TW201722040A - Inverter assembly - Google Patents

Abstract

The present application provides inverter assemblies. The inverter assembly comprising: a housing that encloses: a DC input bus bar sub-assembly; a three phase output AC bus bar sub-assembly; a DC link capacitor electrically coupled to the DC input bus bar sub-assembly; a second DC bus bar sub-assembly that electrically couples the DC link capacitor with a plurality of power modules, wherein the plurality of power modules are electrically coupled to the three phase output AC bus bar sub-assembly; and a cooling sub-assembly that is associated with the plurality of power modules.

Description

Inverter assembly

The present application relates generally to an inverter assembly, and more particularly, but not exclusively, to an inverter assembly that includes a structure configured to convert a DC input to a three-phase AC output.

Currently, there are many applications that need to convert a DC input to an AC output. For example, a DC power source such as a fuel cell system, a battery, and/or a supercapacitor can generate direct current, which must be converted to an AC output such as a three-phase AC output to be supplied to an AC load, such as an electric car or hybrid. A three-phase AC motor in a power car. Most traditional inverter designs are not suitable for electric vehicle applications due to their large footprint and low power capacity. Therefore, it is desirable to have an inverter assembly that is capable of providing sufficient power for an electric vehicle application and having a small footprint to facilitate packaging.

According to various embodiments, the present disclosure is directed to an inverter assembly that includes: (a) a housing that houses: (i) a DC input bus bar subassembly; (ii) a three-phase output AC bus bar subassembly (iii) a DC link capacitor electrically connected to the DC input bus bar subassembly; (iv) a second DC bus bar subassembly electrically coupled to the DC link capacitor and the plurality of power modules, wherein the plurality of power modules are electrically Coupled to a three-phase output AC bus bar subassembly; and (v) a cooling subassembly associated with a plurality of power modules.

Preferably, the three-phase output AC bus bar subassembly includes three substantially symmetrical output tabs, each of which carries a single phase of an AC power signal generated by the plurality of power modules.

Preferably, the three-phase output AC bus bar subassembly comprises three bus bars, each of the three bus bars comprising: a strip body having a front surface and a rear surface; a plurality of powers spaced apart from each other a first power module tab of the plurality of power module tabs connected to the first power module of the inverter component, and a second power of the plurality of power module tabs The module tab is connected to the second power module of the inverter component, the plurality of power module tabs extend away from the rear surface; and the output tabs, the output tabs extend from the front surface; and the three The strip body of the first bus bar in the bus bar is positioned behind the strip body of the second bus bar of the three bus bars, and the third bus bar of the three bus bars is positioned at the three The front of the second bus bar in the bus bar.

Preferably, the second DC bus bar subassembly includes a pair of bus bars, each of the pair of bus bars includes: a strip body; a plurality of input tabs, the plurality of input tabs from the strip body Extending at one end, the plurality of input tabs are coupled to the DC link capacitor; and a plurality of output tabs, wherein the plurality of output tabs are disposed on opposite sides of the strip body relative to each other; The strips of the pair of bus bars overlap each other but are spaced apart from each other; and the plurality of input tabs of the first bus bar of the pair of bus bars are disposed to be more than the second bus bar of the pair of bus bars The input tabs are in alternating and aligned relationship with each other.

Preferably, the plurality of output tabs of the first bus bar of the pair of bus bars are adjacent to the plurality of output tabs of the second bus bar of the pair of bus bars.

Preferably, an output tab of the first bus bar of the pair of bus bars and an output tab of the second bus bar adjacent to the pair of bus bars are electrically connected to the plurality of output tabs A power module in a power module.

Preferably, the inverter assembly further includes a gate driving circuit board, wherein the plurality of power modules are electrically connected to the gate driving circuit board.

Preferably, the gate drive circuit board is recessed to accommodate the plurality of output tabs of the second DC bus bar subassembly.

Preferably, the heat dissipating components of the plurality of power modules are disposed in a cavity formed by sidewalls of the cooling subassembly, wherein a gasket disposed between the plurality of power modules and the gate driving circuit board is the cavity Fluid isolation inside.

Preferably, the cooling subassembly includes an input port and an output port disposed in a middle portion of the housing and disposed between the heat dissipating members of the plurality of power modules.

Preferably, the cooling subassembly includes: an input port disposed on a first end of the lower side of the housing; and an output port disposed on the lower side of the housing On the end.

Preferably, the inverter assembly further includes a wiring board supportingly connecting the DC input bus bar subassembly and the lower casing of the housing.

Preferably, the inverter assembly further includes a positive output bus bar and a negative output bus bar, the positive output bus bar and the negative output bus bar being embedded in the DC link capacitor, wherein the positive output bus bar and the negative output The bus bar is electrically connected to the plurality of input tabs of the second DC bus bar subassembly.

Preferably, the DC input bus bar subassembly is electrically connected to the first connector and the second connector, and each of the first connector and the second connector is at least partially embedded in the DC link capacitor.

