Power converter connection configuration

• US 7,450,388 B2
• Filed: 09/16/2003
• Issued: 11/11/2008
• Est. Priority Date: 01/16/2002
• Status: Expired due to Fees

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Kaishian, Steven C., Radosevich, Lawrence D., Gettelfinger, Lee A., Phillips, Mark G., Kehl, Dennis L., Beihoff, Bruce C.
• Primary Examiner(s): Reichard; Dean A.
• Assistant Examiner(s): NGUYEN, HOA CAO
• Application Number:
  US10/663,172
• Publication Number:
  US 20040066643A1
• Time in Patent Office: 1,883 Days
• Field of Search: 361/801, 361/802, 361/806, 361/434, 361/752, 361/818, 361/816, 361/715, 361/723, 361/709, 363/54, 363/57, 363/58, 363/96, 363/136, 363/137, 363/138, 363/141, 315/194
• US Class Current: 361/715
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 50/50 using propulsion power supplied by batteries or fuel cells
• CPC Class Codes: H02M 1/44 Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

EMI shielding is provided for power electronics circuits and the like via a direct-mount reference plane support and shielding structure. The thermal support may receive one or more power electronic circuits. The support may aid in removing heat from the circuits through fluid circulating through the support. The support forms a shield from both external EMI/RFI and from interference generated by operation of the power electronic circuits. Features may be provided to permit and enhance connection of the circuitry to external circuitry, such as improved terminal configurations. Modular units may be assembled that may be coupled to electronic circuitry via plug-in arrangements or through interface with a backplane or similar mounting and interconnecting structures.

Claims

1. A modular power converter comprising:

a converter including a support including a passage for circulation of a cooling medium and a power electronic switching circuit mounted on the support and configured to convert input power to output power having desired electrical characteristics;

a housing at least partially surrounding the converter;

at least one plug-in connector coupled to the switching circuit and to the housing for establishing electrical continuity between the converter and external circuitry; and

a connection interface coupled to an exterior surface of the housing and including the at least one plug-in connector, wherein the connection interface includes connections for incoming and outgoing cooling fluid.

2. The converter of claim 1, wherein the housing shields the switching circuit from EMI, and wherein the at least one plug-in connector extends EMI shielding from the housing to a region at least partially surrounding conductors of the at least one plug-in connector.

3. The converter of claim 1, wherein the at least one plug-in connector includes a single connector having electrical connections for the input power and the output power.

4. The convener of claim 1, wherein the at least one plug-in connector comprises:

a plurality of conductors coupled to the switching circuit, the plurality of conductors including external portions of the conductors that extend outwardly from an exterior surface of the housing; and

a peripheral wall extending outwardly from the exterior surface of the housing and at least partially surrounding the plurality of conductors in such a manner that the peripheral wall provides EMI shielding to portions of the plurality of conductors outside of the housing.

5. A modular power converter comprising:

a converter including a support including a passage for circulation of a cooling medium and a power electronic switching circuit mounted on the support and configured to convert input power to output power having desired electrical characteristics;

a housing at least partially surrounding the converter and configured to provide integral EMI shielding and at least partially defining an electrical reference plane for the converter;

at least one plug-in connector coupled to the switching circuit and to the housing for establishing electrical continuity between the converter and external circuitry and for extending EMI shielding from the housing to a region at least partially surrounding conductors of the at least one plug-in connector; and

a connection interface coupled to an exterior surface of the housing and including the at least one plug-in connector, wherein the connection interface includes connections for incoming and outgoing cooling fluid.

6. The converter of claim 5, wherein the housing and the at least one plug-in connector are configured to provide contiguous shielding having intrinsically low impedance paths for EMI originating from the switching circuit and from sources external to the converter during operation.

7. The converter of claim 5, wherein the at least one plug-in connector includes a single connector having electrical connections for the input power and the output power.

8. The convener of claim 5, wherein the at least one plug-in connector includes a peripheral flange extending from the housing and at least partially surrounding portions of the conductors located outside the housing, and the peripheral flange is configured to provide EMI shielding to the portions of the conductors located outside the housing.

9. A modular power converter comprising:

a convener including a support including a passage for circulation of a cooling medium and a power electronic switching circuit mounted on the support and configured to convert input power to output power having desired electrical characteristics;

a housing at least partially surrounding the converter and configured to provide integral EMI shielding and at least partially defining an electrical reference plane for the converter;

at least one plug-in connector coupled to the switching circuit and to the housing;

a connector plug adapted to interface with the at least one plug-in connector for establishing electrical continuity between the converter and external circuitry; and

a connection interface coupled to an exterior surface of the housing and including the at least one plug-in connector, wherein the connection interface includes connections for incoming and outgoing cooling fluid;

wherein the at least one plug-in connector and the connector plug mate to extend EMI shielding from the housing to the connector plug.

10. The converter of claim 9, wherein the housing, the at least one plug-in connector and the connector plug are configured to provide contiguous shielding having intrinsically low impedance paths for EMI originating from the switching circuit and from sources external to the converter during operation.

11. The convener of claim 9, wherein the at least one plug-in connector includes a single connector having electrical connections for the input power and the output power.