Engineering application and performance verification of Intelligent laminated busbar in wind power, photovoltaic and electric traction

A Laminated copper bar is an electrical connection component with a multi-layer composite structure, which can be regarded as the "highway" in the power distribution system. Compared with traditional complex, cumbersome, time-consuming, and labor-intensive wiring methods, stacked busbars can construct distribution systems with high technological content and clear structure. Its core features include: repeatable electrical performance, low inductive impedance, strong anti-interference ability, high reliability, simple assembly, and space saving. Stacked busbars can serve as ideal electrical connection components for high-power modules, widely used in power conversion modules for wind power generation, photovoltaics, electric traction equipment, and large-scale network equipment.

The technical advantages of Laminated bus bar for telecom can be summarized as five points: balancing low cost and high safety and reliability; Compact design significantly saves installation space; Optimizing circuit performance through low inductance and low impedance; Easy installation, reducing the probability of installation errors; Compared to traditional cables, it has stronger current carrying capacity and slower temperature rise rate.

The Intelligent laminated busbar has important application value in medium to high power converter scenarios due to its low inductance, high reliability, easy installation, and excellent heat dissipation and current carrying performance. Its main application areas include power conversion modules in wind power generation systems, photovoltaic inverters, power traction equipment, power conversion modules for large network equipment, as well as industrial frequency converters UPS, rail transit traction inverters, etc. In these scenarios, stacked busbars can effectively reduce distributed inductance, suppress voltage spikes, and improve overall system efficiency and long-term operational stability.
 

Through specific application cases, the practical application value and performance advantages of Laminated bus bar for IGBT based motor drives can be clearly demonstrated. In a certain application scenario, the original design scheme without using stacked busbars is as follows: the DC bus voltage is 790V, the IGBT working current is 133A, the bus inductance is as high as 780nH, and the IGBT rated voltage is set to 1700V. Due to the direct connection of copper bars in the original scheme, there is a large inductance between the positive and negative bars, and sufficient margin needs to be reserved for IGBT to meet performance requirements. At the same time, the fan adopts a blowing cooling method, which leads to the accumulation of heat in phase A of the AC output and a rapid temperature rise, seriously affecting the stability of the system.

After introducing Motor drive laminated bus bar for power electronics, the bus inductance was reduced to about 21nH, and the circuit distribution inductance was significantly reduced, effectively avoiding voltage spikes, ensuring that IGBT would not break down, and simplifying the overall design structure. Comparing the two schemes, the installation of DC links using stacked busbars is more convenient, without the need to consider complex issues such as electrical clearance and creepage distance. Simply tighten the installation point bolts to reduce the risk of installation errors.

In terms of insulation reliability, the enclosed edge of the laminated busbar can effectively block the invasion of pollutants and dust, avoid short-circuit faults, and achieve long-term fault free operation. In terms of heat dissipation and current carrying, the flat and wide structure combined with high thermal conductivity insulation film has excellent heat dissipation effect, low resistance, stable temperature rise characteristics, and leaves a large space for increasing current carrying capacity, which can work stably under short-term overload and high current conditions.

Although Laminated bus bar for high current inverter has significant advantages in technical performance, it is important to pay attention to its cost and flexibility characteristics in practical applications. Compared to ordinary copper bars, the manufacturing cost of laminated busbars is slightly higher, and due to the need for specialized molds for processing, subsequent changes to the copper bar structure may require synchronous modifications or even re molding, resulting in insufficient flexibility for design changes.

Therefore, it is recommended that in practical applications, after the design scheme of the Laminated bus bar for spacecraft power inverter is fully determined, the prototype stage demonstration is completed, and the structure is finalized, the processing and production of the laminated bus bar can be carried out to reduce the cost and cycle loss caused by design changes and fully leverage its technical advantages. Overall, laminated copper busbars have significant overall competitiveness in medium to high power converter scenarios due to their low inductance, high reliability, easy installation, and excellent heat dissipation and current carrying performance.

For different application scenarios such as wind power generation, photovoltaic inverters, electric traction, and industrial transmission, the inductance control, insulation structure, and heat dissipation design of Intelligent laminated busbars need to be optimized and matched according to specific working conditions. Welcome to contact us for professional selection advice and engineering support tailored to your project.