Preferably, the DC input bus bar subassembly includes a pair of bus bars, each of the pair of bus bars includes: an input tab; an output tab; and a strip body, the input tab and the strip body The first section extends in alignment and the output tab extends orthogonal to the second section of the strip body.

According to some embodiments, the present application discloses an inverter assembly comprising: (a) a housing containing: (i) a DC input bus bar subassembly; (ii) a three-phase output AC bus bar subassembly The three-phase output AC bus bar subassembly has symmetrically arranged output tabs, each of which carries a single phase of an AC power signal; (iii) a DC link capacitor electrically coupled to the DC input bus bar subassembly; Iv) a gate drive circuit board; (v) a plurality of power modules mounted to the gate drive circuit board, the plurality of power modules generating the AC power signal; and (vi) a second A DC bus bar subassembly electrically connects the DC link capacitor to the plurality of power modules, wherein the plurality of power modules are electrically connectable to the three-phase output AC bus bar subassembly.

Preferably, the gate driving circuit board includes a notch, the notch allowing the input tabs of the plurality of power modules to be directly connected to the plurality of positive output tabs and the negative output tabs of the second DC bus bar subassembly .

Preferably, the gate drive circuit board includes an additional recess that allows the power module tabs of the three-phase output AC bus bar sub-assembly to be directly connected to the output tabs of the plurality of power modules.

Preferably, the DC link capacitor is fixed by an encapsulating material.

According to some embodiments, the present application discloses an inverter assembly including (a) a housing that can include a cover and a lower housing, wherein the lower housing houses: (i) a DC input bus bar subassembly, The DC input bus bar subassembly is mounted to a sidewall of a lower housing of the housing; (ii) a DC link capacitor electrically coupled to the DC input bus bar subassembly by a pair of connectors, the pair of connectors extending up to a DC input bus bar subassembly, the DC link capacitor is packaged into a gap of the housing; (iii) a gate drive circuit board; (iv) a plurality of power modules mounted on the gate drive circuit board On the underside, the plurality of power modules generate an AC power signal from DC power received from the DC link capacitor; (v) a second DC bus bar subassembly that couples the DC link capacitor to the plurality of power modes Electrical connection, wherein the second DC bus bar subassembly bridges the gate drive circuit board and the DC link capacitor at the top; and (vi) the three-phase output AC confluence The sub-assembly, the three-phase output AC bus bar sub-assembly comprises three bus bars, the three bus bars can be physically separated from each other, and the three bus bars each comprise a linearly arranged power module tab, the power module tab And electrically connecting to the linearly arranged output terminals of the plurality of power modules, wherein the three bus bars further comprise output tabs, each of which carries a single phase of the AC power signal.

Although the present invention may be embodied in a number of different embodiments, only a few specific embodiments are illustrated in the drawings, and only the specific embodiments are described in detail in the specification. It should be understood that An example of the principles of the technology is not limited to the illustrated embodiment.

The terminology used herein is for the purpose of describing the particular embodiments, As used herein, the sing " It is also to be understood that the term "comprising", when used in the specification, is intended to mean the presence of the recited features, integers, steps, operations, components and/or components, but does not exclude the presence or addition of one or more other features, integers. , steps, operations, components, components, and/or combinations thereof.

The same or similar elements and/or components referred to herein are denoted by the same reference numerals throughout the drawings. It should also be understood that some of the figures are merely exemplary representations of the disclosure. Therefore, some of the components may not match their actual size for clarity of the image.

In general, the present disclosure relates to an inverter assembly, a method of manufacturing the same, and uses. An exemplary inverter assembly can include a symmetrical structure configured to convert a DC input power source to an AC output power source.

Some embodiments may include a symmetrical DC input section, a symmetrical AC output section, a gate drive circuit board, and a controller. The gate drive circuit board and the controller can be coupled to two inverter power modules in parallel. The power module can provide currents well in excess of 400 amps RMS (root mean square), and in various embodiments, each power module can include an IGBT (insulated gate bipolar transistor) or other suitable component Used to convert DC current into AC current. The total rms current can exceed the rms current typically available from a single commercially available power module. The DC input section can include a DC input bus and a DC bus subassembly. The DC busbar subassembly may have a layered design of a symmetrical structure comprising a positive plate and a negative plate that substantially overlap each other. The positive plate can be connected to the positive terminal of the DC input bus via a plurality of positive input tabs. The negative plate can be connected to the negative terminal of the DC input bus via a plurality of negative input tabs. The positive plate may have two or more positive output tabs and two or more negative output tabs connected to the input terminals of the two inverter power modules.

The AC output section can include a plurality of output bus bars, each having a symmetrical structure. In one embodiment, the AC output section can provide a three phase AC power signal. Each of the output bus bars may correspond to one of the three phase AC power signals (phase). Each bus bar may include: two input tabs connected to the output terminals of each of the two inverter power modules; and an output tab connected to the inverse The AC output terminal of the transformer. The output tabs can be placed at approximately the same distance from the two input tabs of each of the AC bus bars. These and other advantages of the present disclosure will be described in more detail below with reference to the accompanying drawings.

