DE4338277A1 - Liquid-cooled convertor module having circuitry components for power semiconductors which can be turned off - Google Patents

Abstract

A liquid-cooled convertor module having at least one power semiconductor which can be turned off and having circuitry which consists of a plurality of components - such as a capacitor, inductor and diode - for the power semiconductor which can be turned off are proposed, in the case of which all the major components of the circuitry for a power semiconductor which can be turned off are arranged on a single insulating mounting rack (1, 21 to 23). The insulating mounting rack is provided with an integrated electrical power current path busbar system (8) for connecting the circuitry components and with electrical connections (2, 3, 5, 9, 13, 15, 18, 19) for making contact with the circuitry components and circuitry connections and has means (4, 6, 10, 12, 14, 17, 26, 27) for mechanical fastening of the circuitry components. At least one liquid cooler for cooling heat-producing circuitry components is integrated in the insulating mounting rack, and the insulating mounting rack can be produced as a cast or stamped part for high-quality insulating material such as epoxy resin or polyester resin. In the case of a multiphase converter module, one insulating mounting rack is provided per phase, it being possible to arrange the individual insulating mounting racks in a row and to connect them to form an insulating mounting rack assembly (25). <IMAGE>

Description

The invention relates to a liquid-cooled - preferably H₂O-cooled (process water or pure water) - Converter module with circuit components for one switchable power semiconductors and can for example used in converter-fed rail vehicles the.

Such a liquid-cooled converter module with Be circuit components for a power that can be switched off Semiconductors are known from DE 40 08 425 A1. In which proposed, preferably oil-cooled converter Termodul are located in addition to a GTO tension bandage (Gate turn-off thyristors) GTO wiring components (e.g. capacitors, chokes, resistors, diodes) in the Ge inside the house. The GTO wiring components are included washed by the electrically insulating coolant and chilled. When using process water as a coolant is this known and proven technology due to the elek The thermal conductivity of the process water cannot be used.

The invention has for its object a liquid cooled converter module with circuit components for a power semiconductor that can be switched off at the beginning Specify the type mentioned in the short, closely spaced and low inductance connections between the fittings tion components with each other and between wiring components and switchable power semiconductors too when using an electrically conductive coolant are realized.

This task is done in conjunction with the characteristics of Preamble according to the invention by the in the characteristic of Features specified claim 1 solved.

The advantages which can be achieved with the invention are in particular special in that through the integration of electrical Connection rails in the insulating subrack despite the Use of an electrically conductive coolant very much short, closely spaced, rigid and low inductance Ver Bifilar technology bonds between the individual scales tion components and between wiring components and switchable power semiconductors are realized, what the Switching ability of GTO thyristors and diodes improved.

The inductance generated by the splinting is a clearly and precisely predictable and not by assembly flows - for example, flexible piping - change the bear. In addition, the assembly of the wiring components much easier and a faulty "Verka belung "is excluded necessary creepage distances and insulation distances are ex can be calculated and thanks to special insulation design subrack - for example with ribs - just right realizable.  

By using solid insulation between the Power converter rails and component connections and against Earth, d. H. against housing components made of electrically conductive The necessary spatial ab compared to the usual air gap insulation drastically reduced. There is a reduction in volume by a factor of 2 to 3 compared to conventional technology. This volume reduction causes weight loss and a cost reduction.

The design of the creepage distances is preferably directed and insulation distances according to the maximum operating voltage, so that one and the same insulating subrack universal use for both high and low voltages is cash. By integrating the electrical diff The insulation clearances in the insulating subrack are also compared to an open, accessible design drastically reduced, as already mentioned.

For cooling heat-producing wiring components The components of the converter module are not in a coolant is immersed but it's a cool liquid circuit provided in which the cooling liquid speed - preferably process water with antifreeze - in Channels between an external recooler and various NEN cooling devices within the converter module Cooling of heat-producing components circulates. In the Sen cooling circuit, the insulating subrack is over integrated cooler, which is made of insulating material in the direct Thermal contact with heat-producing components - before preferably diodes, rails, plug contacts - stands. Further Components, such as chokes, circuit resistances, have its own cooling system, which is also connected to the cooling system liquid circuit is connected.  

