CN205160384U - Inverter components - Google Patents

Abstract

The utility model provides an inverter assembly. The inverter assembly includes: a casing, the casing is equipped with: a DC input bus bar subassembly; a three-phase output AC bus bar subassembly; a DC side capacitor, and the DC side capacitor is electrically connected to the DC input bus bar assembly; a second DC bus bar subassembly electrically connecting the DC side capacitor to a plurality of power modules, wherein the plurality of power modules are electrically connected to the three-phase output AC bus bar an assembly; and a cooling subassembly associated with the plurality of power modules.

Description

Inverter components

technical field

The present invention generally relates to an inverter assembly, and more particularly but not limited to an inverter assembly comprising an inverter assembly configured to convert a DC input into a three-phase AC output Structure.

Background technique

Today, there are many applications that require converting a DC input to an AC output. For example, DC power sources such as fuel cell systems, batteries, and/or supercapacitors can produce DC power that must be converted to an AC output such as a three-phase AC output to be supplied to an AC load such as in an electric or hybrid vehicle Three-phase AC motor. Most conventional inverter designs are unsuitable for electric vehicle applications due to their large footprint and low power capacity. Therefore, it is desirable to obtain an inverter assembly that can provide sufficient power for electric vehicle applications and has a small footprint for easy packaging.

Utility model content

According to multiple embodiments, the utility model discloses an inverter assembly, which includes: (a) a casing, the casing is equipped with: (i) a DC input bus bar subassembly; (ii) a three-phase output AC a bus bar subassembly; (iii) a DC side capacitor electrically connected to the DC input bus bar subassembly; (iv) a second DC bus bar subassembly electrically connected to the DC side capacitor and a plurality of power modules, wherein the plurality of power modules can electrically connected to a three-phase output AC bus bar subassembly; and (v) a cooling subassembly associated with a plurality of power modules.

Preferably, said three-phase output AC busbar subassembly comprises three substantially symmetrical output tabs, each of said output tabs carrying a single phase of an AC power signal generated by said plurality of power modules.

Preferably, the three-phase output AC bus bar subassembly includes three bus bars, each of the three bus bars includes: a bar body, the bar body has a front surface and a rear surface; a power module tab, the first power module tab of the plurality of power module tabs is connected to the first power module of the inverter assembly, and the second of the plurality of power module tabs is a power module tab associated with a second power module of the inverter assembly, the plurality of power module tabs extending away from the rear surface; and an output tab extending from the front surface ; and the bar body of the first of the three bus bars is positioned behind the bar body of the second of the three bus bars, and the third of the three bus bars Positioned in front of the second of the three bus bars.

Advantageously, said second DC bus bar subassembly comprises a pair of bus bars, each of said pair of bus bars comprising: a bar body; a plurality of input tabs extending from said bar extending from a first end of the main body, the plurality of input tabs coupled to the DC link capacitor; and a plurality of output tabs, wherein the plurality of output tabs are arranged at opposite sides of the bar body relative to each other. on both sides; the bar bodies of the pair of bus bars overlap each other but are spaced apart from each other; The plurality of input tabs of the second bus bar in the bar are in alternating and aligned relationship.

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

Preferably, one output tab of the first bus bar in the pair of bus bars and one output tab of the second bus bar in the pair of adjacent bus bars are electrically connected to One power module in the plurality of power modules.

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 has recesses to accommodate a plurality of output tabs of the second DC bus bar subassembly.

Preferably, the heat dissipation components of the plurality of power modules are disposed in a cavity formed by side walls of the cooling subassembly, wherein the gasket disposed between the plurality of power modules and the gate drive circuit board Fluid isolation in the cavity.

Preferably, the cooling subassembly includes an input port and an output port, and the input port and the output port are arranged in the middle of the housing and arranged between the heat dissipation components of the plurality of power modules.

Preferably, the cooling subassembly comprises: an input port arranged on the first end of the lower side of the housing; and an output port arranged on the lower side of the housing. on the lower second end.

Preferably, the inverter assembly further includes a terminal block, and the terminal block supportively connects the DC input bus bar subassembly with the lower shell of the casing.

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 are embedded in the DC side capacitor, wherein the positive output A bus bar and the negative output bus bar are electrically connected to a plurality of input tabs of the second DC bus bar subassembly.