Referring now to Figure 1, there is shown the positioning of two inverter assemblies, such as the exemplary inverter assembly 102. The inverter assembly can be disposed on the exemplary transmission system 104.

FIGS. 2 and 3 collectively illustrate an exemplary inverter assembly 102 that can include a housing 106 that can include a lower housing 108 and a cover 110.

FIG. 4 is a top view of an exemplary inverter assembly 102 with the cover 110 removed to expose internal components of the inverter assembly 102. In some embodiments, the inverter assembly 102 can include a DC bus subassembly (referred to herein as "DC bus bar 112"), a DC link capacitor 114 (which can include a capacitor bank, and can also be referred to as a DC link capacitor) Group 114), DC input bus bar subassembly 170, gate drive circuit board 116, and three phase output AC bus bar subassembly 118.

FIGS. 5A-5C collectively illustrate an exemplary DC bus bar 112 that may include a pair of bus bars, ie, a positive bus bar 120 and a negative bus bar 122. Each of these bus bars can include an input tab and an output tab. For example, the positive bus bar 120 can include a positive input tab 124 and a positive output tab 126, while the negative bus bar 122 can include a negative input tab 128 and a negative output tab 130.

Both the positive bus bar 120 and the negative bus bar 122 can have strip bodies that extend between their respective input tabs and output tabs. In one embodiment, the positive bus bar 120 can have a positive strip body 132 and the negative bus bar can include a negative strip body 134.

In some embodiments, the shapes of the positive bus bar 120 and the negative bus bar 122 are similar to each other. Both the positive bus bar 120 and the negative bus bar 122 may have a first segment and a second segment. For example, the positive bus bar 120 can have a first segment 136 and a second segment 138. In some embodiments, the first section 136 and the second section 138 can be positioned to be configured at substantially right angles relative to one another. That is, the first section 136 can extend perpendicularly from the second section 138.

The negative bus bar 122 can include a first section 140 and a second section 142. In some embodiments, the first section 140 and the second section 142 can be positioned at a generally right angle relative to each other.

Input tabs on both the positive bus bar 120 and the negative bus bar 122 extend from their respective strip bodies. For example, the positive input tabs 124 can extend in a manner that is linearly aligned with the first section 136 of the strip body 132. The positive output tab 126 can extend rearward from the second section 138 of the positive bus bar 120.

The positive bus bar 120 and the negative bus bar 122 may be placed in a mating relationship such that the positive bus bar 120 may be nested within the negative bus bar 122 in a state of being electrically insulated from the negative bus bar 122. There may be a space between the main body 132 and the negative body 134. The size of this space can be minimized, which can reduce the inductance through the DC bus bar 112 and can minimize noise pickup from stray fields within the inverter housing.

In one embodiment, the negative output tab 130 of the negative bus bar 122 can be biased to one side of the second section 142 of the negative strip body 134. Conversely, the positive output tab 126 of the positive bus bar 120 can be biased to one side of the second section 138 of the strip body 132. In one embodiment, the negative output tabs 130 and the positive output tabs 126 may be spaced apart from each other due to their positioning on respective sides of their associated strip bodies. Similarly, the positive input tabs 124 and the negative input tabs 128 can be spaced apart from each other and can be separately secured to the patch panel, as will be described in greater detail below.

In some embodiments, the space 132 between the positive 134 and the negative main body of the main body of an electrical insulator Mylar ^TM film can be used such as a filler. Also, the mutually facing surfaces of the positive strip main body 132 and the negative strip main body 134 may be coated with a layer of electrically insulating material instead of providing an electrically insulating layer between the positive strip main body 132 and the surfaces of the negative strip main body 134 facing each other. .

In some embodiments, the first section 136 of the strip body 132 and the first section 140 of the strip body 134 can be at least partially surrounded by the input core 149. The input core 149 can be configured to contact the patch panel 146 to which the pair of bus bars can be mounted.

For example, the patch panel 146 can provide a mounting surface that supports the DC bus bar 112. The terminal block 146 can be mounted to the inner side wall of the lower outer casing 108 and the lower support 148 of the lower outer casing 108.

In some embodiments, the input core 149 can be secured to the patch panel 146 using a platen 150. A shim 152 can be disposed between the input core 149 and the platen 150. In one embodiment, the spacer 152 may be a foam block, although other materials known to those of ordinary skill in the art may be utilized in accordance with the present disclosure.

Another example of a DC bus bar 112 is shown in FIG. In this embodiment, the input tabs 141 and 143 can be tilted upwardly and outwardly from the strip body along the reference line A rather than being linearly aligned. Moreover, the input tabs 141 and 143 can extend from the side edges of the strip body, and the output tabs 145 and 147 can extend in line with the reference line B. Indeed, baseline A and baseline B may be substantially perpendicular to each other.

Referring to Figure 7, positive input tab 124 and negative input tab 128 can be coupled to input cables 158 and 160, respectively, as shown.

