Low impedance bus for power electronics

• US 5,172,310 A
• Filed: 07/10/1991
• Issued: 12/15/1992
• Est. Priority Date: 07/10/1991
• Status: Expired due to Term

• Current Assignee: General Electric Company
• Original Assignee: U.S. Windpower, Inc.
• Inventors: Erdman, William L., Deam, David
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): BERHANE, ADOLF D
• Application Number:
  US07/728,112
• Time in Patent Office: 524 Days
• Field of Search: 363/144, 363/132, 363/56, 363/137, 363/141, 361/355, 361/341, 361/361, 307/58, 307/147, 307/148
• US Class Current: 363/144
• CPC Class Codes: H01L 23/52 Arrangements for conducting electric current within the device in operation from one component to another , i.e. interconnections, e.g. wires, lead frames optical interconnections G02B6/00
• CPC Class Codes: H01L 25/115 the devices being arranged next to each other
• 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: H01L 2924/3011 Impedance
• CPC Class Codes: H02G 5/005 Laminated bus-bars
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections

Abstract

A low impedance, high power bus for conduction of electrical power with reduced transient signal effects is described herein. The high power bus can be applied as a high power supply bus between a constant voltage source and a plurality of switching cells positioning at varying locations along the bus, and as branch bus for the switching cells. The power bus can transmit high power: large currents in the hundreds or thousands of amperes, and large voltage potentials in the hundreds or thousands of volts. Particularly, the power bus has use in a DC-to-AC inverter that converts DC from a constant voltage source into three-phase AC for delivery to an electrical power grid. The high power bus includes two conductive bars positioned so that the current flow therethrough is balanced (equal and opposing), and the magnetic field is substantially confined between the bars. The bus includes a dielectric positioned between the conductive bars. In a preferred embodiment, the AC is conducted on extension bars that extend along the power supply bus, so that a main bus is created by the combination of the AC extension bars and the DC power supply bus, and the sum of the currents in the bars is approximately zero at all locations in the bus. The power bus lessens or even obviates the need for the snubber networks commonly used to reduce transients, and reduces the strength of magnetic fields and electric fields that could otherwise interfere with neighboring electrical components.

Claims

1. A low-noise power bus assembly with balanced current flow and reduced transient signal effects, for conducting DC current for high speed switching by high speed transistors, and for conducting an AC waveform defined by switching said high speed transistors, said power bus assembly comprising:

an assembly having a first plurality of conductors coupled to said high speed transistors to receive and conduct DC current, and further having a second plurality of conductors coupled to said high speed transistors to receive and conduct AC current, said first conductors and said second conductors positioned in groups, each group including at least two of said conductors, and within each of said groups, the conductors having a shape and relative position so that each conductor is positioned with respect to at least one adjacent conductor and the currents flowing through each of said adjacent conductors are substantially balanced (equal in amount and opposite in direction); and

,

a plurality of dielectric layers disposed within said assembly, wherein said dielectric layers are interposed between said adjacent conductors.

2. The low-noise power bus assembly as claimed in claim 1, wherein each of said first and second conductors comprise the shape of a bar having a flat surface facing the conductor positioned adjacent thereto, so that adjacent conductors have opposing, flat surfaces and a magnetic field created by a balanced current flow through said conductors is substantially concentrated between said adjacent conductors.

3. The low-noise power bus assembly as claimed in claim 1, wherein said high speed transistors are high power transistors for switching power for power electronics uses.

6. The low-noise power bus assembly as claimed in claim 1, wherein said first and second conductors have a cross-sectional size suitable to conduct current for power electronics uses.

4. A low-noise power bus assembly with balanced current flow and reduced transient signal effects, for conducting DC current for high speed switching, and for conducting an AC waveform, said power bus assembly comprising:

a plurality of switching cells, each of which includes at least one high power transistor;

an assembly having a first plurality of conductors coupled to receive and conduct DC current to said plurality of switching cells, and further having a second plurality of conductors coupled to receive and conduct AC current from said plurality of switching cells, said first conductors and said second conductors having a shape and relative position so that a magnetic field created by the currents flowing therein are substantially contained between said first and second conductors, and wherein two or more of said first and second conductors are configured so that the currents flowing therein are substantially balanced (equal in amount and opposite in direction);

a plurality of dielectric layers disposed within said assembly, wherein said dielectric layers are interposed between said conductors; and

wherein the assembly has a configuration for a DC-to-AC three phase inverter so that

said first conductors include a DC power supply bus;

said second conductors include a phase A extension bar, a phase B extension bar, and a phase C extension bar; and

,

said extension bars and said power supply bus are positioned in a parallel configuration so that the flows of current within said extension bars and said DC power supply bus are substantially balanced.