The proposed insulating subrack is universal for converter modules with 1, 2, 3, 4, 5 or more phases can be used, with an insulating subrack all for one Phase carries the necessary components and depending on the phases Number of several insulating subracks for one insulating construction group carrier association to be composed of the DC link rail or cooling rail can be connected can. For an insulation subrack assembly for one multi-phase converter modules are also not additional mechanical and space dividing mechanical parts required, what saves weight, space and costs and at one very compact structure of the module leads. Overall, the Isolation subrack very flexible to different Customizable requirements. Both the manufacture and the Spare parts inventory is greatly simplified - which makes it Cost advantages result - since only the basic design already contain all circuit components for one phase insulating subrack is required and each iso lier subrack assembly from these basic designs consists.

Advantageous embodiments of the invention are in the Un marked claims.

In particular, the alternatives are partly in the insulating subrack integrated DC link seemed advantageous. There is a space saving, because additional DC link rails outside the current judge module is not required.

The invention is described below with reference to the drawing illustrated embodiments explained. Show it:

Fig. 1 is a view of the front of a Iso lierbaugruppenträgers,

Fig. 2 is a view of the front side of a Iso lierbaugruppenträgers,

Fig. 3 is a view of the rack on the back of an insulating,

Fig. 4 is a side view of a carrier Isolierbaugruppen,

Fig. 5 shows a lateral section through a lierbaugruppenträger Iso along a section line AA,

Fig. 6, the output current path of the busbar Iso lierbaugruppenträgers,

Fig. 7 is a view of the front side of a Iso lierbaugruppenträger Association,

Fig. 8, 9 is a view of the front and a side view of a Isolierbaugruppenträ gers according to a first alternative,

Fig. 10, 11 is a view of the front and a side view of a building components with be tipped teeth Isolierbaugruppenträgers ei ner according to the first alternative,

Fig. 12, 13 is a view of the front and a side view of a Isolierbaugruppenträ gers according to a second alternative,

Fig. 14, 15 is a view of the front and a side view of a building components with be tipped teeth Isolierbaugruppenträgers ei ner according to the second alternative,

Fig. 16, the output current path of the busbar Iso lierbaugruppenträgers according to the first Alterna tive,

Fig. 17, 18 different ways of electrical connection between adjacent insulating group carrier.

In Fig. 1 is a view of the front of an Iso assembly module carrier is shown. The insulating assembly carrier is preferably made as a cast or die-cast part from high quality insulating material such as epoxy resin or polyester resin. In the insulating body, the electrical connecting rails are mainly integrated for splinting the GTO, diode and thyristor components (Lei power circuit path splinting) and preferably "cast in" without gaps and without gaps (hermetically insulated "heavy current circuit board"). These connecting rails are preferably bi-filar and have minimum possible lengths and distances from one another, on the one hand to achieve a low inductance railing and on the other hand to make the insulating group carrier as compact as possible. It is essential that the component connections and rails are hermetically and completely enclosed by insulating material in order to achieve the volume reduction.

On the front of the insulating subrack 1 are cast-in plug-in contact sockets 2 for the plug-in contacts of a clamping assembly (comprising power semiconductors which can be switched off, power sockets and possibly further components, such as resistors), cast-in plug-in contact sockets 3 for the electrical connection, if necessary, of thermal sockets located within the clamping assembly Contacted resistors, several cast-in support points 4 for mechanical fixation of the clamping connection of the cast-in plug-in sockets 5 for the electrical connection of chokes, openings 6 (recesses) for the partial implementation of chokes and several cast-in fastening points 7 for mechanical fastening of the insulating subrack to the housing or frame of the Detect converter module.

The dashed line, embedded in the electrically insulating cast resin compound of the insulating subrack power circuit rail 8 serves for the galvanically conductive connection between individual components of the converter module with one another. At the end of the insulating subrack plug connector sockets 9 are used to connect transducers / toroids.

In Fig. 2, a view of the end face of an insulating subrack is shown. In particular, the cast-in plug-in contact sockets 9 and the cast-in fastening points 10 for transducers / toroids can be seen. Numeral 7 in turn cast attachment points for mounting the insulating subassembly 1 on the frame of the converter module are designated. The insulating subrack has an integrated cooler which is in thermal contact with heat-producing components - preferably wiring diodes. The hydraulic connections 11 (before run / return) of the cooler are accessible at the front of the insulating module rack and can be flange-mounted to a cooling rail via sealing rings.