FIG. 8 is a top plan view of an exemplary DC link capacitor 114 showing an inverter assembly, wherein the DC link capacitor can include a capacitor bank. As shown in FIG. 8, in some embodiments, the DC bus bar 112 can be electrically coupled to the DC link capacitor 114 via the first connector 154 and the second connector 156. (The first connector 154 and the second connector 156 may each be a positive connector or a negative connector according to the polarity setting provided by the DC bus bar 112). According to some embodiments, the first connector 154 and the second connector 156 may be connected to or embedded in the DC link capacitor 114. Of course, the DC link capacitor 114 can be packaged in place within the lower housing 108; the first connector 154 and the second connector 156 are embedded in the DC link capacitor 114 during the packaging process.

Additionally, the positive output bus bar 162 can be embedded in the DC link capacitor 114 along with the negative output bus bar 164. The positive output bus bar 162 and the negative output bus bar 164 include a plurality of output tabs. For example, positive output bus bar 162 can include positive output tabs 166A-166C, while negative output bus bar 164 can include negative output tabs 168A-168C. In some embodiments, positive output tabs 166A-166C and negative output tabs 168A-168C can be positioned in line with each other. As just one example, positive output tabs 166A-166C and negative output tabs 168A-168C may alternatively be positioned such that negative output tab 168A may be positioned between positive output tab 166A and positive output tab 166B. .

In some cases, DC link capacitor 114 can be packaged into void 169. In one embodiment, the DC link capacitor 114 is secured in the void 169 with an encapsulating material that may include a mixture of polyol and isocyanate. In some embodiments, the encapsulating material can include 100 parts polyol to 20 parts isocyanate. The DC link capacitor material can be poured into the void 169 and reach a height of 45 mm to 50 mm below the upper edge of the void 169. In various embodiments, the DC link capacitor material can be cured at 25 degrees Celsius for 24 hours, at 60 degrees Celsius for 2 hours, or at 100 degrees Celsius for 20 to 30 minutes.

Referring now to Figures 9A through 10, an exemplary DC input bus bar subassembly 170 is shown. The DC input bus bar subassembly 170 may also be referred to as a "second DC bus bar subassembly" or a "DC input bus bar 170." The DC input bus bar 170 may include a positive bus bar 174 and a negative bus bar 176. Similar to the DC bus bar 112, the positive bus bar 174 and the negative bus bar 176 may be disposed in a cooperative relationship.

The positive bus bar 174 can include a plurality of positive input tabs 178A-178C, and the negative bus bar 176 can include a plurality of negative input tabs 180A-180C. When installed, the positive bus bar 174 can be coupled to the DC link by connecting the plurality of positive input tabs 178A-178C of the positive bus bar 174 with the positive output tabs 166A-166C of the positive output bus bar 162 of the DC link capacitor 114. The positive output bus bar 162 of the capacitor 114 is connected. Similarly, the negative bus bar 176 can be coupled to the DC link capacitor 114 by connecting the plurality of negative input tabs 180A-180C of the negative bus bar 176 with the negative output tabs 168A-168C of the negative output bus bar 164 of the DC link capacitor 114. The negative output bus bar 164 is connected.

A plurality of positive input tabs 178A-178C and a plurality of negative input tabs 180A-180C are alternately arranged and configured in a straight line.

The positive bus bar 174 and the negative bus bar 176 can be placed in an overlapping mating relationship with each other. In some embodiments, a space 175 may be provided between the positive bus bar 174 and the negative bus bar 176, which may be filled with an electrically insulating material. The space 175 between the positive bus bar 174 and the negative bus bar 176 may allow current through the DC input bus bar subassembly 170 to have a lower inductance.

The positive bus bar 174 can include a pair of positive output tabs 182A and 182B, and the negative bus bar 176 can include a pair of negative output tabs 184A (shown in FIG. 10) and 184B. The pair of positive output tabs 182A and 182B can be disposed on opposite sides of the positive bus bar 174 with respect to each other. The pair of negative output tabs 184A and 184B can also be disposed on opposite sides of the negative bus bar 176 with respect to each other. The pair of negative output tabs and the pair of positive output tabs can be arranged such that the positive output tab 182A can be located proximal to the negative output tab 184b and the positive output tab 182B can be located at the negative output tab 184B. Near side.

As best shown in FIG. 10, the DC input bus bar 170 can provide an electrical connection between the DC link capacitor 114 and the power modules of the gate drive circuit board 116, as will be described in greater detail below. In one embodiment, the positive output tab 182A and the negative output tab 184A can be coupled to the first power module 188 via an opening in the gate drive circuit board 116. The positive output tab 182B and the negative output tab 184B can be connected to the second power module 186.

11 is a partially exploded perspective view showing an exemplary first power module 186 and a second power module 188 with the gate drive circuit board removed, and the respective bus bars and DC link capacitors described above. Each of the first power module 186 and the second power module 188 can include a pair of positive input terminals and a negative input terminal. For example, the first power module 186 can include a positive terminal 190 and a negative terminal 192. Each of the power modules can be coupled to the bottom of the lower housing 108 using a gasket, such as washer 194. In various embodiments, the gasket can be used to create a fluid impermeable seal that prevents fluid from the cooling subassembly from entering the lower outer casing 108. As will be described in greater detail herein, the cooling subassembly allows the heat dissipating components of power modules 186 and 188 to be exposed to the coolant fluid. The coolant fluid removes excess heat from the power module to improve the performance of the power module.

