagnetic interference (EMI), limited space, and exposure to moisture, dirt, and chemicals, which degrade performance and require improved electromagnetic compatibility (EMC) and protection from mechanical damage.
Innovation Solution
A compact power converter assembly with separate housings for power converter units and a busbar, where connecting elements are galvanically isolated from the housings, providing electromagnetic shielding and protection against pollutants, and using a busbar instead of cables to reduce impedance and DC link inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If power converter units are integrated in a compact assembly, then space utilization is improved, but electromagnetic interference increases
Solution Approach 1:
The power converter assembly is segmented into separate enclosed units, each housing individual power converter modules. These modular enclosures physically separate the high-frequency switching components, reducing electromagnetic coupling between units while maintaining a compact overall assembly volume.
Solution Approach 2:
Galvanically isolated connecting elements serve as intermediaries between power converter units and the busbar housing. These isolated connections minimize galvanic loops and electromagnetic interference pathways while enabling necessary electrical connections, thus reducing EMI in the compact assembly.
2Ease of operation
If components are exposed to harsh environments, then accessibility and heat dissipation are improved, but protection from environmental damage is reduced
Solution Approach 1:
Each power converter unit is enclosed in a protective housing that acts as a barrier shell against moisture, dirt, and chemicals. These enclosures protect internal components from environmental contaminants while incorporating features for heat dissipation and controlled accessibility.
Solution Approach 2:
The assembly is divided into multiple independent enclosed units, each providing individual protection against environmental factors. This segmentation allows selective access to specific units for maintenance while protecting other units, balancing accessibility with environmental protection.
3Ease of manufacture
If cables are used for connections, then flexibility and ease of installation are improved, but impedance and DC link inductance increase
Solution Approach 1:
Flexible cables are replaced with rigid busbar connections that provide lower impedance and inductance pathways for current flow. The busbar system maintains electrical flexibility through its design while eliminating the high-frequency parasitic effects associated with cable-based connections.
4Reliability
If galvanic connections are used between components and housings, then electrical connectivity is improved, but electromagnetic shielding is reduced
Solution Approach 1:
Galvanically isolated connecting elements act as intermediaries that provide electrical connectivity between power converter units and the busbar housing while preventing direct galvanic paths. This isolation maintains necessary electrical connections while blocking electromagnetic interference pathways through the housing structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves enhanced EMC, protects components from environmental factors, and facilitates a modular, scalable design suitable for harsh environments in working machines and vehicles, while maintaining efficient performance.
Implementation Method 1
The inverter units are interconnected by means of a busbar, providing low impedance and reducing power losses in the inverter assembly
Implementation Method 2
at least one converter housing, wherein the at least one converter housing encloses and shields at least one of said power converter units
Implementation Method 3
at least two connecting elements, each connecting element galvanically connecting one of said power converter units to the busbar
Data Source
AI summary
The invention relates to a power converter assembly including at least two power converter units; a busbar; at least two connecting elements, each connecting element electrically connecting one of said power converter units to the busbar, thereby interconnecting the at least two power converter units; and at least one converter housing, enclosing and shielding at least one of said power converter units. It further includes a busbar housing in which the busbar is contained and shielded, wherein the at least two connecting elements are electrically isolated from the busbar housing and from the at least one converter housing. The invention further relates to a working machine and a power system including said power converter assembly.