In Fig. 3 a view of the rear of an insulating subrack is shown. The insulating subrack 1 has receiving pockets 12 for storage capacitors and cast connector sockets 13 within these pockets for the electrical connection of the storage capacitors. The storage capacitors are mounted on a capacitor cover, which is connected to the insulating subrack by means of cast fastening points 14 . Furthermore, cast plug-in sockets 15 for electrical contacting of an RC element (circuit component for GTO thyristor) and the plug-in contact sockets 3 for contacting resistors can be seen. The plug contact sockets 3 are continuous from the front to the rear, so that the insulating subrack is universally suitable both for resistors of lower power arranged within the clamping assembly (electrical connection follows via plug contact sockets 3 on the front) and for resistors of higher power located separately within the converter module (electrical connection it follows via plug contact sockets 3 on the rear).

Fig. 3 also shows the integrated power resin power rail 8 , the mounting points 7 for me mechanical attachment of the insulating subrack, the openings 6 for the chokes and the cast connector sockets 5 for the electrical connection of the chokes. The recess 26 (receiving pocket) enables the throttles, which are preferably pre-assembled to form a unit with a cooling device, to be seated precisely. The throttle assembly takes place via cast-in fastening points 27 , wherein the fastening points 7 and 27 can at least partially coincide.

FIG. 3 also shows a cooler contact surface 16 of the cast-in cooler mentioned above at the base of a receiving pocket 17 for circuit diodes (see number 20 according to FIG. 5). Both the electrical connection and the assembly of the wiring diodes takes place via electrical contact surfaces 18 for diode connection with integrated threaded holes. The electrical insulation between the electrically grounded cooler and the circuit diodes is carried out by means of good thermal conductivity of the insulating washers - preferably AlN washers - which are placed on the cooler contact surfaces. Above the wiring diodes, wiring capacitors are expediently arranged, the electrical connections of which are made via one of the plug sockets 19 , and the other is by means of a direct contact, not shown, in the capacitor cover. The capacitor cover is mounted at attachment points 14 '.

In general, it is advantageous that the cylindrical Kon capacitors and chokes with respect to their main axes are arranged at right angles to the insulating subrack.  

This allows you to change the insulating subrack optional circuit components of different nominal values such as voltage, capacitance, inductance etc. and so on different lengths can be used to Stromrich Term modules of different types (voltage classes, lei stung) to create.

In Fig. 4 a side view of an insulating assembly carrier 1 is shown. There are the cast-in plug contacts 2 , 3 , 5 , 9 , 13 , 15 , 19 , the cast-in support point 4 , the fastening point 27 and the receiving pocket 12 for storage capacitors.

In Fig. 5 is a side section through an insulating subrack along a section line AA. The section line AA is shown in FIGS. 1 and 3. In particular, the integration of the power current path 8 can be seen clearly within the insulating subrack 1 . The power current rail 8 is preferably coated with polyimide and only then poured into the casting resin, resulting in an elastic embedding. In particular, FIG. 5 shows cast plug contact sockets 2, 5, 9, 13, a fastening point 7, a base 4 and the built-in cooler 20, the hydraulic connection 11 already Fig. 2 is mentioned.

In Fig. 6, the power current rail 8 of the insulating subrack is shown before the gate. To counter adverse effects of the "skin effect" (for example, uneven heating of the current-carrying conductors), the individual busbars are built up in layers. The plug contact sockets, such as 2 , 5 , 9, are electrically conductively connected to the busbars.

In Fig. 7, a view of the end face of an insulating assembly assembly is shown schematically. A multiphase converter module is created by such an insulating subrack assembly. The Isolierbau group carrier association 25 has a plurality of insulating assemblies carrier 1 , 21 , 22 , 23 , which are arranged side by side in such a way and connected to the frame of the converter module that the hydraulic connections 11 can be flanged to a common, continuous cooling rail 24 . The plug contact sockets 9 for external converters are lined up next to one another, so that a very simple external connection of the converter module is made possible.

So that the cooling rail not only diodes, but the ge entire insulation subrack cools, can become elastic Thermal grease between the cooling rail and the insulation group carriers.

