Laminated Busbar Design Guide: Minimizing Stray Inductance nyob rau hauv siab -Power Inverters

Laminated busbars txo inverter hloov lub voj inductance los ntawm kev sib xyaw zoo thiab tsis zoo conductors rau hauv cov txheej txheem compact nrog kev tswj dielectric qhov sib txawv. Rau SiC thiab IGBT fais fab modules, lub laminated busbar ua tau zoo tuaj yeem ua tiav inductance qis dua 10nH, txo qhov voltage overshoot thaum lub sij hawm siab - zaus hloov.

 

Xiamen Apollo Technology tsim kev cai laminated busbars siv C1100 ntshiab tooj liab, precision stamping, molecular diffusion vuam, thiab ntau - txheej txheem kub nias. Kev ua tau zoo hluav taws xob raug txheeb xyuas los ntawm CMM tshuaj xyuas, dielectric tiv thaiv kev sim, thiab PPAP Qib 3 cov ntaub ntawv rau kev siv tsheb thiab lub zog cia.

 

 

 

Niaj hnub nimno EV traction inverters thiab ESS lub zog hloov dua siab tshiab tau txais SiC MOSFET thiab siab -ceev IGBT modules. Cov khoom siv no hloov ntawm cov zaus ntau dua nrog lub sijhawm luv luv, ua rau cov kab mob parasitic inductance hauv DC txuas tus qauv ua qhov cuam tshuam ncaj qha cuam tshuam rau qhov voltage spikes thiab semiconductor kev ntseeg tau.

 

Kev sib raug zoo ntawm stray inductance thiab switching voltage overshoot raws li nram no:

ΔV=L × di/dt

Qhov twg:

ΔV=voltage overshoot

L=stray inductance ntawm lub voj tam sim no

di/dt=tus nqi hloov tam sim no

Rau 800V EV inverter ua haujlwm nrog SiC modules:

 

Parameter	Conventional Busbar	Laminated Busbar Design
DC txuas inductance	50-150 nH	<10nH
Tus neeg xyuas pib sib nrug	5-15 hli	0.1-1mm dielectric txheej
Txoj kev tam sim no	Cais cov kab zoo/tsis zoo	Parallel laminated qauv
Magnetic teb tshem tawm	txwv	Ua kom zoo
Hloov voltage overshoot	Siab dua	Txo

 

Lub laminated qauv tso qhov zoo thiab tsis zoo conductors nyob ze. Cov lus qhia tam sim no ua rau muaj qhov sib txawv ntawm qhov sib nqus, txo cov hlau nplaum sab nraud thiab txo qis lub voj inductance.

 

1.1 Magnetic Field Cancellation Txoj Cai Nrog Copper Layer Optimization

Lub laminated busbar tsim nyob ntawm:

Copper thickness xaiv

Txheej txheej

Dielectric thickness

Terminal txoj hauj lwm

Tam sim no faib symmetry

 

Hom EV inverter laminated busbar tsis:

Khoom siv tooj liab: C1100 electrolytic tawv pitch tooj liab

Conductivity: Ntau dua lossis sib npaug li 99% IACS

Copper thickness: 0.5mm-5mm

Flatness kam rau ua: Tsawg dua lossis sib npaug ntawm 0.05mm

Terminal txoj hauj lwm kam rau ua: ± 0.1mm

Kev kho deg: npib tsib xee plating / tin plating

Tsis sib xws tus neeg xyuas pib geometry tsim cov cheeb tsam hauv cheeb tsam tam sim no, nce ob qho tib si kuj thiab electromagnetic cuam tshuam.

 

 

 

Cov khoom siv hluav taws xob ncaj qha txiav txim siab tam sim no - nqa lub peev xwm, kev ua haujlwm thermal, thiab kev cia siab ntev ntev -.

 

Rau EV inverter thiab ESS daim ntawv thov, cov tooj liab ntshiab yog nyiam vim nws cov hluav taws xob ntau dua thiab qis dua Joule cua sov.

 

Khoom Khoom	C1100 ntshiab tooj liab	C2680 tooj dag
Cov ntsiab lus tooj liab	Ntau dua lossis sib npaug li 99.90%	60-65%
Kev coj ua	Ntau dua lossis sib npaug li 99% IACS	26-30% IAB
Kev tiv thaiv	0.0172 Ω·mm² / m	Siab dua
Thermal conductivity	~390 W/m·K	~120 W/m·K
Tej daim ntawv thov	Lub hwj chim busbar, inverter DC txuas	Mechanical terminals, connectors
Tam sim no muaj peev xwm nqa tau	Siab	Nruab nrab

 

C1100 tooj liab raug xaiv rau:

EV roj teeb pob busbars

SiC inverter DC txuas txuas

Lub zog cia PCS kev sib txuas

Charging pawg zog modules

C2680 tooj dag yog tsuas yog siv qhov twg txhua yam muaj zog thiab kev ua tau zoo yog qhov tseem ceeb.