5. The low-noise power bus assembly as claimed in claim 4, wherein the first conductors further include a plurality of bus connectors for connecting the power supply bus with the switching cells, and a plurality of AC bars for connecting the switching cells with the AC extension bars, and the bus connectors and the AC bars are positioned in an adjacent relationship so that the flows of current therein are substantially balanced (equal and in opposite directions).

7. A low impedance, low-noise, high power supply bus for conducting a large current between a constant voltage source and a plurality of electrical cells including high speed, high power switching transistors, said electrical cells being positioned along the bus at various locations, said high power supply bus comprising:

a pair of current conductive bars for connecting the voltage source with the plurality of electrical cells, wherein said conductive bars have a cross-sectional size suitable to conduct current for power electronics uses, the conductive bars having parallel, opposing flat surfaces, said pair of bars being positioned, with respect to the voltage source and the plurality of electrical cells, so that the current flows therethrough in respectively opposing directions;

a dielectric positioned between said pair of conductive bars; and

,

means for connecting the power supply bus with the plurality of electrical cells, said means being physically positioned at selected locations along the length of the power supply bus.

8. A low-noise low impedance high power branch bus providing a current path between a DC power supply bus and a phase line of an AC source, through a pair of high power, high speed switching cells including a first switching cell and a second switching cell, the DC power supply bus positioned between the first and second switching cells, and also providing a current path for an AC waveform from the pair of switching cells, said branch bus comprising:

a first bus connector bar for conducting current between DC voltage power supply bus and the first switching cell, wherein said first bus connector bar has a cross-sectional size suitable to conduct current for power electronics uses, and said first bus connector bar has a first flat surface;

a second bus connector bar for conducting current between DC voltage power supply bus and the second switching cell, wherein said second bus connector bar has a cross-sectional size suitable to conduct current for power electronics uses, and said second bus connector bar has a second flat surface;

an AC bar for conducting current from the pair of switching cells to the phase line, said AC bar having a cross-sectional size suitable to conduct current for power electronics uses, said AC bar positioned in an opposing, substantially parallel relationship facing the bus connector bar, said AC bar being positioned to conduct current in a direction opposed to the direction of current flow through the bus connector bar, said AC bar having a third flat surface positioned opposing the first flat surface of the first bus connector bar, and a fourth flat surface positioned opposing the second flat surface of the second bus connector bar; and

,

a dielectric positioned between said flat surfaces of the first and second bus connector bars and said AC bar.

9. A low-noise, low impedance power bus assembly that substantially confines a current induced magnetic field within its physical boundaries, said assembly switching DC electrical power among a plurality of high speed electrical switching cells, said power bus assembly comprising:

a power supply bus for conducting DC current, said power supply bus including a pair of parallel bus bars having flat, opposing adjacent surfaces positioned so that their current flows are in respectively opposing directions, said power supply bus further including a dielectric positioned between the flat, opposing surfaces on the adjacent parallel bus bars; and

,

a plurality of branch buses positioned at various locations along the length of the power supply bus, each branch bus including;

at least one DC bus connector bar connecting the power supply bus with a respective switching cell, said DC bus connector bar including a flat surface;

an AC bar coupled to the respective switching cell, said AC bar having a flat surface situated in an opposing, parallel relationship adjacent with the flat surface on the DC bus connector bar so that the current flow through the AC bar opposes the current flow through the DC bus connector bar and so that the flows of current in said bars are substantially balanced; and

,

a dielectric positioned between the adjacent surfaces of each AC bar and the proximate DC bus connector bars.

