System including curved capacitor bus
By designing a bent capacitor bus in an electric vehicle and connecting it to the main bus through laser welding, the connection problem caused by changes in capacitor size is solved, and a stable and reliable capacitor connection is achieved.
Patent Information
- Application Number
- CN202380076960.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-10-06
- Filing Date
- 2023-08-28
- Publication Date
- 2025-06-13
AI Technical Summary
In electric vehicles, the size of the capacitor changes cause the connection between the capacitor busbar and the main busbar to be invalid or error-prone to making effective welding.
A system consisting of a bending capacitor busbar is designed, which connects the capacitor to the main busbar by laser welding. The second portion of the capacitor busbar extends from the first portion, is perpendicular to the first portion and coplanar with the main busbar, adapting to various dimensional changes of the capacitor.
Through the design of the bending capacitor busbar, it can effectively adapt to the size changes of the capacitor, ensure the stable connection between the capacitor busbar and the main busbar, and improve the effectiveness and reliability of welding.
Smart Images
Figure CN120153450A_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to a system that includes: a capacitor for an electronic device of an electric vehicle; a set of main buses; and a set of capacitor buses for connecting the capacitor to the main buses. More specifically, the present disclosure relates to a system that includes curved capacitor buses for connecting the capacitor to the main buses via laser welding. Background Art
[0002] Capacitors (e.g., high-capacity capacitors, DC-link capacitors, etc.) stabilize the output of a power source in the event of unavailable current. Capacitors have various applications and are commonly used in vehicles, renewable energy devices, medical devices, consumer devices, etc.
[0003] An electric vehicle may include a capacitor for an electronic device (such as an inverter, a converter, etc.). The capacitor may be connected to the main bus of the electric vehicle via a capacitor bus. The main bus may include a corresponding cavity into which the capacitor bus is inserted. Further, the capacitor bus may be laser welded to the inner circumferential surface of the cavity of the bus. The capacitor bus may be substantially straight. Thus, and in some cases, there may be a gap between the inner circumferential surface of the main bus and the capacitor bus. For example, dimensional variations of the capacitor may result in such a gap. In such a case, the capacitor bus cannot be welded to the main bus, or the connection between the capacitor bus and the main bus may be ineffective or error-prone. Therefore, an improvement in the connection between the capacitor bus and the main bus is needed to accommodate dimensional variations of the capacitor. Summary of the Invention
[0004] According to an example embodiment, a system may include: a capacitor for an electronic device of an electric vehicle; a main bus; and a capacitor bus configured to connect the capacitor to the main bus, wherein the capacitor bus includes a first portion perpendicular to the main bus, and wherein the capacitor bus includes a second portion that extends from the first portion, is perpendicular to the first portion, and is coplanar with the main bus.
[0005] The capacitor bus may be laser welded to the main bus.
[0006] The capacitor may be a DC-link capacitor.
[0007] The capacitor may be disposed above the main bus in a vertical direction, and the capacitor bus may be disposed on one side of the capacitor in a horizontal direction.
[0008] The capacitor may be disposed below the main bus in a vertical direction, and the capacitor bus may be disposed on one side of the capacitor in a horizontal direction.
[0009] The system may include: a second main busbar; and a second capacitor busbar. The second busbar may include a cavity, and the second capacitor busbar extends through the cavity.
[0010] The system may include: a second main busbar; and a second capacitor busbar. The second busbar may include a cavity, and the second capacitor busbar extends through the cavity. The second capacitor busbar may be welded to a side surface of the cavity.
[0011] The system may include: a second main busbar; and a second capacitor busbar. The second busbar may include a cavity, and the capacitor busbar extends through the cavity.
[0012] The capacitor busbar may include an inner surface facing the capacitor and an outer surface facing away from the capacitor. The outer surface may be welded to the main busbar.
[0013] According to an example embodiment, an electric vehicle may include: a capacitor for an electronic device of the electric vehicle; a main busbar; and a capacitor busbar configured to connect the capacitor to the main busbar, wherein the capacitor busbar includes a first portion perpendicular to the main busbar, and wherein the capacitor busbar includes a second portion that extends from the first portion, is perpendicular to the first portion, and is coplanar with the main busbar.