The above-mentioned receiving pockets 12 , 17 , 26 are designed such that a sealed, vibration-proof installation of the components (in particular capacitors, diodes, chokes) is supported. Sealing rings on the side walls of the receiving pockets ensure an elastic and sealed mechanical connection. The penetration of moisture is prevented and creepage distances are extended. A similar assembly technique can also be done with the plug contact sockets by increasing the contact pressure between plug contacts and sockets by means of an elastic O-ring. In addition, there is protection against dust and dirt, which results in permanent insulation of the electrical contacts. In order to increase the creepage distance and thus to increase the maximum voltage that can be applied, rib contours are provided on the insulating subrack between the plug contact sockets with different potentials.

In a first variant of the insulating subrack, the toroids / bushings are plugged in and are therefore not an integral part of the insulating subrack itself. This variant is indicated by dashed lines in FIGS . 2, 3, 4, 5 and 7, the socket of the toroid / converter being numbered 28 is designated.

In a second variant of the insulating subrack the section of the insulation carrying the chokes is eliminated subrack, while the insulating subrack in remaining unchanged. This variant is for lei less powerful converter modules suitable for which no powerful, liquid-cooled chokes are required.

In a third variant of the insulating subrack be there is no hydraulic connection for the radiator more at the front, but at the front in the Close to the tension bandage assembly points. This variant will preferably used when no liquid-cooled Chokes are required (see second variant).

In a fourth variant, the connections between the cooling rail and the individual insulating subracks so massive that the Isolierraugruppenträ ger bandage mechanically reinforced by the cooling rail is, the cooling rail quasi as an additional mechani scaffold girder.

In Fig. 8 is a view of the front of an insulating module carrier 29 is shown according to a first alternative. In this first alternative - which is shown in FIGS . 8 to 11 - in contrast to the basic design according to FIGS . 1 to 6, the intermediate circuit rails of a converter configuration rectifier - intermediate circuit inverter are also partially ("module-divided") integrated in the insulating subrack itself . This also applies to the second alternative according to FIGS. 12 to 15, the first and second alternatives differing in the fact that in the second alternative the section of the insulating module carrier carrying the chokes is omitted (see also the aforementioned second variant of the basic design). In the insulating subrack according to the first and second alternative, the receiving pockets and contact bushings for screw-on toroidal converters are omitted, so that a receiving pocket 30 for an AC converter is available. Alternatively, the AC converter bushing bolt can also be cast in.

In Fig. 9 a side view of the Isolierbaugruppenträ gers 29 is shown according to the first alternative. It is outlined that the intermediate circuit rails 31 , 32 and a center potential rail 33 in the short-legged section from the L-shaped insulating subrack 29 are integrated. The rails 31 , 32 , 33 are cast in where there are recesses in connections (see numbers 49 , 50 , 51 according to FIG. 16). Running parallel to the rails are receiving grooves 35 , 36 , which accommodate connecting bridges for the connection to neighboring insulating subracks and which, in addition to connecting the individual rails of adjacent insulating subracks, also perform current management tasks in the case of powerful converter devices with a high intermediate circuit current. In Fig. 9, a toroidal converter 34 (di / dt converter) is outlined, which he summarizes the short-circuit current increases possibly flowing in the phases or out of the phase. Each rail 31 , 32 is associated with such a toroidal converter (pulse converter). These toroidal converters are preferably cast in the insulating subrack, which results in cost advantages compared to plug-in converters of its own and also saves space and weight.

FIG. 10 shows a view of the front of an insulating sub-rack equipped with structural components according to the first alternative. There are the Spannver band 37 with semiconductor cells and heat sinks, the coolant telverteiler 38 to supply the clamping bandage heat sink with coolant, the coolant connection 39 for the throttle and the AC converter 40 can be seen.

FIG. 11 shows a side view of an insulating subassembly equipped with structural components according to the first alternative. The intermediate circuit rails 31 , 32 and the center potential rail 33 are again indicated. There are a choke 41 , capacitors 42 , a wiring diode 43 , the AC converter 40 , the clamping assembly 37 , the coolant distributor 38 and the coolant connection 39 for the throttle.