10. The power bus assembly as claimed in claim 9, further comprising a plurality of AC extension bars, each of said AC extension bars being electrically coupled to a respective AC bar, said extension bars being positioned in a parallel, adjacent relationship with the power supply bus, so that the flows of current within said adjacent extension bars and power supply bus are substantially balanced.

11. A low-noise, low impedance power bus assembly for conducting electrical power between a constant DC voltage supply and an AC waveform, using a plurality of switching cells for switching between AC and DC electrical power, said power bus assembly comprising:

a power supply bus for conducting DC current to the switching cells, said power supply bus including a pair of parallel bus bars, a +DC bus bar and a -DC bus bar, positioned in an adjacent relationship so that the flows of current in said bus bars are in respectively opposing directions, and further including a dielectric positioned between said adjacent bus bars;

a first +DC bus connector bar for connecting the +DC bus bar to a first +DC electrical switching cell;

a first -DC bus connector bar for connecting the -DC bus bar to a first -DC electrical switching cell, said first bus connector bars being positioned on opposite sides of the power supply bus;

a first AC bar having a first end coupled to the first +DC electrical switch, and a second end coupled to the first -DC electrical switch, said first AC bar having a +DC section situated in an opposing, parallel, adjacent relationship with the first +DC bus connector bar, and a -DC section situated in an opposing, parallel, adjacent relationship with the first -DC bus connector bar so that the current flow through each section of the first AC bar opposes the current flow through the adjacent DC bus connector bar; and

,

a dielectric layer positioned between the adjacent sections of the first AC bar and the first DC bus connector bars.

12. The power bus assembly as claimed in claim 11;

further comprising a main bus including;

the power supply bus; and

,

a first AC extension bar coupled to the first AC bar, said first AC extension bar being positioned adjacent to the power supply bus so that it parallels the power supply bus, and also comprising a dielectric layer positioned between the power supply bus and said first AC extension bar.

13. The power bus assembly as claimed in claim 11, further comprising:

a second +DC bus connector bar for connecting the +DC bus bar to a second +DC electrical switching cell, and a second -DC bus connector bar for connecting the -DC bus bar to a second -DC electrical switching cell, said second bus connector bars being positioned on opposite sides of the power supply bus;

a second AC bar having a first end coupled to the second +DC electrical switch, and a second end coupled to the second -DC electrical switch, said second AC bar having a +DC section situated in an opposing, parallel, adjacent relationship with the second +DC bus connector bar, and a -DC section situated in an opposing, parallel, adjacent relationship with the second -DC bus connector bar so that the current flow through each section of the second AC bar opposes the current flow through the adjacent DC bus connector bar; and

,

a dielectric layer positioned between the adjacent sections of the second AC bar and the second DC bus connector bars.

14. The power bus assembly as claimed in claim 13, further comprising a main bus including:

the power supply bus;

a first AC extension bar coupled to the first AC bar, said first AC extension bar being positioned in an adjacent, parallel relationship with the power supply bus, and also comprising a dielectric layer positioned between the power supply bus and said first AC extension bar; and

,

second AC extension bar coupled to the second AC bar, said second AC extension bar being positioned in an adjacent, parallel relationship with the power supply bus, and also comprising a dielectric layer positioned between said second AC extension bar and the bar on the main bus that is proximate thereto.

15. The power bus assembly as claimed in claim 13, further comprising:

a third +DC bus connector bar for connecting the +DC bus bar to a third +DC electrical switching cell, and a third -DC bus connector bar for connecting the -DC bus bar to third -DC electrical switching cell, said third bus connector bars being positioned on opposite sides of the power supply bus;

a third AC bar having a first end coupled to the third +DC electrical switch, and a second end coupled to the third -DC electrical switch, said third AC bar having a +DC section situated in an opposing, parallel, adjacent relationship with the third +DC bus connector bar, and a -DC section situated in an opposing, parallel, adjacent relationship with the third -DC bus connector bar so that the current flow through each section of the third AC bar opposes the current flow through the adjacent DC bus connector bar; and

,

a dielectric layer positioned between the adjacent sections of the third AC bar and the third DC bus connector bars.

