THREE-LEVEL POWER CONVERTER AND POWER UNIT THEREOF

• US 20160094153A1
• Filed: 07/14/2015
• Published: 03/31/2016
• Est. Priority Date: 09/26/2014
• Status: Active Grant

• Current Assignee: Delta Electronics Incorporated
• Original Assignee: Delta Electronics Incorporated
• Inventors: LI, Yan, ZHONG, Qinglong, WEN, Senlin, HU, Guangcheng
• Granted Patent: US 9,520,810 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H02M 7/487 Neutral point clamped inverters
• CPC Class Codes: H02M 7/797 using semiconductor devices only

Abstract

Provided are a three-level power converter and a power unit thereof. The power unit includes a power switch module and a laminated busbar structure. The power switch module includes a first power semiconductor switch module and a clamping diode module, which have a first, second, and third terminal respectively. The laminated busbar structure includes a third, second, and first busbar layer laminated on the power switch module. The third busbar layer includes a first sub-busbar connecting to the first terminal of the first power semiconductor switch module, a second sub-busbar connecting to the third terminal of the first power semiconductor switch module and the first terminal of the clamping diode module, a third sub-busbar connecting to the second terminal of the clamping diode module and the third terminal of the second power semiconductor switch module, and a fourth sub-busbar connecting to the second terminal of the second power semiconductor switch module.

Claims

1. A power unit comprising a power switch module and a laminated busbar structure, wherein,

the power switch module comprising:

a first power semiconductor switch module having a first terminal, a second terminal and a third terminal;

a clamping diode module having a first terminal, a second terminal and a third terminal; and

a second power semiconductor switch module having a first terminal, a second terminal and a third terminal;

the laminated busbar structure comprising a third busbar layer, a second busbar layer and a first busbar layer laminated on the power switch module;

wherein,

the first busbar layer electrically connects to the third terminal of the clamping diode module;

the second busbar layer electrically connects to the second terminal of the first power semiconductor switch module and the first terminal of the second power semiconductor switch module respectively;

the third busbar layer comprises a first sub-busbar, a second sub-busbar, a third sub-busbar and a fourth sub-busbar;

the first sub-busbar electrically connects to the first terminal of the first power semiconductor switch module;

the second sub-busbar electrically connects to the third terminal of the first power semiconductor switch module and the first terminal of the clamping diode module respectively;

the third sub-busbar electrically connects to the second terminal of the clamping diode module and the third terminal of the second power semiconductor switch module respectively; and

the fourth sub-busbar electrically connects to the second end of the second power semiconductor switch module.

2. The power unit according to claim 1, wherein an insulation structure is set between every two of the third busbar layer, the second busbar layer and the first busbar layer.

3. The power unit according to claim 1, wherein,

the first sub-busbar comprises a connection hole electrically connecting to the first terminal of the first power semiconductor switch module;

the second busbar layer comprises a connection hole electrically connecting to the second terminal of the first power semiconductor switch module;

the second sub-busbar comprises a connection hole electrically connecting to the third terminal of the first power semiconductor switch module;

the second busbar layer comprises through holes respectively corresponding to the connection hole of the first sub-busbar and the connection hole of the second sub-busbar;

the first busbar layer comprises through holes respectively corresponding to the connection hole of the first sub-busbar, the connection hole of the second sub-busbar and the connection hole of the second busbar layer.

4. The power unit according to claim 1, wherein,

the second sub-busbar comprises a connection hole electrically connecting to the first terminal of the clamping diode module;

the third sub-busbar comprises a connection hole electrically connecting to the second terminal of the clamping diode module;

the first busbar layer comprises a connection hole electrically connecting to the third terminal of the clamping diode module;

the second busbar layer comprises through holes respectively corresponding to the connection hole of the second sub-busbar, the connection hole of the third sub-busbar and the connection hole of the first layer busbar; and

the first busbar layer comprises through holes respectively corresponding to the connection hole of the second sub-busbar and the connection hole of the third sub-busbar.

5. The power unit according to claim 1, wherein,

the second busbar layer comprises a connection hole electrically connecting to the first terminal of the second power semiconductor switch module;

the fourth sub-busbar comprises a connection hole electrically connecting to the second terminal of the second power semiconductor switch module;

the third sub-busbar comprises connection holes electrically connecting to the third terminal of the second power semiconductor switch module;

the second busbar layer comprises through holes respectively corresponding to the connection hole of the fourth sub-busbar and the connection hole of the third sub-busbar; and

the first busbar layer comprises through holes respectively corresponding to the connection hole of the fourth sub-busbar, the connection hole of the third sub-busbar and the connection hole of the second busbar layer.

6. The power unit according to claim 1, wherein,

the first terminal of the first power semiconductor switch module comprises two first sub-terminals connected with each other, and the first sub-busbar comprises two connection holes electrically connecting to the two first sub-terminals respectively;

the second terminal of the first power semiconductor switch module comprises two second sub-terminals connected with each other, and the second busbar layer comprises two connection holes electrically connecting to the two second sub-terminals respectively;

the second sub-busbar comprises a connection hole electrically connecting to the third terminals of the first power semiconductor switch module;

the second busbar layer comprises through holes respectively corresponding to the connection holes of the first sub-busbar and the connection hole of the second sub-busbar; and

the first busbar layer comprises through holes respectively corresponding to the connection holes of the first sub-busbar, the connection holes of the second sub-busbar and the connection hole of the second busbar layer.

