Bus bar assembly for use with a compact power conversion assembly

• US 20040062004A1
• Filed: 06/05/2003
• Published: 04/01/2004
• Est. Priority Date: 09/27/2002
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Kasunich, John M., Pfeifer, David W., Sheppard, Richard
• Granted Patent: US 6,885,553 B2
• Time in Patent Office: Days
• US Class Current: 361/699
• CPC Class Codes: F28D 2021/0029 Heat sinks
• CPC Class Codes: F28F 2265/10 for preventing overheating, e.g. heat shields thermal insulation F28F2270/00
• CPC Class Codes: F28F 3/12 Elements constructed in the shape of a hollow panel, e.g. with channels F28D1/02, F28D1/03 take precedence
• CPC Class Codes: H01L 23/473 by flowing liquids H01L23/4332, H01L23/4338 take precedence
• CPC Class Codes: H01L 25/16 the devices being of types provided for in two or more different main groups of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. forming hybrid circuits
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/14329 specially adapted for the configuration of power bus bars

Abstract

An electronic converter assembly comprising a first heat sink member having at least a first mounting surface and a length dimension, a plurality of power switching device modules wherein each module includes at least four separate power switching devices, the modules mounted to the first sink mounting surface such that the switching devices are aligned along the length of the sink member, each switching device including inter-converter connection terminals linkable to at least one of a load and a source and intra-converter connection terminals linkable, each intra-converter connection terminal linkable to at least one of a positive and a negative DC bus, first, second and third bus bars, each bus bar linked to the inter-converter connection terminals of at least first and second pairs of the power switching devices where the at least first and second pairs of power switching devices linked to specific ones of the bus bars are from different switching device modules and a linkage assembly including a plurality of conductors that link the intra-converter connection terminals of the power switching devices to form a power conversion topology.

Claims

1. An electronic converter assembly comprising:

a first heat sink member having at least a first mounting surface and a length dimension;

a plurality of power switching device modules wherein each module includes at least four separate power switching devices, the modules mounted to the first sink mounting surface such that the switching devices are aligned along the length of the sink member, each switching device including inter-converter connection terminals linkable to at least one of a load and a source and intra-converter connection terminals linkable, each intra-converter connection terminal linkable to at least one of a positive and a negative DC bus;

first, second and third bus bars, each bus bar linked to the inter-converter connection terminals of at least first and second pairs of the power switching devices where the at least first and second pairs of power switching devices linked to specific ones of the bus bars are from different switching device modules; and

a linkage assembly including a plurality of conductors that link the intra-converter connection terminals of the power switching devices to form a power conversion topology.

2. The apparatus of claim 1 wherein the linkage assembly links the intra-converter connection terminals to form at least one of a rectifier and an inverter.

3. The apparatus of claim 1 further including fourth, fifth and sixth bus bars and, wherein, the linkage assembly links the intra-converter connection terminals to form at least first and second converter bridges, the first, second and third bus bars linked to the inter-converter connection terminals of the switching devices that form the first converter bridge and the fourth, fifth and sixth bus bars linked to the inter-converter connection terminals of the switching devices that form the second converter bridge.

4. The apparatus of claim 1 wherein the modules include at least first and second modules, each of the modules includes first, second, third, fourth, fifth and sixth switching devices aligned in a row where the first and second devices form a first device pair, the third and fourth devices form a second device pair and the fifth and sixth devices form a third device pair on each module, the linkage assembly linking the intra-converter connection terminals of each of the first, third and fifth switching devices in each module to a positive DC bus and linking the intra-converter connection terminals of each of the second, fourth and sixth switching devices in each module to a negative DC bus, the first bus bar linked to the inter-converter connection terminals of the first pair of devices of each module, the second bus bar linked to the inter-converter connection terminals of the second pair of devices of each of each module and the third bus bar is linked to the inter-converter connection terminals of the third pair of devices of each of each module.

5. The apparatus of claim 4 wherein the modules further include a third module that includes first, second, third, fourth, fifth and sixth switching devices, the linking assembly further linking the intra-converter connection terminals of each of the first, third and fifth switching devices in the third module to the positive DC bus and linking the intra-converter connection terminals of each of the second, fourth and sixth switching devices in the third module to the negative DC bus, the first bus bar also linked to the inter-converter connection terminals of the first and second switching devices of the third module, the second bus bar linked to the inter-converter connection terminals of the third and fourth switching devices of the third module and the third bus bar linked to the inter-converter connection terminals of the fifth and sixth switching devices of the third module.

6. The apparatus of claim 5 wherein the modules further include a fourth module that includes first, second, third, fourth, fifth and sixth switching devices, the linking assembly further linking the intra-converter connection terminals of each of the first, third and fifth switching devices in the fourth module to the positive DC bus and linking the intra-converter connection terminals of each of the second, fourth and sixth switching devices in the fourth module to the negative DC bus, the first bus bar also linked to the inter-converter connection terminals of the first and second switching devices of the fourth module, the second bus bar linked to the inter-converter connection terminals of the third and fourth switching devices of the fourth module and the third bus bar linked to the inter-converter connection terminals of the fifth and sixth switching devices of the fourth module.