Preferably, the DC input busbar subassembly is electrically connected to a first connector and a second connector, each of the first connector and the second connector being at least partially embedded in the DC side capacitor.

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

According to some embodiments, the utility model discloses an inverter assembly, which includes: (a) a casing, the casing is equipped with: (i) a DC input bus bar subassembly; (ii) a three-phase output AC bus bar a sliver assembly having a symmetrical arrangement of output tabs each carrying a single phase of the AC power signal; (iii) a DC side capacitor electrically connected to the DC input bus sliver Components; (iv) a gate drive circuit board; (v) a plurality of power modules mounted on the gate drive circuit board, the plurality of power modules generating the AC power signal; and (vi ) A second DC bus bar subassembly electrically connects the DC side capacitor to a plurality of power modules, wherein the plurality of power modules can be electrically connected to the three-phase output AC bus bar subassembly.

Advantageously, said gate drive circuit board includes notches allowing input tabs of said plurality of power modules to engage with a plurality of positive output tabs and negative output tabs of said second DC bus bar subassembly direct connection.

Preferably, the gate drive circuit board includes additional notches allowing direct connection of the power module tabs of the three-phase output AC bus bar subassembly to the output tabs of the plurality of power modules.

Preferably, the DC side capacitor is fixed by packaging material.

According to some embodiments, the utility model discloses an inverter assembly, which includes (a) a casing, the casing can include a cover and a lower casing, wherein the lower casing contains: (i) a DC input bus bar assembly, the DC input bus subassembly is mounted to the side wall of the lower shell of the housing; (ii) a DC side capacitor, the DC side capacitor is electrically connected to the DC input bus subassembly using a pair of connectors, the one A pair of connectors extending up to the DC input bus bar subassembly, the DC side capacitors are encapsulated into the void of the housing; (iii) a gate drive circuit board; (iv) a plurality of power modules, the plurality of power modules mounted On the lower side of the gate drive circuit board, the plurality of power modules generate an AC power signal using the DC power received from the DC side capacitor; (v) a second DC bus bar subassembly, the second DC bus bar subassembly will a DC link capacitor electrically connected to the plurality of power modules, wherein a second DC busbar subassembly bridges the gate drive circuit board and the DC link capacitors above; and (vi) a three-phase output AC busbar subassembly, the three-phase output AC The bus bar subassembly includes three bus bars, the three bus bars can be physically separated from each other, and each of the three bus bars includes linearly arranged power module tabs, and the power module tabs are linearly aligned with the plurality of power modules. The arrayed output terminals are electrically connected, wherein the three bus bars also include output tabs, each of which carries a single phase of the AC power signal.

Description of drawings

Certain embodiments of the invention are shown in the accompanying drawings. It should be understood that the drawings are not necessarily to scale and that details that are not necessary for an understanding of the technology or that render other details difficult to understand may be omitted. It should be understood that the techniques of the present invention are not limited to the specific embodiments shown here.

1 is a perspective view of an exemplary drive train that can include an inverter assembly of the present invention;

2 is a perspective view of an exemplary inverter assembly;

3 is an exploded perspective view of the exemplary inverter assembly of FIG. 2;

Figure 4 is an overturned view of the exemplary inverter assembly with the top cover removed;

5A, 5B and 5C are different views of an exemplary DC bus bar subassembly;

6 is a perspective view of a portion of another exemplary DC bus bar subassembly;

7 is a perspective view of an exemplary DC bus subassembly connected to a cable;

8 is a top view showing an exemplary DC link capacitor of an inverter assembly, wherein the DC link capacitor may include a capacitor bank;

9A is a perspective view of an exemplary DC input bus bar connecting a DC link capacitor to a power module;

9B is an exploded perspective view of another exemplary DC input bus bar of FIG. 9A;

9C is a cross-sectional view of the exemplary DC input bus bar of FIGS. 9A and 9B;

10 is a perspective view of an exemplary DC input bus bar installed into an inverter assembly;

11 is a partially exploded perspective view of an exemplary power module;

12 is a perspective view of an exemplary three-phase output AC bus bar subassembly;

13 is another perspective view of an exemplary three-phase output AC bus bar subassembly;