 

2.1 Precision Stamping thiab Forming Control Raws li IATF 16949 Yuav Tsum Tau

Siab -tam sim no laminated busbars feem ntau yuav tsum tau complex terminal geometry, suav nrog:

90℃dabtsi yog khoov
Terminal qhov
Positioning slots
Nias - haum cov qauv
Hauv -cov ntsiab lus tuag riveting

 

Manufacturing Parameters:

Progressive tuag stamping kam rau ua: ± 0.01mm
Burr qhov siab tswj: Tsawg dua lossis sib npaug li 10% cov khoom tuab
Cov cuab yeej saib xyuas lub neej: Ntau dua lossis sib npaug rau 500,000 stamping cycles
CMM qhov ntsuas qhov ntsuas: 100% rau qhov loj me

Hauv - tuag riveting integrates mechanical fastening rau hauv cov txheej txheem stamping, txo kev sib dhos sib txawv thiab txhim kho cov khoom sib xws.

 

Thov Kev Ntsuam Xyuas DFM Dawb & Tso Cai

 

 

Lub dielectric txheej txiav txim siab kev ntseeg tau ntawm rwb thaiv tsev, thermal endurance, thiab mechanical stability ntawm laminated busbars.

 

Lub siab - lub zog inverter busbar yuav tsum tswj xyuas kev ua haujlwm rwb thaiv tsev raws li:

Thermal cycling

High voltage hloov

Mechanical vibration

Humidity raug

Cov khoom siv rwb thaiv tsev:

 

Cov khoom siv rwb thaiv tsev	Kev ntsuas kub	Dielectric zog	Daim ntawv thov
Kapton Polyimide Zaj duab xis	269 ​​degree rau 400 degree	>200kV / hli	SiC inverter kub aav
PET zaj duab xis	-40℃rau 150 degree	150-250kV / hli	Standard EV fais fab mov modules
Nomex Ntawv	Mus txog 220 degree	Siab thermal tsis kam	ESS thiab industrial fais fab system

 

3.1 Epoxy hmoov txheej vs Zaj duab xis rwb thaiv tsev rau Laminated Busbars

 

Parameter	Epoxy hmoov txheej	Polyimide / PET Zaj duab xis
Txheej thickness	100-500μm	25-125μm
Dielectric zog	>15 kV / hli	>150 kV / hli
Kub tiv taus	120-180 degree	150-400 degree
Thickness tswj	Nruab nrab	Siab
Daim ntawv thov	Complex 3D qhov chaw	Precision laminated qauv

 

Rau EV inverter laminated busbars, nyias zaj duab xis rwb thaiv tsev muab me me dielectric spacing, txhim kho electromagnetic kev ua tau zoo.

 

Yuav tsum tau tswj kom zoo:

Rwb thaiv tsev thickness ntsuas

High voltage withstand xeem

Kev kuaj tawm ib nrab

Kev kuaj adhesion

Thermal aging test

 

Hom validation qauv:

IEC 60664 rwb thaiv tsev kev sib koom ua ke

UL94 V-0 nplaim taws ntsuas

ISO 16750 Automotive ib puag ncig kuaj

 

 

 

Ntau- txheej laminated busbars yuav tsum tau tswj cov thermal bonding ntawm tooj liab conductors thiab cov ntaub ntawv rwb thaiv tsev.

 

Cov txheej txheem tsim khoom muaj xws li:

Copper daim ntawv txiav thiab stamping

Deburring thiab ntxuav qhov chaw

Plating kev kho mob

Rwb thaiv tsev zaj duab xis positioning

Lub tshuab nqus tsev kub nias

Terminal machining

Kev tshuaj xyuas hluav taws xob

 

4.1 Kub nias txheej txheem Parameters rau Automotive qib ntau lawm

Hom ntau lawm parameter:

 

Txheej Txheem Parameter	Tswj ntau yam
Xovxwm kub	150-220 degrees
Nias siab	2-8MPa
Txheej alignment kam rau ua	± 0.1 hli
Flatness	Tsawg dua los yog sib npaug li 0.05mm
Bonding zog	Raws li cov khoom specification
Ntau lawm validation	PPAP Qib 3

 

Kev tswj lamination tsis zoo yuav ua rau:

Huab cua void tsim

Cov ntsiab lus tso tawm ib nrab

Rwb thaiv tsev tawg

Txheej txheej

Lub tshuab nqus tsev kub nias tshem tawm cov cua hauv nruab nrab ntawm tooj liab thiab dielectric txheej, txhim kho lub sijhawm ntev - hluav taws xob kev ntseeg tau.

 

 

Siab -tam sim no cov davhlau ya nyob twg yuav tsum tau qis- cov pob qij txha tiv thaiv muaj peev xwm tuav tau rov ua dua thermal cycling.