Each of the exemplary power modules 186 and 188 can include three output terminals, each of which can output a different phase of an AC power signal that can be generated by the power module. For example, the first power module 186 can include output terminals 187A, 187B, and 187C, and the second power module 188 can include output terminals 189A, 189B, and 189C.

Figures 12 and 13 collectively illustrate an exemplary three-phase output AC bus bar subassembly (hereinafter referred to as "AC bus bar 118"). In some embodiments, the AC bus bar 118 can include three bus bars, such as a first bus bar 202, a second bus bar 204, and a third bus bar 206.

Each of the first bus bar 202, the second bus bar 204, and the third bus bar 206 may include a strip body. For example, the first bus bar 202 can include a strip body 208, the second bus bar 204 can include a strip body 210, and the third bus bar 206 can include a strip body 212. Each of the first bus bar 202, the second bus bar 204, and the third bus bar 206 may include a front surface and a rear surface. For example, the strip body 208 of the first bus bar 202 can include a front surface 214 and a back surface 216. The strip body 210 of the second bus bar 204 may include a front surface 218 and a rear surface 220, and the strip body 212 of the third bus bar 206 may include a front surface 222 and a rear surface 224.

In one embodiment, the first bus bar 202, the second bus bar 204, and the third bus bar 206 may be spaced apart from each other and simultaneously positioned in a nested configuration. Thus, there is a space 205 between the front surface 214 of the first bus bar 202 and the rear surface 216 of the second bus bar 204. Likewise, the third bus bar and the second bus bar may be spaced apart from each other to form a space 207 between the front surface 214 of the second bus bar 204 and the rear surface 220 of the third bus bar 206. Each of the spaces 205 and 207 can be filled with an electrically insulating material. In other embodiments, the front and/or back surfaces of the first bus bar 202, the second bus bar 204, and the third bus bar 206 may be coated with an insulating layer suitable for providing a material that is electrically insulating.

Each of the first bus bar 202, the second bus bar 204, and the third bus bar 206 may further include a plurality of power module tabs, each of the plurality of power module tabs may be associated with each of the bus bars The power module 186 and the second power module 188 are electrically connected (see FIG. 11). For example, the first bus bar 202 can include power module tabs 226 and 228, and the second bus bar 204 can include power module tabs 230 and 232. The third bus bar 206 can include power module tabs 234 and 236. The power module tabs of any of these bus bars can be spaced apart from one another to allow the bus bars to be connected to each power module.

A plurality of power module tabs of each of the bus bars can extend away from the rear surface of their respective strip bodies. The plurality of power module tabs 226, 228, 230, 232, 234, and 236 may be coplanar and aligned with each other along the longitudinal alignment axis Ls (see Figure 13).

In some embodiments, the first bus bar 202, the second bus bar 204, and the third bus bar 206 can be placed in a nested but offset relationship with one another. For example, the second bus bar 204 may be disposed in front of the first bus bar 202, and the third bus bar 206 may be disposed in front of the second bus bar 204. Moreover, the bus bars can be staggered or offset from one another. The second bus bar 204 can be offset from the first bus bar 202 and the third bus bar 206 can be offset from the second bus bar 204. In this configuration, the power module tabs 230 of the second bus bar 204 can be positioned between the power module tabs 226 of the first bus bar 202 and the power module tabs 234 of the third bus bar 206. . The power module tab 234 of the third bus bar can be positioned between the power module tab 230 of the second bus bar 204 and the power module tab 228 of the first bus bar 202. The power module tab 228 of the first bus bar 202 can be positioned between the power module tab 234 of the third bus bar 206 and the power module tab 232 of the second bus bar 204. The power module tab 232 can be positioned between the power module tab 228 of the first bus bar 202 and the power module tab 236 of the third bus bar 206.

In some embodiments, the power module tabs 234, 236 of the third bus bar 206 of the three bus bars may have a length greater than the power module tabs 230, 232 of the second bus bar 204 of the three bus bars. length. Moreover, the length of the power module tabs 230, 232 of the second bus bar 204 of the three bus bars may be greater than the length of the power module tabs 226, 228 of the first bus bar 202 of the three bus bars.

Each of the first bus bar 202, the second bus bar 204, and the third bus bar 206 may further include output tabs that may extend from the front surface of their respective strip bodies. For example, the first bus bar 202 can include an output tab 238, the second bus bar 204 can include an output tab 240, and the third bus bar 206 can include an output tab 242.

In one embodiment, the output tabs 238, 240, and 242 can be arranged such that their positions are symmetrical with respect to each other. Due to the spacing of the output terminals of each of the power modules (as described above) and to maintain the symmetry of the output tabs 238, 240, and 242, the output tab 240 can have a generally curved portion 244 that is 244 Output tab 240 can be positioned between output tabs 238 and 242.

