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Registered Member #54503
Joined: Sun Feb 22 2015, 10:35PM
Location: New Zealand
Posts: 288
I had my busbars designed with solidworks for the coil im working on.
I am using CM300 IGBT modules, and these busbars are a similar layout to loneoceans' latest coil. Im not sure if the screw hole spacings are different on larger bricks like cm600's etc, but this could very well fit those too, as my CM300DY-24H seem the same size as a CM600 series.
Im fairly sure most caps this size have the same spacing between terminals also. The larger ones around 6800uF seem to be longer, thats all.
Other brands could very well fit also, but at least this design can be modified to suit.
I have attached the STEP file for reference.
I would have liked mine in copper but its really hard to find copper sheet in small amounts in New Zealand! I can only get it by a large sheet worth about $1200! lol
I dont know if its a big deal or not as Loneoceans is only using alloy on his coils.
Photos are also attached, hopefully this will help other coilers and i welcome anyone to modify to suit other IGBt's and capacitors etc.
Registered Member #54503
Joined: Sun Feb 22 2015, 10:35PM
Location: New Zealand
Posts: 288
lol I didnt take a good look at yours and thought yours were cut by hand at the time!
Anyway, interesting that alloy works OK, i assume the losses are not too big a deal?
How does yours compare to mine?
I was going to ask you about spacer washers, because where there is a cut out on the insulator, its impossible to bolt up to the IGBT without a packer or else it would buckle the alloy.
I assume you have added a spacer washer where the cutouts are on the back?
lol I didnt take a good look at yours and thought yours were cut by hand at the time!
Anyway, interesting that alloy works OK, i assume the losses are not too big a deal?
How does yours compare to mine?
I was going to ask you about spacer washers, because where there is a cut out on the insulator, its impossible to bolt up to the IGBT without a packer or else it would buckle the alloy.
I assume you have added a spacer washer where the cutouts are on the back?
There are a lot other more significant places for losses, you don't gain a huge lot by using copper over aluminium. I'd prefer copper but aluminium works just fine.
For spacer washers I simply made a bunch of aluminium washers out of the same sheet material. It looks like you CNCed it and it should be relatively easy to get that cut out with little tabs to hold the washers in place which can then be cut by some flush cutters.
Registered Member #54503
Joined: Sun Feb 22 2015, 10:35PM
Location: New Zealand
Posts: 288
Sweet, i had exactly the same thing in mind and had some washers cut out of the same alloy.
Its a good relief to know that copper is not critical to say the least!
I probably will replace the bolts on the IGBT's and caps with Hex headed screws, it seems everyone is using those for making a good connection and firmly bolting everything together nice and tight.
I had alot of trouble to find FR4 fibreglass board, but finally found some from a PCB manufacturer which was good.
CNC cutting sure makes things easy, I want to build a 3D printer and CNC router after i finish my coil!
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CNC machined Full Bridge laminated busbar design!