7. The apparatus of claim 6 wherein the linkage assembly links the intra-converter connection terminals to form at least one of a rectifier and an inverter.

8. The apparatus of claim 6 wherein the linkage assembly links the intra-converter connection terminals to form each of a rectifier and an inverter.

9. The apparatus of claim 6 wherein the first through fourth modules are a first module set, the apparatus further including a second heat sink member, a second module set and fourth, fifth and sixth bus bars, the second sink member having at least a first mounting surface and a length dimension, the second module set including fifth through eighth power switching device modules, the fifth through eighth modules mounted to the second sink mounting surface such that the switching devices that comprise the second module set are aligned along the length of the second sink member, the linkage assembly linking the intra-converter connection terminals of each of the first, third and fifth switching devices in each module to a positive DC bus and linking the intra-converter connection terminals of each of the second, fourth and sixth switching devices in each module to a negative DC bus, the fourth bus bar linked to the inter-converter connection terminals of the first and second switching devices on each of the fifth, sixth, seventh and eighth modules, respectively, the fifth bus bar linked to the inter-converter connection terminals of the third and fourth switching devices on each of the fifth, sixth, seventh and eighth modules, respectively, the sixth bus bar linked to the inter-converter connection terminals of the fifth and sixth switching devices on each of the fifth, sixth, seventh and eighth modules, respectively.

10. The apparatus of claim 9 further including a bracket member and a plurality of capacitors, the bracket member rigidly mounted between and separating the first and second heat sink members and having a bracket mounting surface that faces in the same direction as each of the first and second sink mounting surfaces, the capacitors mounted to the bracket mounting surface and linked to the linkage assembly conductors to form a part of the conversion topology.

11. The apparatus of claim 10 wherein the power devices of the first module set and the second module set are linked together via the linkage assembly conductors so as to form a rectifier and an inverter, respectively.

12. The apparatus of claim 1 wherein the sink member further includes oppositely facing lateral surfaces that extend along the length of the sink member such that the sink mounting surface and the first and second lateral surfaces together form first and second lateral edges, respectively and, wherein, the inter-converter and intra-converter connection terminals of each device extend in opposite directions from the device, the switching devices mounted to the sink mounting surface such that the inter-converter connection terminals are proximate the second lateral edge and the intra-converter connection terminals are proximate the first lateral edge.

13. The apparatus of claim 12 wherein the first bus bar includes a first bus spine member and a plurality of first bus rib members linked to the first spine member and extending laterally therefrom, each of the first rib members linked to at least two of the inter-converter terminals on one of the device modules and linked to no more than two inter-converter terminals on each of the device modules, the second bus bar including a second bus spine member and a plurality of rib members linked to the second bus spine member and extending laterally therefrom, each of the second rib members linked to at least two of the inter-converter terminals on one of the device modules and linked to no more than two inter-converter terminal on each of the device modules, the third bus bar including a third bus spine member and a plurality of rib members linked to the third spine member and extending laterally therefrom, each of the third rib members linked to at least two of the inter-converter terminals on one of the device modules and linked to no more than two inter-converter terminal on each of the device modules.

14. The apparatus of claim 13 wherein each of the modules includes first, second, third, fourth, fifth and sixth switching devices and, wherein, the first bus bar includes a separate rib member for each pair of first and second switching devices in each of the modules, the second bus bar includes a separate rib member for each pair of third and fourth switching devices in each of the modules and the third bus bar includes a separate rib member for each pair of fifth and sixth switching devices in each of the modules.

15. An electronic converter assembly comprising:

a heat sink member having at least a first mounting surface, a length dimension and first and second oppositely facing lateral surfaces that extend parallel to the length dimension, the mounting surface and first and second lateral surfaces forming first and second lateral edges, respectively;

first, second, third and fourth power switching device modules wherein each module includes first, second, third, fourth, fifth and sixth separate power switching devices, each switching device including inter-converter connection terminals and intra-converter connection terminals that extend from the device in opposite directions, the modules mounted to the sink mounting surface such that the switching devices are aligned along the length of the sink member with the intra-converter connection terminals proximate the first lateral edge and the inter-converter terminals proximate the second lateral edge; and

first, second and third bus bars, each of the bus bars linked to a sub-set of the connection terminals of switching devices in at least two different device modules.

16. The apparatus of claim 15 further including a linkage assembly including a plurality of conductors that link the intra-converter connection terminals of the power switching devices to form a power conversion topology.

17. The apparatus of claim 16 wherein the linkage assembly links the intra-converter connection terminals together to form at least one of an inverter topology and a rectifier topology.

