Presentations

Abstract

This paper introduces a groundbreaking approach to designing high-current three-phase AC busbars for megawatt-sized converters, specifically in wind energy systems. Traditional designs suffer from high AC resistance and inefficient material use due to their reliance on parallel-connected rectangular copper busbars. Complex routing in converter panels adds further inefficiencies, including contact losses and uneven current distribution. Interleaving phases can reduce AC resistance but has been difficult to implement with conventional methods due to complex crossings and additional intersections, which result in suboptimal material utilization and increased contact losses. Advances in Additive Manufacturing (AM) technology, particularly in mechanical properties such as material consistency, grain size, and layer thickness, have enhanced the electrical conductivity of AM-produced parts. These improvements allow alloys with higher conductivity to be employed in busbar designs, significantly boosting performance in high-power applications and making AM a key enabler for the innovations presented in this paper. By leveraging advanced AM technologies such as Laser Powder Bed Fusion (LPBF), Wire Arc Additive Manufacturing (WAAM), and Directed Energy Deposition (DED), this research presents a solution that significantly reduces material weight and the number of electrical joints. The design allows a transition from copper to aluminum, reducing weight by 54%, electrical joints by 72%, and parts by 55%, all while maintaining comparable electrical performance. AM's ability to apply material precisely where necessary, based on current flow, has enabled these improvements. Additionally, the printed conductors enhance thermal management by integrating the cooling of breaker losses into the design. This innovation paves the way for more sustainable manufacturing of high-current conductors, providing significant reductions in weight, cost, and complexity while improving overall reliability. This novel approach addresses the current industry need for both improved efficiency and sustainability in high-power converter applications.