[0014] The capacitor busbar may be laser welded to the main busbar.
[0015] The capacitor may be a DC link capacitor.
[0016] The capacitor may be disposed above the main busbar in a vertical direction, and the capacitor busbar may be disposed on one side of the capacitor in a horizontal direction.
[0017] The capacitor may be disposed below the main busbar in a vertical direction, and the capacitor busbar may be disposed on one side of the capacitor in a horizontal direction.
[0018] The electric vehicle may include: a second main busbar; and a second capacitor busbar. The second busbar may include a cavity, the second capacitor busbar extends through the cavity, and the second capacitor busbar may be welded to a side surface of the cavity.
[0019] The capacitor busbar may include an inner surface facing the capacitor and an outer surface facing away from the capacitor. The outer surface may be welded to the main busbar.
[0020] According to an example embodiment, a method of connecting a capacitor of an electric vehicle to a main busbar of the electric vehicle may include: laser welding a capacitor busbar to the main busbar to connect the capacitor to the main busbar, wherein the capacitor busbar includes a first portion perpendicular to the main busbar, and wherein the capacitor busbar includes a second portion that extends from the first portion, is perpendicular to the first portion, and is coplanar with the main busbar.
[0021] The method may include extending a capacitor busbar through a cavity of a second main busbar.
[0022] The method may include laser welding a second capacitor busbar to the second main busbar to connect the capacitor to the second main busbar. The second capacitor busbar may include an inner surface facing the capacitor and an outer surface facing away from the capacitor. The inner surface may be laser welded to the cavity of the second main busbar.
[0023] The capacitor busbar may include an inner surface facing the capacitor and an outer surface facing away from the capacitor. The outer surface may be laser welded to the main busbar.
[0024] It should be understood that the foregoing general description and the following detailed description are merely exemplary and explanatory and do not limit the claimed invention. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Figure 1A and Figure 1B are schematic views of a system for connecting a capacitor to a main busbar, the system including a curved capacitor busbar on the lower right side.
[0026] Figure 2A and Figure 2B are schematic views of a system for connecting a capacitor to a main busbar, the system including a curved capacitor busbar on the lower left side.
[0027] Figure 3A and Figure 3B are schematic views of a system for connecting a capacitor to a main busbar, the system including a curved capacitor busbar on the upper left side.
[0028] Figure 4A and Figure 4B are schematic views of a system for connecting a capacitor to a main busbar, the system including a curved capacitor busbar on the upper right side.
[0029] Figure 5 is a schematic view of an electric vehicle including an electronic device and a system for connecting a capacitor to a main busbar, the system including a curved capacitor busbar. DETAILED DESCRIPTION
[0030] Figure 1A and Figure 1B are schematic views of a system for connecting a capacitor to a main busbar, the system including a curved capacitor busbar on a first side (e.g., the lower right side). As Figure 1A and Figure 1BAs shown, system 100 may include a capacitor 110, a first main busbar 120, a second main busbar 130, a first capacitor busbar 140, a second capacitor busbar 150, a first cavity 160, a first weld 170, a second cavity 180, a third cavity 190, and a second weld 200. The first main busbar 120 and the second main busbar 130 may be substantially parallel to each other and may be arranged along an axis in the X direction. A first portion 153 of the first capacitor busbar 140 and the second capacitor busbar 150 may be substantially parallel to each other and may be arranged along an axis in the Z direction. A second portion 154 of the second capacitor busbar 150 may be substantially perpendicular to the first portion 153 of the second capacitor busbar 150 and the first capacitor busbar 140, may be substantially parallel to the first main busbar 120 and the second main busbar 130, and may be arranged along the X axis.
[0031] The capacitor 110 may be a DC link capacitor, a bulk capacitor, etc., and may be used in combination with the electronic device 400 (such as an electronic control unit (ECU), an inverter, a converter, etc.) of the electric vehicle 300 (as Figure 5 shown). The capacitor 110 may be configured to stabilize the output of the power supply in the case where current is unavailable.