In some embodiments, the first bus bar 202, the second bus bar 204, and the third bus bar 206 can be held in their respective positions using a mounting plate 246 (see Figure 12). Mounting plate 246 has a hole. Output tabs 238, 240, and 242 can extend through the apertures. In one embodiment, a locking member, such as locking member 248, can secure output tabs 238, 240, and 242 in position on mounting plate 246.

The mounting plate 246 can be connected to the second bus bar and the third bus bar of the above three bus bars (see the example shown in FIG. 12).

Referring now to Figures 14 and 15 (and Figures 11, 12 and 13), power module tabs 226 and 228 of the first bus bar 202 (see Figure 12) may be used in accordance with some embodiments. It is connected to the output terminal 187A of the first power module 186 (see also FIG. 11) and the output terminal 189A of the second power module 188. The second bus bar 204 can be connected to the output terminal 187B of the first power module 186 and the output terminal 189B of the second power module 188. The third bus bar 206 can be connected to the output terminal 187C of the first power module 186 and the output terminal 189C of the second power module 188.

In Fig. 16, a plurality of cables (e.g., cable 250) may be coupled to the output tabs 238, 240, and 242 of the AC bus bar 118 (see Figures 14 through 15).

FIG. 17 illustrates an exemplary cooling subassembly 252 that can include a cooling chamber 254, a gasket 256, a cover plate 258, an input port 260, and an output port 262 and a cleaning bowl 264. Generally, a cooling cavity 254 can be formed by the side wall 266 that is formed in the lower outer casing 108 of the housing. Heat sinks 268 and 270 of power modules 186 and 188, respectively, may be exposed to cooling chamber 254. As described above, the power modules 186 and 188 are isolated by a gasket to prevent fluid within the cooling chamber 254 from entering the housing.

When the cover plate 258 is coupled to the lower outer casing 108 of the casing, a fluid such as a coolant may be pumped into the cooling chamber 254 through the input port 260 using a pump (not shown) and the fluid such as the coolant may be withdrawn. The trapped air can be purged from the cooling chamber 254 using a cleaning bowl 264 as needed.

In one embodiment, the input port 260 and the output port 262 can be disposed adjacent the center of the housing, which can help to allow fluid to reach each of the cooling chambers at equal flow rates.

Figures 18A through 18C collectively illustrate another embodiment of a cooling subassembly. In one embodiment, the first power module 186 and the second power module 188 can be mounted to the board 280. The sidewall (see, for example, 266 in Figure 17) defines a cooling cavity (see, for example, 254 in Figure 17). Heat sinks 268 and 270 can be positioned within cooling cavity 254. The input port 286 can be positioned on one end of the cooling chamber 254 and the output port 288 can be positioned on the opposite end of the cooling chamber 254. Since fluid can be introduced into the input port 286 and removed from the output port 288, the fluid can remove heat from the first power module 186 and the second power module 188 as the fluid passes through the heat dissipating members 268 and 270, so that A substantially equal share of coolant is provided for each power module. In other embodiments (see, for example, Figure 17), the input weir may be positioned generally intermediate the heat dissipating members 268 and 270 such that the coolant can enter from a generally intermediate portion so that the coolant can flow bidirectionally ( That is, flowing through the heat dissipating member 268 in one direction and flowing through the heat dissipating member 270 in the other direction and being collected in the substantially central portion to provide a substantially equal portion of the coolant to each of the power modules, thereby reducing the electric mode. The difference in temperature of the group.

Although a plurality of embodiments have been described above, it should be understood that they are given by way of example only and not by way of limitation. The above description is not intended to limit the scope of the technology to the specific forms set forth herein. Therefore, none of the above-described exemplary embodiments should limit the scope of the preferred embodiments. It is to be understood that the foregoing description is illustrative and not restrictive. The description is intended to cover alternatives, modifications, and equivalents, which are within the spirit and scope of the invention as defined by the appended claims. Therefore, the scope of protection of the technology should not be determined by reference to the above description, and the scope of protection of the technology should be determined with reference to the appended claims and their equivalents.