In Figs. 12 and 13 a side view to the front and a side view are of a Isolierbaugruppenträ gers 29 'is shown according to the second alternative. There are a receiving pocket 30 'for an AC converter, the intermediate circular rails 31 ', 32 ', center potential rail 33 ' and the grooves 35 ', 36 ' for connecting bridges or additional rails can be seen. This version is also very suitable for symmetrical converter circuits, e.g. B. the Mc-Murray circuit, the storage capacitors are omitted and the choke fills the free space thus formed (see dashed line). The insulating subrack is thus advantageously universally usable for different converter circuits.

In Figs. 14 and 15 are a side view to the front and a side view of a building components with be tipped teeth Isolierbaugruppenträgers the second age illustrated in accordance with native. There are in addition to the intermediate circuit rails 31 ', 32 ' and the center potential rail 33 'of the Spannver band 37 ', the coolant distributor 38 ', the coolant circuit 39 ' for the external, ie not attached to the Isolierbaugrup carrier itself, the AC converter 40 ' to know the capacitors 42 'and the wiring diode 43 '. The coolant connection 39 'leads via a coolant line 44 to the external throttle.

In Fig. 16, the power current rail 45 of the insulating subrack according to the first alternative is Darge. The power current rail 45 has additional to the power current rail 8 according to FIG. 6, the above-mentioned intermediate circuit rails 31 , 32 and the center potential rail 33 . The toroid transducers 34 encompass conductor cross-sectional constrictions 46 at the connections between the intermediate circuit rails and the rest of the power current path rail. The signal voltages produced with the help of the To roid converter 34 at Stromän change can be tapped via connecting lines 47 . Zif fer 48 denotes the plug contact socket or the screw-on surface for a fixed bushing converter bolt for the AC converter.

In order to be able to electrically contact the intermediate circuit rails 31 , 32 and the center potential rail 33 in a multi-phase arrangement in a simple manner with adjacent intermediate circuit rails and center potential rails (see insulating subrack assembly according to FIG. 7), the intermediate circuit rails 31 and 32 with connections 49 and 50 and the center potential rail 33 are provided with connections 51 . In Figs. 17 and 18 is shown, which speeds possible with regard to the electrical contact with the rails 31, 32, 33 consist of adjacent Isolierbaugruppenträger.

In Fig. 17, two power current busbars 45 , 45 'of two adjacent insulating subracks are to be recognized, whose intermediate circuit rails and center potential rails are electrically connected to one another via connecting bridges 52 , 53 . The connecting bridges 52 , 53 are screwed, for example, to the connections 49 , 50 , 51 of the rails. The connecting bridges 52 are located in the grooves 35 , 36 . This first option of the rail connection is used in the lower and medium power range, it being necessary to ensure that the currents flowing over the rails 31 , 32 , 33 and connecting bridges 52 , 53 do not lead to an impermissibly high thermal load.

In the upper power range with a high current load, the second possibility shown in FIG. 18 of the rail connection of adjacent power current path rails 45 , 45 'is used. Additional rails 54 are used to connect the DC link rails via their connections 49 , 50 . These additional rails 54 additionally take the next Verbin-making task current managerial responsibilities. As in the example according to FIG. 17, the center potential rails are electrically contacted via connecting bridges 53 .

In the above-mentioned alternatives with insulation Subrack integrated proportional DC link rails it is also possible in a simple manner the DC link rails with additional connections for the connection with externally arranged DC link capacitors to provide sensors and / or DC link inductors.

Claims (17)

1. Liquid-cooled converter module with at least one switchable power semiconductor and a circuit comprising several components, such as a capacitor, choke and diode, for the switchable power semiconductor, characterized in that

• - That all essential components of the circuit for a power semiconductor that can be switched off are arranged on a single insulating subrack ( 1 , 21 to 23 , 29 , 29 '),
• - That the insulating subrack with an integrating electrical power current path rail ( 8 , 45 , 45 ') for interconnecting the wiring components and with electrical connections ( 2 , 3 , 5 , 9 , 13 , 15 , 18 , 19 ) for contacting the loading components and Wiring connections is seen,
• - That the insulating subrack has means ( 4 , 6 , 10 , 12 , 14 , 17 , 26 , 27 ) for mechanically attaching the wiring components,
• - That at least one liquid cooler for cooling heat-producing construction elements is integrated in the insulating subrack,
• - That the insulating subrack can be produced as a casting or pressure casting from high-quality insulating material, such as epoxy resin or polyester resin, and
• - That in a multi-phase converter module an Iso lier module rack is provided for each phase, the individual insulating subracks being connected to one another in a row and connected to form an insulating subassembly ( 25 ).