14 is a perspective view of exemplary three bus bars of a three-phase output AC bus bar subassembly;

Figure 15 is an overturned view of an exemplary three-phase output AC bus bar subassembly installed into an inverter assembly;

16 is a perspective view of an exemplary three-phase output AC bus bar subassembly associated with an electrical cable;

Figure 17 is an exploded view of an exemplary cooling assembly;

18A-18C illustrate exemplary alternative cooling assemblies.

detailed description

Although the technology of the present utility model can be implemented in many different ways, only a few specific embodiments are shown in the accompanying drawings and only these specific embodiments are described in detail in the description. It should be understood that the present invention The disclosure is only an example of the technical principle of the present invention, and does not limit the technology of the present invention to the illustrated embodiments.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, unless stated otherwise, the singular forms "a" and "the" are intended to include the plural forms as well. It should also be understood that when used in the specification, the term "comprising" specifies the presence of stated features, integers, steps, operations, elements and/or parts, but does not exclude the presence or addition of one or more other features, integers , steps, operations, elements, parts and/or combinations thereof.

It should be understood that like reference numerals are used throughout the drawings to designate like or similar elements and/or components referred to herein. It should also be understood that some of the drawings are merely exemplary representations of the present disclosure. Therefore, for image clarity, some of the components may not be exactly their actual size.

In general, the present disclosure relates to inverter assemblies and their manufacturing methods and uses. An exemplary inverter assembly may include a symmetrical structure configured to convert DC input power to AC output power.

Some embodiments may include a symmetrical DC input, a symmetrical AC output, a gate drive circuit board, and a controller. The gate drive board and controller can be connected with two inverter power modules in parallel. The power modules 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 components, Used to convert DC current into AC current. The total rms current can exceed that typically obtainable with a single commercially available power module. The DC input section may include a DC input bus and a DC bus subassembly. The DC bus subassembly may have a layered design symmetrical structure including positive and negative plates substantially overlapping each other. The positive plate may be coupled to the positive terminal of the DC input bus through a plurality of positive input tabs. The negative plate may be coupled to the negative terminal of the DC input bus through a plurality of negative input tabs. The positive plate may have two or more positive output tabs and two or more negative output tabs coupled to the input terminals of the two inverter power modules.

The AC output part can include a plurality of output bus bars, and each output bus bar has a symmetrical structure. In one embodiment, the AC output unit can provide a three-phase AC power signal. Each of the output bus bars may correspond to a channel (phase) of the three-phase AC power signal. Each bus bar may include: two input tabs coupled to output terminals of each channel of the two inverter power modules; and output tabs coupled to The AC output terminal of the inverter. The output tabs may be arranged approximately the same distance from the two input tabs of each AC bus bar. These and other advantages of the present disclosure will be described in more detail below with reference to the accompanying drawings.

Referring now to FIG. 1 , the positioning of two inverter assemblies, such as exemplary inverter assembly 102 , is shown. An inverter assembly may be disposed on the exemplary driveline 104 .

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

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

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

Both the positive bus bar 120 and the negative bus bar 122 may have a bar body extending between their respective input and output tabs. In one embodiment, the positive bus bar 120 can have a positive bar body 132 , while the negative bus bar can include a negative bar body 134 .

In some embodiments, the positive bus bar 120 and the negative bus bar 122 are similar in shape 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 may have a first segment 136 and a second segment 138 . In some embodiments, first segment 136 and second segment 138 may be positioned in a substantially right-angle configuration relative to each other. That is, the first segment 136 may extend perpendicularly from the second segment 138 .

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

The input tabs on both the positive bus bar 120 and the negative bus bar 122 extend from their respective bar bodies. For example, the positive input tab 124 can extend in a linear alignment with the first segment 136 of the positive strip body 132 . The positive output tab 126 can extend rearwardly from the second section 138 of the positive bus bar 120 .

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

In one embodiment, the negative output tab 130 of the negative bus bar 122 may be offset to one side of the second segment 142 of the negative bar body 134 . Conversely, the positive output tab 126 of the positive bus bar 120 may be offset to one side of the second segment 138 of the positive bar body 132 . In one embodiment, the negative output tab 130 and the positive output tab 126 may be spaced apart from each other due to their positioning on respective sides of the strip body with which they are associated. Similarly, the positive input tab 124 and the negative input tab 128 can be spaced apart from each other and can be separately secured to the terminal block, as will be described in more detail below.