102‧‧‧Inverter components
104‧‧‧Transmission system
106‧‧‧Shell
108‧‧‧ Lower casing
110‧‧‧ Cover
112‧‧‧DC bus bar
114‧‧‧DC chain capacitor
116‧‧‧Gate drive circuit board
118‧‧‧Three-phase output AC busbar subassembly
120, 174‧‧‧ positive bus bars
122, 176‧‧‧ negative bus bars
124, 178A-178C‧‧‧ positive input tab
126, 166A-166C, 182A, 182B‧‧‧ positive output tabs
128, 180A-180C‧‧‧ Negative input tab
130, 168A-168C, 184A, 184B‧‧‧ negative output tabs
132‧‧‧Article body
134‧‧‧ Negative article body
Sections 136, 138, 140, 142‧‧
141, 143‧‧‧ input tabs
145, 147, 238, 240, 242‧‧‧ output tabs
146‧‧‧Wiring board
148‧‧‧lower support
149‧‧‧ input core
152‧‧‧shims
150‧‧‧ pressure plate
154, 156‧‧‧ connectors
158, 160‧‧‧ input cable
162‧‧‧Is output bus bar
164‧‧‧negative output bus bar
169‧‧‧ gap
170‧‧‧DC input busbar subassembly
175, 205, 207 ‧ ‧ space
186, 188‧‧‧ Power Module
187A, 187B, 187C, 189A, 189B, 189C‧‧‧ output terminals
190‧‧‧ positive terminal
192‧‧‧negative terminal
194, 256‧‧‧ washers
202, 204, 206‧‧ ‧ bus bars
208, 210, 212‧‧‧ subjects
Front surface of 214, 218, 222‧‧
216, 220, 224‧‧ ‧ back surface
226, 228, 230, 232, 234, 236‧‧‧ power module tabs
246‧‧‧Installation board
248‧‧‧Locking members
250‧‧‧ cable
252‧‧‧ Cooling subassembly
254‧‧‧ Cooling chamber
258‧‧‧ cover
260, 286‧‧‧ input 埠
262, 288‧‧‧ Output埠
264‧‧‧ Cleaning 埠
266‧‧‧ side wall
268, 270‧‧‧ heat sink parts
280‧‧‧ board
A, B‧‧ ‧ baseline
Ls‧‧‧ longitudinal alignment axis

Certain embodiments of the present disclosure are shown in the drawings. It is understood that the drawings are not necessarily to scale, and the detail It should be understood that the technology is not limited to the specific embodiments shown herein. 1 is a perspective view of an exemplary transmission system that may include an inverter assembly of the present disclosure; FIG. 2 is a perspective view of an exemplary inverter assembly; and FIG. 3 is an exemplary inverter of FIG. An exploded perspective view of the assembly; Figure 4 is a top view of an exemplary inverter assembly with the top cover removed; Figures 5A, 5B, and 5C are different views of an exemplary DC bus bar subassembly; Figure is a perspective view of a portion of another exemplary DC bus bar subassembly; Figure 7 is a perspective view of an exemplary DC bus bar subassembly connected to a cable; Figure 8 is an exemplary DC link showing the inverter assembly A top view of the capacitor, wherein the DC link capacitor can include a capacitor bank; Figure 9A is a perspective view of an exemplary DC input bus bar connecting the DC link capacitor to the power module; Figure 9B is another exemplary DC of Figure 9A An exploded perspective view of the input bus bar; Figure 9C is a cross-sectional view of an exemplary DC input bus bar of Figures 9A and 9B; Figure 10 is a perspective view of an exemplary DC input bus bar mounted to the inverter assembly ; 11 is a partial exploded perspective view of an exemplary power module; FIG. 12 is a perspective view of an exemplary three-phase output AC bus bar subassembly; and FIG. 13 is another perspective view of an exemplary three-phase output AC bus bar subassembly Figure 14 is a perspective view of an exemplary three bus bars of a three-phase output AC bus bar subassembly; Figure 15 is a top view of an exemplary three-phase output AC bus bar subassembly mounted to the inverter assembly; Figure 16 is a perspective view of an exemplary three-phase output AC bus bar subassembly coupled to a cable; Figure 17 is an exploded view of an exemplary cooling assembly; and Figures 18A through 18C illustrate an exemplary alternative cooling assembly.

102‧‧‧Inverter components

104‧‧‧Transmission system

Claims (20)

