Superimposed Power Traces in Electronic Modules for Rotary Machines
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Solution Overview
Problem
Existing electronic modules for rotating electrical machines, such as alternators, face challenges with high switching losses and heat generation due to the inductance of power traces, which affects the efficiency and reliability of the modules.
Innovation Solution
The design features power traces that are superimposed on each other, reducing inductance and switching losses, and are arranged axially to enhance cooling, with an insulating envelope and structural features that optimize heat dissipation and trace placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If power traces are arranged separately from the bottom of the case, then the inductance of the traces is reduced and switching speed is increased, but the device complexity increases due to the need for superimposed trace arrangement
Solution Approach 1:
The patent applies dimensionality change by arranging power traces in the axial direction (vertical dimension) rather than only in the horizontal plane. The positive and negative traces are superimposed along the axial direction, with the positive trace extending from the front face through the bottom to the rear face, and the negative trace similarly arranged. This three-dimensional trace layout reduces inductance by minimizing the loop area while managing the increased structural complexity through systematic spatial organization.
2Temperature
If power modules are mounted on the bottom of the case, then heat dissipation is improved, but the inductance of power traces increases leading to higher switching losses
Solution Approach 1:
The patent resolves this contradiction by transitioning from a two-dimensional planar trace layout to a three-dimensional configuration. Power traces are routed in the axial direction through the bottom plate, superimposing positive and negative traces to minimize loop area and inductance. This allows power modules to remain mounted on the bottom for effective heat dissipation while the vertical trace arrangement reduces the magnetic loop area, thereby minimizing switching losses despite the thermal management requirements.
3Temperature
If the axial distance between traces and bottom is increased, then cooling efficiency is improved, but the inductance of traces increases
Solution Approach 1:
The patent optimizes the balance between cooling efficiency and inductance by utilizing the axial dimension for trace routing. Power traces are positioned at an optimal distance from the bottom surface, extending through the axial direction rather than being placed far from the bottom in the horizontal plane. This vertical arrangement minimizes the loop area and inductance while maintaining sufficient thermal coupling with the bottom plate for effective heat dissipation, resolving the trade-off between cooling efficiency and switching losses.
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
This configuration increases switching speed, reduces heating of power modules, and improves cooling efficiency, leading to enhanced performance and reliability of the electronic modules.
Implementation Method 1
The superposition of the positive and negative traces, also called trace B+ and trace B-, makes it possible to reduce the inductances of these traces. This makes it possible to increase the switching speed of the power modules and thus to reduce the switching losses.
Implementation Method 2
The bottom evacuates the heat generated by the power modules in operation.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to an electronic module (36) for a rotating electrical machine (10) comprising: - a housing (40) including a base (41), - a set of power modules, mounted on the base (41) of the housing, capable of rectifying a polyphase current system from the phases of a stator of the electronic machine and optionally, capable of supplying a polyphase current system to the phases of the stator, - a positive terminal (43) and a negative terminal (44) for supplying current to the set of power modules, the positive terminal being electrically connected to the set of power modules by a positive trace (45) disposed at a distance from the base of the housing, the negative terminal being electrically connected to the set of modules by a negative trace (46) disposed at a distance from the base of the housing, characterized in that the negative trace and the positive trace are superimposed on each other at least partially.