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

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

For example, terminal block 146 can provide a mounting surface to support DC bus bar 112 . The terminal block 146 is mountable to the inner side wall of the lower housing 108 and the lower support 148 of the lower housing 108 .

In some embodiments, the input core 149 may be secured to the terminal block 146 using a pressure plate 159 . A spacer 152 can be arranged between the input core 149 and the pressure plate 150 . In one embodiment, spacer 152 may be a block of foamed silicon, although other materials known to those skilled in the art may equally be utilized in light of this disclosure.

Another example of a DC bus bar 112 is shown in FIG. 6 . In this embodiment, the input tabs 141 and 143 can slope upwards and outwards from the bar body along the reference line A, rather than in a linear arrangement. Also, the input tabs 141 and 143 can extend from side edges of the bar body, and the output tabs 145 and 147 can extend in line with the reference line B. Referring to FIG. Indeed, reference line A and reference line B can be substantially perpendicular to each other.

Referring to FIG. 7, the positive input tab 124 and the negative input tab 128 can be associated with input cables 158 and 160, respectively, as shown.

FIG. 8 is a top view illustrating an exemplary DC link capacitor 114 of an inverter assembly, wherein the DC link capacitor may comprise a capacitor bank. As shown in FIG. 8 , in some embodiments, the DC bus bar 112 may be electrically connected to the DC link capacitor 114 through a first connecting member 154 and a second connecting member 156 . (According to the polarity arrangement scheme provided by the DC bus bar 112, both the first connecting piece 154 and the second connecting piece 156 can be a positive connecting piece or a negative connecting piece). According to some embodiments, the first connector 154 and the second connector 156 may be coupled 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 into the DC link capacitor 114 during the packaging process.

Additionally, the positive output bus bar 162 may be embedded into the DC link capacitor 114 together with the negative output bus bar 164 . Positive output bus bar 162 and 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, the positive output tabs 166A- 166C and the negative output tabs 168A- 168C can be positioned in a linear alignment with one another. 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 by an encapsulation material, which can 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 to 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 FIGS. 9A-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 "DC input bus bar 170". The DC input bus bar 170 can include a positive bus bar 174 and a negative bus bar 176 which can be arranged in cooperative relationship similar to the DC bus bar 112 described above.

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 connected to the DC side by connecting the plurality of positive input tabs 178A-178C of the positive bus bar 174 to the positive output tabs 166A-166C of the positive output bus bar 162 of the DC side capacitor 114. The positive output bus bar 162 of capacitor 114 is connected. Likewise, negative bus bar 176 can be connected to DC side capacitor 114 by connecting multiple negative input tabs 180A-180C of negative bus bar 176 to negative output tabs 168A-168C of negative output bus bar 164 of DC side capacitor 114. The negative output bus bar 164 is connected.

The plurality of positive input tabs 178A- 178C and the plurality of negative input tabs 180A- 180C can be alternately arranged and configured in a line.

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

Positive bus bar 174 can include a pair of positive output tabs 182A and 182B, while 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 positive output tab 182A can be located proximal to negative output tab 184b and positive output tab 182B can be located adjacent to negative output tab 184B. near side.

As shown most clearly in FIG. 10 , the DC input bus bar 170 can provide electrical connection between the DC link capacitor 114 and the power module of the gate drive circuit board 116 , which will be described in more 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 through openings in the gate drive circuit board 116 . The positive output tab 182B and the negative output tab 184B can be coupled to a second power module 186 .

FIG. 11 is a partially exploded perspective view showing exemplary first and second power modules with the gate driving 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 and negative input terminals. 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 connected to the bottom of the lower housing 108 with a gasket, such as gasket 194 . In various embodiments, a gasket can be used to create a fluid impermeable seal that prevents fluid from the cooling subassembly from entering the lower housing 108 . As will be described in greater detail herein, the cooling subassembly enables the heat dissipation components of the power modules 186 and 188 to be exposed to the coolant. The coolant improves the performance of the power module by removing excess heat from 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 the 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, while the second power module 188 can include output terminals 189A, 189B, and 189C.