An inverter assembly, comprising: a housing, the housing is provided with: a DC input bus bar subassembly; a three-phase output AC bus bar subassembly; a DC link capacitor, the DC link capacitor electrical connection To the DC input bus bar subassembly; a second DC bus bar subassembly, the second DC bus bar subassembly electrically connecting the DC link capacitor to a plurality of power modules, wherein the plurality of power modules are electrically connected to the three a phase output ac bus bar subassembly; and a cooling subassembly coupled to the plurality of power modules. The inverter assembly of claim 1, wherein the three-phase output AC bus bar subassembly comprises three substantially symmetrical output tabs, each of the output tabs being carried by the plurality of power modules A single phase of an AC power signal. The inverter assembly of claim 1, wherein the three-phase output AC bus bar subassembly comprises: three bus bars, each of the three bus bars comprising: a body having a front surface and a rear surface; a plurality of power module tabs spaced apart from each other, a first power module tab of the plurality of power module tabs and a first power module of the inverter component a plurality of power module tabs of the plurality of power module tabs are connected to a second power module of the inverter component, the plurality of power module tabs extending away from the rear surface An output tab extending from the front surface; and the body of one of the three bus bars is positioned at a second bus bar of the three bus bars Behind the strip body, and a third bus bar of the three bus bars is positioned in front of the second bus bar of the three bus bars. The inverter assembly of claim 1, wherein the second DC bus bar subassembly comprises: a pair of bus bars, each of the pair of bus bars comprising: a body; a plurality of input tabs The plurality of input tabs extend from a first end of the strip body, the plurality of input tabs being coupled to the DC link capacitor; and a plurality of output tabs, wherein the plurality of output tabs are relative to each other And disposed on opposite sides of the body of the strip; the strips of the pair of bus bars overlap each other but are spaced apart from each other; and the plurality of input tabs of a first bus bar of the pair of bus bars The plurality of input tabs of a second bus bar of the pair of bus bars are disposed in an alternating and aligned relationship. The inverter assembly of claim 4, wherein the plurality of output tabs of the first bus bar of the pair of bus bars and the second bus bar of the pair of bus bars Multiple output tabs are adjacent. The inverter assembly of claim 5, wherein an output tab of the first bus bar of the pair of bus bars and the second one of the pair of bus bars adjacent thereto An output tab of the bus bar is electrically connected to one of the plurality of power modules. The inverter assembly of claim 1, further comprising a gate driving circuit board, wherein the plurality of power modules are electrically connected to the gate driving circuit board. The inverter assembly of claim 7, wherein the gate drive circuit board is recessed to accommodate a plurality of output tabs of the second DC bus bar subassembly. The inverter assembly of claim 1, wherein the heat dissipating members of the plurality of power modules are disposed in a cavity formed by a side wall of the cooling subassembly, wherein the plurality of electric powers are disposed A gasket between the module and a gate drive circuit board isolates a fluid within the chamber. The inverter assembly of claim 9, wherein the cooling subassembly includes an input port and an output port, the input port and the output port are disposed in a middle portion of the housing, and are disposed in the Between the heat dissipating members of the plurality of power modules. The inverter assembly of claim 9, wherein the cooling subassembly comprises: an input port disposed on a first end of a lower side of the housing; and an output port The output port is disposed on a second end of the lower side of the housing. The inverter assembly of claim 1, wherein the inverter assembly further includes a wiring board supportingly connecting the DC input bus bar subassembly and the lower housing of the housing. The inverter assembly of claim 1, further comprising a positive output bus bar and a negative output bus bar, the positive output bus bar and the negative output bus bar being embedded in the DC link capacitor The medium output bus bar and the negative output bus bar are electrically connected to the plurality of input tabs of the second DC bus bar subassembly. The inverter assembly of claim 1, wherein the DC input bus bar subassembly is electrically connected to a first connecting member and a second connecting member, wherein the first connecting member and the second connecting member are Each is at least partially embedded in the DC link capacitor. The inverter assembly of claim 14, wherein the DC input bus bar subassembly comprises a pair of bus bars, each of the pair of bus bars comprising: an input tab; an output a tab; and a body extending in alignment with a first section of the body, the output tab extending perpendicular to a second section of the body. An inverter assembly, comprising: a housing, the housing is provided with: a DC input bus bar subassembly; a three-phase output AC bus bar subassembly, the three-phase output AC bus bar sub-assembly has symmetric Arranging a plurality of output tabs, each of the output tabs carrying a single phase of an AC power signal; a DC link capacitor electrically coupled to the DC input bus bar subassembly; a gate drive circuit board a plurality of power modules, the plurality of power modules being mounted to the gate drive circuit board, the plurality of power modules generating the AC power signal; and a second DC bus bar subassembly, the second DC bus bar The component electrically connects the DC link capacitor to the plurality of power modules, wherein the plurality of power modules are electrically connected to the three-phase output AC bus bar subassembly. The inverter assembly of claim 16, wherein the gate drive circuit board includes a recess that allows an input tab of the plurality of power modules and the second DC bus bar subassembly A plurality of positive output tabs and negative output tabs are directly connected. The inverter assembly of claim 16, wherein the gate drive circuit board includes an additional recess that allows the power module tab of the three-phase output AC bus bar sub-assembly to be The output tabs of the power modules are directly connected. The inverter assembly of claim 16, wherein the DC link capacitor is fixed by an encapsulating material. An inverter assembly comprising: a housing including a cover and a lower housing, wherein the lower housing houses: a DC input bus bar subassembly to which the DC input bus bar subassembly is mounted a side wall of the lower casing of the casing; a DC link capacitor electrically connected to the DC input bus bar subassembly by a pair of connecting members, the pair of connecting members extending upward to the DC input bus bar The DC link capacitor is packaged into a gap in the housing; a gate driving circuit board; a plurality of power modules, the plurality of power modules being mounted on a lower side of the gate driving circuit board, The power module generates an AC power signal from the DC current received from the DC link capacitor; a second DC bus bar subassembly electrically connecting the DC link capacitor and the plurality of power modules, wherein The second DC bus bar subassembly bridges the gate drive circuit board and the DC link capacitor at a top; and a three-phase output AC bus bar a sub-assembly, the three-phase output AC bus bar sub-assembly includes three bus bars, the three bus bars are physically separated from each other, and the three bus bars comprise linearly arranged power module tabs, the power module tabs and the The linearly arranged output terminals of the plurality of power modules are electrically connected, wherein the three bus bars further comprise output tabs, each of the output tabs carrying a single phase of the AC power signal.