Cov kev sib koom ua ke feem ntau suav nrog laser vuam thiab tiv thaiv nyiaj brazing.

 

Vuam txoj kev	Laser Vuam Cu-Al	Resistance Silver Brazing
Thaum tshav kub kub- thaj tsam cuam tshuam	Me me	Loj dua
Kev sib koom ua ke muaj zog	Siab	Siab
Hluav taws xob tsis kam	Tsawg	Tsawg heev
Ntau lawm ceev	Siab	Nruab nrab
Cov ntaub ntawv tsim nyog	Copper, aluminium ua ke	tooj liab terminals
Automotive daim ntawv thov	Roj teeb modules, inverter terminals	Siab - kev sib cuag tam sim no

 

Rau tooj liab-aluminium txuas:

Laser vuam tsis yuav tsum tswj porosity

Beam zog ceev yuav tsum optimization

Hla- yuav tsum tau kuaj xyuas ntu

 

Rau silver brazing:

Brazing alloy xaiv muaj feem xyuam rau conductivity

Kev sib koom ua ke yuav tsum tau tswj

Metallurgical bonding zoo yuav tsum tau soj ntsuam microscopic

 

Kev tshuaj xyuas zoo suav nrog:

Weld cross-section tsom xam

Kev ntsuam xyuas lub zog tensile

Kev ntsuas hluav taws xob tiv thaiv

Thermal cycling validation

 

 

 

Automotive laminated busbars yuav tsum tau tswj kev tsim cov txheej txheem los ntawm cov qauv siv rau kev tsim khoom loj.

Xiamen Apollo siv:

 

6.1 Dimensional Inspection Raws li ± 0.01mm Tolerance Requirements

 

Cov cuab yeej tshuaj xyuas:

CMM tswj kev ntsuas tshuab

Optical ntsuas qhov system

Thickness ntsuas

Nto roughness tester

 

Qhov loj me tseem ceeb:

Terminal qhov chaw

Copper txheej alignment

Rwb thaiv tsev clearance

Mounting interface

 

6.2 Kev kuaj hluav taws xob thiab kev ntseeg siab

 

Kev kuaj muaj peev xwm suav nrog:

 

Cov khoom kuaj	Standard / Requirement
Dielectric tiv thaiv kev xeem	>15kV / hli rwb thaiv tsev muaj peev xwm
DC tsis kam kuaj	Micro-ohm qib ntsuas
Thermal cycling	ISO 16750 Kev Tswj Xyuas
Ntsev tsuag	ISO 9227 Kev Tswj Xyuas
Kev ntsuam xyuas tawg	Rau kev sib xyaw ua ke cua txias
Cov ntaub ntawv PPAP	Qib 3

 

Lub pob zoo suav nrog:

Txheej Txheem Flow Diagram

PFMEA

Tswj Plan

MSA

SPC cov ntaub ntawv

Cov ntaub ntawv pov thawj

 

 

High-power inverter laminated busbars yuav tsum tau tswj ib txhij ntawm hluav taws xob, thermal, mechanical, thiab manufacturing parameters. Tus qauv qis inductance qis dua 10nH nyob ntawm tus neeg xyuas pib symmetry, dielectric thickness tswj, xaiv cov khoom siv tooj liab, thiab cov txheej txheem lamination precision.

 

Rau EV, ESS, thiab photovoltaic fais fab hloov tshuab, Xiamen Apollo muabkev cai laminated busbarkev tsim khoom los ntawm DFM tsom xam, kev txhim kho cov cuab yeej, stamping, vuam, rwb thaiv tsev lamination, tshuaj xyuas, thiab PPAP Theem 3 xa khoom.

 

 

1. Lub sij hawm xa khoom ntawm PPAP Theem 3 yog dab tsi rau kev cai laminated busbars?

PPAP Theem 3 kev xa khoom feem ntau xav tau 4-8 lub lis piam tom qab kev pom zoo siv cuab yeej, suav nrog kev lees paub qhov ntev, kev txheeb xyuas cov khoom siv, thiab cov ntaub ntawv tsim khoom.

 

2. Laminated busbar manufacturers tuaj yeem lav pwm lub neej rau kev tsim tsheb?

Yog lawm. Kev vam meej stamping tuag raug saib xyuas nrog kev tiv thaiv kev tiv thaiv thiab feem ntau tsim los rau ntau tshaj 500,000 lub voj voog stamping.

 

3. Yuav ua li cas rwb thaiv tsev thickness kuaj ntawm laminated busbars?

Rwb thaiv tsev thickness raug txheeb xyuas los ntawm kev ntsuas thickness, dielectric tiv thaiv kev ntsuas, thiab hluav taws xob rwb thaiv tsev validation raws li IEC cov qauv.