Figures 12 and 13 together illustrate an exemplary three-phase output AC bus bar subassembly (hereinafter "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 can include a bar body. For example, the first bus bar 202 can include a bar body 208 , the second bus bar 204 can include a bar body 210 , and the third bus bar 206 can include a bar body 212 . Each of the first bus bar 202 , the second bus bar 204 and the third bus bar 206 can include a front surface and a rear surface. For example, the bar body 208 of the first bus bar 202 can include a front surface 214 and a rear surface 216 . The bar body 210 of the second bus bar 204 can include a front surface 218 and a rear surface 220 , while the bar body 212 of the third bus bar 206 can 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 can be spaced apart from one another 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 can 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 spaces 205 and 207 may be filled with an electrically insulating material. In other embodiments, the front and/or rear surfaces of the first bus bar 202 , the second bus bar 204 and the third bus bar 206 can be coated with an insulating layer of a material suitable for providing electrical insulation.

Each of the first bus bar 202, the second bus bar 204, and the third bus bar 206 can also include a plurality of power module tabs that can connect each bus bar to the first power supply module. The module 186 is electrically connected to the second power module 188 (see FIG. 11 ). For example, first bus bar 202 can include power module tabs 226 and 228 , while 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 the bus bars can be spaced apart from each other to allow the bus bar to be connected to each power module.

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

In some embodiments, first bus bar 202 , second bus bar 204 , and third bus bar 206 can be placed in a nested but offset relationship to one another. For example, the second bus bar 204 can be arranged in front of the first bus bar 202 , and the third bus bar 206 can be arranged in front of the second bus bar 204 . Also, the bus bars can be staggered or offset from each other. 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 tab 230 of the second bus bar 204 can be positioned between the power module tab 226 of the first bus bar 202 and the power module tab 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 may 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 may 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 length of the power module tabs 234, 236 of the third of the three bus bars 206 may be greater than the length of the power module tabs 230, 232 of the second of the three bus bars 204 . Also, the length of the power module tabs 230 , 232 of the second of the three bus bars 204 may be greater than the length of the power module tabs 226 , 228 of the first of the three bus bars 202 .

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

In one embodiment, the output tabs 238, 240, and 242 can be arranged such that their positions are symmetrical relative 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 meandering portion 244 that Output tab 240 can be positioned between output tabs 238 and 242 .

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

The mounting plate 246 can be coupled to a second bus bar and a third bus bar of the three bus bars described above (eg, as shown in FIG. 12 ).

Referring now to FIGS. 14 and 15 (as well as FIGS. 11 , 12, and 13), according to some embodiments, the power module tabs 226 and 228 of the first bus bar 202 (see FIG. 12 ) can be connected to the output terminals 187A of the first power module 186. (See also FIG. 11 ) is connected to the output terminal 189A of the second power supply module 188 . The second bus bar 204 may 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 may 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, such as cable 250, can be coupled to output tabs 238, 240, and 242 of AC bus bar 118 (see FIGS. 14-15).

FIG. 17 shows an exemplary cooling subassembly 252 that can include a cooling cavity 254 , a gasket 256 , a cover plate 258 , an input port 260 and an output port 262 , and a purge port 264 . Generally, the cooling cavity 254 may be formed by side walls 266 formed in the lower housing 108 of the housing. The heat dissipation components 268 and 270 of the power modules 186 and 188 , respectively, can be exposed to the cooling cavity 254 . As mentioned above, the power modules 186 and 188 are separated by gaskets to prevent fluid in the cooling cavity 254 from entering the housing.

When the cover plate 258 is attached to the lower shell 108 of the housing, a pump (not shown) can be used to pump fluid such as coolant into the cooling cavity 254 through the input port 260 and can be pumped out of the fluid such as coolant. . If desired, purge port 264 may be used to remove trapped air from cooling cavity 254 .

In one embodiment, the input port 260 and the output port 262 can be arranged near the center of the housing, which can help provide an equal flow of fluid to each cooling cavity.