18. The apparatus of claim 15 wherein the first bus bar is linked to the inter-converter connection terminals of the first and second switching devices in each of the switching modules, the second bus bar is linked to the inter-converter connection terminals of the third and fourth switching devices in each of the modules and the third bus bar is linked to the inter-converter connection terminals of the fifth and sixth switching devices in each of the modules.

19. An electronic converter assembly comprising:

a first heat sink member having at least a first mounting surface, a length dimension and first and second oppositely facing lateral surfaces that extend parallel to the length dimension, the mounting surface and first and second lateral surfaces forming first and second lateral edges, respectively;

a second heat sink member having at least a first mounting surface, a length dimension and first and second oppositely facing lateral surfaces that extend parallel to the length dimension, the mounting surface and first and second lateral surfaces of the second sink member forming first and second lateral edges, respectively;

first and second module sets, the first module set including first, second, third and fourth power switching device modules and the second module set including fifth, sixth, seventh and eighth power switching device modules wherein each module includes first, second, third, fourth, fifth and sixth separate power switching devices, each switching device including inter-converter connection terminals and intra-converter connection terminals that extend from the associated module in opposite directions, the modules in the first module set mounted to the first sink member mounting surface such that the switching devices are aligned along the length of the first sink member, the intra-converter connection terminals proximate the first lateral edge and the inter-converter terminals proximate the second lateral edge of the first sink member, the modules in the second module set mounted to the second sink member mounting surface such that the switching devices are aligned along the length of the second sink member, the intra-converter connection terminals proximate the first lateral edge and the inter-converter terminals proximate the second lateral edge of the second sink member;

first, second, third, fourth, fifth and sixth bus bars, each of the first, second and third bus bars linked to the inter-converter connection terminals of switching devices in at least two different device modules in the first module set and each of the fourth, fifth and sixth bus bars linked to the inter-converter connection terminals of switching devices in at least two different device modules in the second module set; and

a linkage assembly linking the intra-converter connection terminals of the switches in each of the first, second, third, fourth, fifth, sixth, seventh and eighth modules together to form the converter topology.

20. The apparatus of claim 19 wherein the linkage assembly links the intra-converter connection terminals together to form at least one of an inverter and a rectifier.

21. The apparatus of claim 19 wherein the first lateral surfaces of the first and second sink members face each other.

22. An electronic converter assembly comprising:

at least a first heat sink member having at least a first mounting surface, a length dimension and first and second oppositely facing lateral surfaces, the mounting surface and the first and second lateral surfaces forming first and second lateral edges, respectively;

at least first and second power switching device modules wherein each module includes first, second, third, fourth, fifth and sixth separate power switching devices, each switching device including inter-converter connection terminals and intra-converter connection terminals that extend from the device in opposite directions, the modules mounted to the first mounting surface with the switching devices aligned along the length of the sink member, the intra-converter connection terminals proximate the first lateral edge and the inter-converter terminals proximate the second lateral edge;

first, second and third bus bars, each of the bus bars linked to at least a subset of the switching device inter-converter connection terminals of each of the modules; and

a linkage assembly linking the intra-converter connection terminals of the switches in each of the modules together to form the converter topology.

23. The apparatus of claim 22 wherein the linkage assembly includes a positive DC but and a negative DC bus, the linkage assembly links the intra-converter connection terminals of each of the first, third and fifth switching devices in each module to the positive DC bus and linking the intra-converter connection terminals of each of the second, fourth and sixth switching devices in each module to the negative DC bus, the first bus bar is linked to the inter-connection terminals of the first and second switching devices in each of the modules, the second bus bar is linked to the inter-connection terminals of the third and fourth switching devices in each of the modules and the third bus bar is linked to the inter-connection terminals of the fifth and sixth switching devices in each of the modules.

24. A bus bar assembly for use with an electronic converter assembly having a plurality of switching device modules, each module including first, second and third pairs of power switching devices, each pair including a first device linked to a positive DC bus and a second device linked to a negative DC bus, the first and second devices of each pair having adjacent inter-converter connection terminals aligned along an edge of the sink member, the assembly comprising:

a first rigid bus bar linkable to the inter-converter connection terminals of the first pair of switching devices in each module;

a second rigid bus bar linkable to the inter-converter connection terminals of the second pair of switching devices in each module; and

a third rigid bus bar linkable to the inter-converter connection terminals of the third pair of switching devices in each module.

25. The apparatus of claim 24 wherein each of the first, second and third bus bars includes an elongated spine member and a plurality of rib members that extend in the same direction from the spine member, the first bus bar rib members spaced apart along the spine member so as to align with the first switching device pairs on each of the modules and linkable to the first switching device pair connection terminals, the second bus bar rib members spaced apart along the spine member so as to align with the second switching device pairs on each of the modules and linkable to the second switching device pair connection terminals and the third bus bar rib members spaced apart along the spine member so as to align with the third switching device pairs on each of the modules and linkable to the third switching device pair connection terminals.

26. The apparatus of claim 25 wherein each of the first, second and third bus bars is formed of steel.