2. Converter module according to claim 1, characterized in that the insulating subrack ( 1 , 21 to 23 , 29 , 29 ') plug contact sockets ( 2 ) for the plug contacts of a clamping assembly and / or plug contact sockets ( 3 , 5 , 9 , 13 , 15 , 19 ) for connecting resistors and / or chokes and / or converters / toroids and / or storage capacitors and / or RC elements and / or diodes and / or wiring capacitors. 3. Converter module according to claim 2, characterized in that the plug contact sockets ( 3 ) run at least partially continuously to enable the double-sided connection of components of different performance classes and / or voltage classes. 4. Converter module according to one of claims 1 to 3, characterized in that at least individual components, such as capacitors, chokes and diodes in pockets ( 12, 17, 26 ) of the insulating subassembly, which support mechanical fastening and electrical insulation, wherein elastic sealing rings are provided on the side walls of the receiving pockets. 5. Converter module according to one of claims 1 to 4, characterized in that at least individual components, such as chokes, are partially mechanically fixed in recesses ( 6 ) of the insulating module carrier. 6. converter module according to one of claims 1 to 5, characterized in that at least individual components elements with respect to their main axis perpendicular to the insulation Subracks are arranged so that components under different lengths can be used. 7. converter module according to one of claims 1 to - 6, characterized in that the power current path announcement ( 8 , 45 , 45 ') is constructed in layers to counteract the skin effect. 8. converter module according to one of claims 1 to 7, characterized in that the power current path ( 8 , 45 , 45 ') is coated with polyimide and is only then embedded in insulating material. 9. Converter module according to one of claims 1 to 8, characterized in that current sensors in the form of toroids / transducers are an integral part of the insulating group carrier ( 1 , 21 to 23 , 29 , 29 '). 10. Converter module according to one of claims 1 to 9, characterized in that the hydraulic connections ( 11 ) of the cooler ( 20 ) can be flanged to a cooling rail ( 24 ) via sealing rings. 11. A converter module according to claim 10, characterized in that the cooling rail ( 24 ) supports the mechanical connection of the insulation carrier assembly thus formed, carrier assembly ( 25 ) when a number of insulating sub-assemblies are juxtaposed. 12. Converter module according to one of claims 1 to 11, characterized in that the power current path ( 45 , 45 ') additionally contains the intermediate circuit rails ( 31 , 31 ', 32 , 32 ') of a multi-phase Isolierraugruppenträ ger association ( 25 ). 13. Converter module according to claim 12, characterized in that the power current rail ( 45 , 45 ') additionally contains a center potential rail ( 33 , 33 ') of a multi-phase insulating subassembly ( 25 ). 14. Converter module according to claim 12, characterized in that DC converters ( 34 ) at Leiterquerschnittsver narrowings ( 45 , 45 ') of the supply / discharge lines to / from the intermediate circuit rails ( 31 , 31 ', 32 , 32 ') arranged and in Isolierbau group carriers are integrated. 15. Power converter module according to one of claims 12 to 14, characterized in that the connection of the power circuit busbars ( 45 , 45 ') and in particular the intermediate circuit rails and / or center potential rails be adjacent insulating subracks via connecting bridges ( 52 , 53 ), the intermediate circuit rails and / or center potential rail with suitable connections ( 49 , 50 , 51 , 51 ') are provided. 16. Converter module according to one of claims 12 to 14, characterized in that the connection of the power supply rail connections ( 45 , 45 ') and in particular the intermediate circuit rails of adjacent insulating subracks is carried out via additional rails ( 54 ) which, in addition to the connection task, additionally perform current-carrying tasks, where at the DC link rails are provided with suitable connections ( 49 , 50 ). 17. Converter module according to claims 15 and / or 16, characterized in that the connecting bridges ( 52 , 53 ) and / or additional rails ( 54 ) in receiving grooves ( 35 , 35 ', 36 , 36 ') of the insulating subrack can be integrated.