18A-18C collectively illustrate another embodiment of a cooling subassembly. In one embodiment, the first power module 186 and the second power module 188 are mountable to the board 280 . The side walls (see eg 266 in Figure 17) define a cooling cavity (see eg 254 in Figure 17). Heat sink components 268 and 270 can be positioned within cooling cavity 254 . The input port 286 may be positioned on one end of the cooling cavity 254 and the output port 288 may be positioned on the opposite end of the cooling cavity 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 sink members 268 and 270 to provide heat for each Each power module provides a roughly equal share of coolant. In other embodiments (see, e.g., FIG. 17 ), the inlet port may be positioned approximately midway between heat sinks 268 and 270 such that coolant may enter from approximately the middle, thereby allowing coolant to flow bidirectionally (i.e., along the heat sink 268 in one direction and heat sink 270 in the other direction) and are collected in the generally middle to provide a generally equal share of coolant to each power module, thereby reducing the differential temperature of the power modules .

While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. The above description is not intended to limit the scope of the inventive technology to the specific forms set forth herein. Therefore, any of the above-described exemplary embodiments should not limit the scope of the preferred embodiments. It should be understood that the foregoing description is illustrative rather than restrictive. This description is intended to cover alternatives, modifications and equivalents within the spirit and scope of the technology of the present invention as defined by the appended claims, as well as others that may occur to those skilled in the art. Therefore, the protection scope of the present utility model should not be determined with reference to the above description, but should be determined with reference to the appended claims and all their equivalent scopes.

Claims (20)

1. an inverter assembly, described inverter assembly comprises:

Housing, described housing is equipped with:

Direct current input busbar sub-component;

Three-phase output AC busbar sub-component;

DC bus capacitor device, described DC bus capacitor device is electrically connected to described direct current input busbar sub-component;

Second direct current busbar sub-component, described DC bus capacitor device is electrically connected with multiple power module by described second direct current busbar sub-component, and wherein, described multiple power module is electrically connected to described three-phase output AC busbar sub-component; With

Cooling sub-component, described cooling sub-component and described multiple power module are connected.

2. inverter assembly according to claim 1, wherein, described three-phase output AC busbar sub-component comprises the output tab of three almost symmetries, and each described output tab all carries the single-phase of the ac supply signal produced by described multiple power module.

3. inverter assembly according to claim 1, wherein, described three-phase output AC busbar sub-component comprises:

Three busbars, each in described three busbars includes:

Bar main body, described bar main body has front surface and rear surface;

Spaced multiple power module tab, the first power module tab in described multiple power module tab and the first power module of described inverter assembly are connected, and the second source module tab in described multiple power module tab and the second source module of described inverter assembly are connected, and described multiple power module tab is extended described rear surface;

Export tab, described output tab extends from described front surface; And

After the bar main body of second busbar of bar agent localization in described three busbars of the first busbar in described three busbars, and the 3rd busbar in described three busbars is positioned at before described second busbar in described three busbars.

4. inverter assembly according to claim 1, wherein, described second direct current busbar sub-component comprises:

A pair busbar, each in described a pair busbar includes:

Bar main body;

Multiple input tab, described multiple input tab extends from the first end of described bar main body, and described multiple input tab is connected to described DC bus capacitor device; With

Multiple output tab, wherein

Described multiple output tab is relative to each other arranged on the relative both sides of described bar main body;

The described bar main body of described a pair busbar is mutually overlapping up and down but be spaced from each other; And

Multiple input tabs of the first busbar in described a pair busbar are arranged to strike a bargain with multiple input tabs of the second busbar in described a pair busbar and replace and the relation of aliging.

5. inverter assembly according to claim 4, wherein, multiple output tabs of described second busbar in multiple output tab of described first busbar in described a pair busbar and described a pair busbar are adjacent.

6. inverter assembly according to claim 5, wherein, an output tab of one of described first busbar in described a pair busbar described second busbar exported in tab and described a pair busbar adjacent is with it electrically connected to a power module in described multiple power module.

7. inverter assembly according to claim 1, described inverter assembly also comprises gate driver circuit plate, and wherein, described multiple power module is electrically connected to described gate driver circuit plate.

8. inverter assembly according to claim 7, wherein, described gate driver circuit plate has recess, to hold multiple output tabs of described second direct current busbar sub-component.

9. inverter assembly according to claim 1, wherein, the thermal component of described multiple power module is arranged in the chamber formed by the sidewall of described cooling sub-component, wherein, is arranged in packing ring between described multiple power module and gate driver circuit plate by the fluid isolation in described chamber.

