Power module with current sensing
First Claim
Patent Images
1. A power module operable for use within a vehicle to rectify a three-phase, AC input to a DC output, the power module comprising:
- a housing;
a first input terminal, a second input terminal, and a third input terminal, each of the first, second, and third input terminals being disposed within the housing and operable to establish an electrical connection to one of three busbars carrying the AC input;
a first output terminal and a second output terminal, each of the first and second output terminals being disposed within the housing, and operable to establish an electrical connection to any one of two busbars carrying the DC output;
a rectifier disposed within the housing between the input terminals and the output terminals, the rectifier having a plurality of switches operably connected between the input terminals and the output terminals to rectify the three-phase AC input to the DC output;
a shunt electrically disposed between the connection to one of the output terminals and at least one of the switches such that current flow through the one of the output terminals must pass through the shunt;
a first shunt pin and a second shunt pin, each of the first and second shunt pins being adhered to the shunt at spaced apart locations; and
a printed circuit board (PCB) having control electronics operable to control opening and closing of each of the switches and measurement electronics operable to measure a voltage drop between the first and second shunt pins.
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Accused Products
Abstract
A power module operable to sense current, such as but not limited to a power module operable within a vehicle to sense current while rectifying an AC input to a DC output. The power module may include a shunt disposed relative an output of the power module to facilitate the current measurement.
49 Citations
20 Claims
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1. A power module operable for use within a vehicle to rectify a three-phase, AC input to a DC output, the power module comprising:
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a housing; a first input terminal, a second input terminal, and a third input terminal, each of the first, second, and third input terminals being disposed within the housing and operable to establish an electrical connection to one of three busbars carrying the AC input; a first output terminal and a second output terminal, each of the first and second output terminals being disposed within the housing, and operable to establish an electrical connection to any one of two busbars carrying the DC output; a rectifier disposed within the housing between the input terminals and the output terminals, the rectifier having a plurality of switches operably connected between the input terminals and the output terminals to rectify the three-phase AC input to the DC output; a shunt electrically disposed between the connection to one of the output terminals and at least one of the switches such that current flow through the one of the output terminals must pass through the shunt; a first shunt pin and a second shunt pin, each of the first and second shunt pins being adhered to the shunt at spaced apart locations; and a printed circuit board (PCB) having control electronics operable to control opening and closing of each of the switches and measurement electronics operable to measure a voltage drop between the first and second shunt pins. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A power module operable for use within a vehicle to rectify an AC input to a DC output, the power module comprising:
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a housing; a first input terminal and a second input terminal, each of the first and second input terminals being disposed within the housing and operable to establish an electrical connection to the AC input; a first output terminal and a second output terminal, each of first and second output terminals being disposed within the housing and operable to establish an electrical connection to any one of two busbars carrying the DC output; a circuit disposed within the housing between the input terminals and the output terminals, the circuit having a plurality of switches operably connected between the input terminals and the output terminals to rectify the AC input to the DC output; a shunt electrically disposed between the connection to one of the output terminals and one of the switches such that current flow through the one of the output terminals must pass through the shunt; and a printed circuit board (PCB) having control electronics operable to control opening and closing of each of the switches and measurement electronics operable to measure a voltage drop across a portion of the shunt. - View Dependent Claims (13, 14, 15, 16, 17)
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18. A power module having an input and an output, the power module comprising:
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a non-conducting housing; at least two conducting input terminals disposed within the housing, each input terminal having an insert operable with a threaded fastener to mechanically and electrically connect to at least one input busbar; at least two conducting output terminals disposed within the housing, each output terminal having an insert operable with a threaded fastener to mechanically and electrically connect to at least one output busbar; a circuit disposed within the housing, the circuit electrically connecting between the input terminals and the output terminals to manipulate AC current received at the input busbars to DC current output to the output busbars; a shunt electrically connected between the circuit and a first one of the output terminals such that DC current to the first one of the output terminals, and thereby DC current to a first one of the output busbars, flows through the shunt; the circuit having an insert operable with a threaded fastener to mechanically electrically connect to a first end of the shunt, a second end of the shunt having an aperture through which the threaded fastener used to connect the first one of the output busbars to the first one of the output terminals passes in order to mechanically and electrically connect the shunt to the first one of the output terminals and the first one of the output busbars; a first shunt pin and a second shunt pin, each of the first and second shunt pins being adhered at spaced apart portions of the shunt; and a printed circuit board (PCB) having control electronics operable to control opening and closing of each of the switches, the first and second shunt pins passing through apertures within the PCB to electrically connect to measurement electronics operable to measure a voltage drop between the first and second shunt pins. - View Dependent Claims (19, 20)
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Specification