16. The power bus assembly as claimed in claim 15, further comprising a main bus including:

the power supply bus;

a first AC extension bar coupled to the first AC bar, said first AC extension bar being positioned in an adjacent, parallel relationship with the power supply bus, and also comprising a dielectric layer positioned between the power supply bus and said first AC extension bar;

second AC extension bar coupled to the second AC bar, said second AC extension bar being positioned in an adjacent, parallel relationship with the power supply bus, and also comprising a dielectric layer positioned between said second AC extension bar and the bar on the main bus that is adjacent thereto; and

,

a third AC extension bar coupled to the third AC bar, said third AC extension bar being positioned in an adjacent, parallel relationship with the power supply bus, and also comprising a dielectric layer positioned between said third AC extension bar and the bar on the main bus that is adjacent thereto.

17. A low-noise power inverter for converting electrical energy between electrical energy at a substantially constant voltage and three phase AC electrical energy by high speed switching, said low-noise power inverter comprising:

a power supply bus for conducting current from the voltage source, said power supply bus including a pair of parallel bus bars including a +DC bus bar and a -DC bus bar, positioned in an adjacent relationship so that their flows of current are in respectively opposing directions, and further including a dielectric positioned between the bus bars of the power supply bus;

a plurality of pairs of switching cells, each cell including a first switching cell and a second switching cell; and

,

a plurality of branch buses for connecting the power supply bus with the plurality of switching cells and providing an output therefrom, said branch buses positioned along the length of the power supply bus, each branch bus including

a first bus connector bar connecting the power supply bus with a first switching cell of a selected pair of switching cells,

a second bus connector bar connecting the power supply bus with a second switching cell of said selected pair of switching cells,

an AC bar for supplying an output from the first and second switching cells, said AC bar coupled to the first and second switching cells, said AC bar being situated in an opposing, parallel, adjacent relationship with the first and second DC bus connector bars so that the current flow through the first DC bus connector bar and a section of the AC bar adjacent thereto is substantially balanced, and the current flow through the second DC bus connector bar and a section of the AC bar adjacent thereto is substantially balanced, and,

a dielectric positioned between each AC bar and the DC bus connector bar adjacent thereto.

18. The power inverter as claimed in claim 17, wherein the three phases of the three-phase electrical energy are defined by a phase A, a phase B, and phase C, and wherein the plurality of AC bars includes a phase A bar, a phase B bar, and a phase C bar.

19. The power inverter as claimed in claim 18, wherein the switching cells include a phase A switch pair coupled to the phase A bar, a phase B switch pair coupled to the phase B bar, and a phase C switch pair coupled to the phase C bar.

20. The power inverter as claimed in claim 19, wherein:

the power supply bus includes a +DC bus bar and a -DC bus bar having flat opposing surfaces;

for each branch bus in said plurality of branch buses, the first bus connector bar and an adjacent portion of the AC bar have flat, opposing surfaces, and the second bus connector bar and an adjacent portion of the AC bar have flat opposing surfaces.

21. The power inverter as claimed in claim 20, wherein for each pair of switches, the first switch is positioned on the side of the power supply bus corresponding to the +DC bus bar, and the second switch is positioned on the other side of the power supply bus, the side corresponding to the -DC bus bar.

22. The power inverter as claimed in claim 17, further comprising a plurality of extension bars, including:

a phase A extension bar coupled to the phase A bar;

a phase B extension bar coupled to the phase B bar; and

,

a phase C extension bar coupled to the phase C bar;

wherein said extension bars are positioned so that they parallel the power supply bus and are adjacent therewith, and so that the flows of current within said extension bars and said power supply bus are substantially balanced at all points in the bus structure.

23. The power inverter as claimed in claim 22, wherein the power supply bus and the adjacent extension bars have flat, opposing surfaces, and the power inverter further comprises a plurality of dielectric layers positioned between the adjacent parallel extension bars and the DC bus bars.

24. The power inverter as claimed in claim 17, wherein the DC bus bars, the bus connector bars, and AC bars have a cross-sectional size suitable to conduct current for power electronics uses.

25. The power inverter as claimed in claim 24, wherein each switching cell comprises at least one high power transistor.

26. The power inverter as claimed in claim 25, wherein each switching cell comprises a pair of high power transistors.