10. inverter assembly according to claim 9, wherein, described cooling sub-component comprises input port and delivery outlet, and described input port and described delivery outlet are arranged in the middle part of described housing, and between the thermal component being arranged in described multiple power module.

11. inverter assemblies according to claim 9, wherein, described cooling sub-component comprises: input port, and described input port is arranged on the first end of the downside of described housing; And delivery outlet, described delivery outlet is arranged on the second end of described downside of described housing.

12. inverter assemblies according to claim 1, described inverter assembly also comprises terminal block, and described terminal block supports the lower casing that ground connects described direct current input busbar sub-component and described housing.

13. inverter assemblies according to claim 1, described inverter assembly also comprises positive pole and exports busbar and negative pole output busbar, described positive pole exports busbar and described negative pole output busbar is embedded in described DC bus capacitor device, wherein, described positive pole output busbar and described negative pole export multiple input tabs that busbar is electrically connected to described second direct current busbar sub-component.

14. inverter assemblies according to claim 1, wherein, described direct current input busbar sub-component is electrically connected with the first connector and the second connector, and each in described first connector and described second connector is embedded in described DC bus capacitor device all at least in part.

15. inverter assemblies according to claim 14, wherein, described direct current input busbar sub-component comprises a pair busbar, and each busbar in described a pair busbar includes:

Input tab;

Export tab; With

Bar main body, the first paragraph of described input tab and described bar main body extends alignedly, and the second segment that described output tab is orthogonal to described bar main body extends.

16. 1 kinds of inverter assemblies, described inverter assembly comprises:

Housing, described housing is equipped with:

Direct current input busbar sub-component;

Three-phase output AC busbar sub-component, described three-phase output AC busbar sub-component has the output tab arranged symmetrically, and each described output tab all carries the single-phase of ac supply signal;

DC bus capacitor device, described DC bus capacitor device is electrically connected to described direct current input busbar sub-component;

Gate driver circuit plate;

Multiple power module, described multiple power module is installed on described gate driver circuit plate, and described multiple power module produces described ac supply signal; With

Second direct current busbar sub-component, described DC bus capacitor device is electrically connected with described multiple power module by described second direct current busbar sub-component, and wherein, described multiple power module is electrically connected to described three-phase output AC busbar sub-component.

17. inverter assemblies according to claim 16, wherein, described gate driver circuit plate comprises recess, and described recess allows the input tab of described multiple power module and multiple positive poles of described second direct current busbar sub-component to export tab and negative pole to export tab and be directly connected.

18. inverter assemblies according to claim 16, wherein, described gate driver circuit plate comprises additional recesses, and described additional recesses allows the power module tab of described three-phase output AC busbar sub-component to be directly connected with the output tab of described multiple power module.

19. inverter assemblies according to claim 16, wherein, described DC bus capacitor device is fixed by encapsulating material.

20. 1 kinds of inverter assemblies, described inverter assembly comprises:

Housing, described housing comprises lid and lower casing, and wherein, described lower casing accommodates:

Direct current input busbar sub-component, described direct current input busbar sub-component is installed on the sidewall of described lower casing of described housing;

DC bus capacitor device, described DC bus capacitor device utilizes a pair connector to be electrically connected to described direct current input busbar sub-component, described a pair connector extends up to described direct current input busbar sub-component, and described DC bus capacitor device is packaged in the space in described housing;

Gate driver circuit plate;

Multiple power module, described multiple power module is arranged on the downside of described gate driver circuit plate, and described multiple power module utilizes the direct current received from described DC bus capacitor device to produce ac supply signal;

Second direct current busbar sub-component, described second direct current busbar sub-component is electrically connected described DC bus capacitor device and described multiple power module, wherein, described second direct current busbar sub-component gate driver circuit plate described in bridge joint and described DC bus capacitor device up; With

Three-phase output AC busbar sub-component, described three-phase output AC busbar sub-component comprises three busbars, described three mutual physical separation of busbar are opened, described three busbars comprise linearly aligned power module tab, described power module tab is electrically connected with the linearly aligned lead-out terminal of described multiple power module, wherein, described three busbars also comprise output tab, and each described output tab all carries the single-phase of described ac supply signal.