Stacked Power Electronics Unit for Reduced Interference
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Solution Overview
Problem
In electric and hybrid vehicles, the existing power electronics units face challenges in minimizing electromagnetic interference and ensuring precise current measurement due to the spatial distance between current sensors and the CPU, leading to potential phase shifts and inefficiencies in energy conversion between DC circuits and polyphase machines.
Innovation Solution
A stacked construction of the power module, driver circuit board, and control circuit board with phase current rails routed through the control circuit board, allowing for integrated current sensors and reduced cable lengths, thereby minimizing electromagnetic interference and improving signal quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If current sensors are placed far from the CPU on separate circuit boards, then electromagnetic interference is reduced, but measurement precision and signal quality deteriorate due to cable length and phase shifts
Solution Approach 1:
The patent merges the current sensors and CPU into a single integrated control circuit board, eliminating separate cable connections and reducing electromagnetic interference while maintaining measurement precision through integrated signal paths
Solution Approach 2:
The patent transitions from a distributed three-dimensional layout with separate boards to a planar integrated layout on a single board, reducing the spatial distance between sensors and CPU while maintaining electrical isolation through circuit board design
2Measurement precision
If current sensors are integrated close to the CPU on the same circuit board, then measurement precision and signal quality improve, but electromagnetic interference and thermal effects worsen
Solution Approach 1:
The patent applies different design qualities to different regions of the circuit board, with current sensors placed in low-interference zones and the CPU in protected zones, using localized shielding and grounding strategies to minimize electromagnetic interference while maintaining integration benefits
Solution Approach 2:
The patent introduces intermediary elements such as shielding layers, grounding paths, and filtering circuits between the current sensors and CPU to mediate electromagnetic interactions and reduce interference while maintaining signal integrity
3Adaptability or versatility
If a stacked construction with multiple separate circuit boards is used, then functional separation is achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple functional components (current sensors, CPU, power electronics interface) into a single integrated control circuit board, reducing assembly complexity while maintaining functional separation through circuit board design and signal routing
4Reliability
If separate driver circuit board and control circuit board are used, then high-voltage and low-voltage circuits are isolated, but cable length and material costs increase
Solution Approach 1:
The patent integrates the driver circuit and control circuit into a single control circuit board with distinct voltage domains, eliminating separate high-voltage and low-voltage boards while maintaining voltage isolation through circuit design, thereby reducing cable length and material costs
Data Source
AI summary
A vehicle includes a power electronics unit for converting energy between a DC circuit and a polyphase machine, wherein the power electronics unit has a power module, a driver board, and a control board. The power electronics unit has two DC current rails, wherein the DC circuit can be connected to the same, and the power electronics unit has phase current rails, wherein the polyphase machine can be connected to the same. The number of the phase current rails corresponds to the number of the phases of the polyphase machine. The arrangement of the power module, the driver board, and the control board corresponds to a stacked or sandwiched construction, the phase current rails are electrically connected to the power module, and the control board has a passage for each of the phase current rails, wherein one phase current rail is fed through each passage.