7. The power unit according to claim 1, wherein,

the first terminal of the clamping diode module comprises two first sub-terminals connected with each other, and the second sub-busbar comprises two connection holes electrically connecting to the two first sub-terminals respectively;

the second terminal of the clamping diode module comprises two second sub-terminals connected with each other, and the third sub-busbar comprises two connection holes electrically connecting to the two second sub-terminals respectively;

the first busbar layer comprises a connection hole electrically connecting to the third terminal of the clamping diode module;

the second busbar layer comprises through holes respectively corresponding to the connection holes of the second sub-busbar, the connection holes of the third sub-busbar and the connection hole of the first busbar layer; and

the first busbar layer comprises through holes respectively corresponding to the connection holes of the second sub-busbar and the connection holes of the third sub-busbar.

8. The power unit according to claim 1, wherein,

the first terminal of the second power semiconductor switch module comprises two first sub-terminals connected with each other, and the second busbar layer comprises two connection holes electrically connecting to the two first sub-terminals respectively;

the second end of the second power semiconductor switch module comprises two second sub-terminals connected with each other, and the fourth sub-busbar layer comprises two connection holes electrically connecting to the two second sub-terminals respectively;

the third sub-busbar comprises a connection hole electrically connecting to the third terminal of the second power semiconductor switch module;

the second busbar layer comprises through holes respectively corresponding to the connection holes of the fourth sub-busbar and the connection hole of the third sub-busbar; and

the first busbar layer comprises through holes respectively corresponding to the connection holes of the fourth sub-busbar, the connection hole of the third sub-busbar and the connection holes of the second busbar layer.

9. The power unit according to claim 1, wherein,

the first sub-busbar comprises a first connection terminal configured to connect to a positive DC end;

the fourth sub-busbar comprises a second connection terminal configured to connect to a negative DC end;

the first busbar layer comprises a third connection terminal configured to connect to a neutral point voltage end; and

the second busbar layer comprises a fourth connection terminal configured to connect to an AC end.

10. The power unit according to claim 1, wherein,

the third busbar layer is set on the power switch module, the first busbar layer is set on the third busbar layer, and the second busbar layer is set on the first busbar layer.

11. The power unit according to claim 1, wherein, the third busbar layer is set on the power switch module, the second busbar layer is set on the third busbar layer, and the first busbar layer is set on the second busbar layer.

12. The power unit according to claim 10, wherein, the projection region of the first busbar layer on the power switch module completely covers the projection region of the third busbar layer on the power switch module.

13. The power unit according to claim 10, wherein, the projection region of the second busbar layer on the power switch module at least covers the projection region of the second sub-busbar and the third sub-busbar of the third busbar layer on the power switch module.

14. The power unit according to claim 9, wherein, further comprises a positive bus capacitor bank electrically connected between the positive DC end and neutral point voltage end, and a negative bus capacitor bank electrically connected between the negative DC end and neutral point voltage end;

the first sub-busbar comprises a plurality of first capacitor connection holes, and the fourth sub-busbar comprises a plurality of second capacitor connection holes;

the first busbar layer comprises a plurality of third capacitor connection holes, and the first busbar layer comprises through holes respectively corresponding to the first capacitor connection holes and second capacitor connection holes; and

the second busbar layer comprises through holes respectively corresponding to the first capacitor connection holes and second capacitor connection holes;

wherein, one end of the positive bus capacitor bank respectively connects to the first capacitor connection holes, and one end of the negative bus capacitor bank respectively connects to the second capacitor connection holes;

the other end of the positive bus capacitor bank and the other end of the negative bus capacitor bank respectively connects to the third capacitor connection holes.

15. The power unit according to claim 14, wherein,

the first sub-busbar, the second sub-busbar, the third sub-busbar and the fourth sub-busbar are arranged in order, and the positive bus capacitor bank is set adjacent to a side of the first sub-busbar, and the negative bus capacitor bank is set adjacent to a side of the fourth sub-busbar.

16. The power unit according to claim 1, wherein,

the first power semiconductor switch module comprises a first power semiconductor switch and a second power semiconductor switch connected with each other in series;

the second power semiconductor switch module comprises a third power semiconductor switch and a fourth power semiconductor switch connected with each other in series.

17. The power unit according to claim 16, wherein,

the first power semiconductor switch module further comprises a first fly-wheel diode connected in parallel with the first power semiconductor switch, and a second fly-wheel diode connected in parallel with the second power semiconductor switch;

the second power semiconductor switch module further comprises a third fly-wheel diode connected in parallel with the third power semiconductor switch, and a fourth fly-wheel diode connected in parallel with the fourth power semiconductor switch.

18. A three-level power converter comprising a plurality of power units according to claim 9, the first connection terminals of the laminated busbar structure of each power unit are connected with each other by a conductor;

the second connection terminals of the laminated busbar structure of each power unit are connected by a conductor; and

the third connection terminals of the laminated busbar structure of each power unit are connected by a conductor.

19. The three-level power converter according to claim 18, wherein the number of the power unit is 3 or 6.