[0032] The busbars of the present disclosure may be, for example, rigid conductors formed of a material having high conductivity (as a non-limiting example, copper or a copper alloy) in order to conduct high current (for example, more than 200 amperes). The busbars may be used to construct a circuit configured to carry high current. The busbars may be coated with a conductive material such as nickel (Ni), tin (Sn), zinc (Zn), nickel palladium (Pd), silver (Ag), gold (Au), aluminum (Al), copper (Cu), etc. in order to provide corrosion resistance to the busbars.
[0033] As shown in FIGS. 1 to Figure 5 B, the Z direction (vertically extending on the page) may correspond to the vertical direction, the X direction (horizontally extending on the page) may correspond to the transverse direction, and the Y direction (extending into and out of the page) may correspond to the longitudinal direction. However, it should be understood that the Z, X, and Y directions may respectively correspond to any one of the vertical, transverse, and longitudinal directions. Thus, as used herein, "above", "below", "right", "left", etc. may be relative terms, and they may or may not correspond to the actual spatial directions of the components when implemented in an electric vehicle. As used herein, "substantially perpendicular" may mean that a first surface forms a 90° angle with a second surface, or within a threshold angle of the second surface (for example, 85°, 95°, etc.). As used herein, "substantially coplanar" may mean that a first surface forms a 0° angle with a second surface, or within a threshold angle of the second surface (for example, 5°, -5°, etc.).
[0034] The system 100 may be incorporated into the electric vehicle 300, asFigure 5 As shown. As a specific example, system 100 can be used in combination with the electronic devices 400 of the electric vehicle 300 (such as inverters, converters, electronic control units (ECUs), etc.). Alternatively, system 100 can be incorporated into renewable energy devices, medical devices, consumer devices, etc.
[0035] As Figure 1A and Figure 1B As shown, the capacitor 110 can be disposed above the first main busbar 120. The first main busbar 120 can be disposed above the second main busbar 130. The first capacitor busbar 140 can be disposed on the first side, for example, the left side of the capacitor 110. The second capacitor busbar 150 can be disposed on the second side, opposite to the first side, for example, the right side of the capacitor 110.
[0036] The first main busbar 120 and the second main busbar 130 can be connected to the power supply of the electric vehicle 300 and can connect various components to the power supply of the electric vehicle 300. The first main busbar 120 can be the positive busbar, and the second main busbar 130 can be the negative busbar. Alternatively, the first main busbar 120 can be the negative busbar, and the second main busbar 130 can be the positive busbar.
[0037] The capacitor 110 can be connected to the first main busbar 120 and the second main busbar 130 via the first capacitor busbar 140 and the second capacitor busbar 150, respectively. The capacitor 110 can be integrated with the first capacitor busbar 140 and the second capacitor busbar 150. Alternatively, the capacitor 110 can be connected to the first capacitor busbar 140 and the second capacitor busbar 150 via any suitable connection technique (such as via laser welding). The first capacitor busbar 140 and the second capacitor busbar 150 can be connected to the first main busbar 120 and the second main busbar 130 via any suitable connection technique (such as via laser welding).
[0038] The first main busbar 120 can include a first cavity (or opening) 160 extending in the Z direction. The first capacitor busbar 140 can extend into the first cavity 160. The first capacitor busbar 140 can include an inner surface 141 facing (and can be in direct contact with) the capacitor 110 and an outer surface 142 facing away from the capacitor 110. A part of the inner surface 141 can be laser welded to the inner surface, for example, the circumferential surface 161 of the first cavity 160 of the first main busbar 120, via the first weld 170. Alternatively, the first capacitor busbar 140 can be laser welded to another surface of the first main busbar 120, such as the outer side surface, the inner side surface, the inner surface, the outer surface, etc.
[0039] The second capacitor busbar 150 may include an inner surface 151 facing (and may be in direct contact with) the capacitor 110, and an outer surface 152 facing away from the capacitor 110. The second capacitor busbar 150 may include a first portion 153 and a second portion 154. The first portion 153 may extend along the capacitor 110 in the Z direction and may be substantially perpendicular to the second main busbar 130. The second portion 154 may extend substantially perpendicularly from the first portion 153 in the X direction, may extend substantially coplanarly with the second main busbar 130 in the X direction, and may include a bend. The first portion 153 is substantially perpendicular to the second portion 154. The second portion 154 may be located within the second cavity 180 and may be located between the first main busbar 120 and the second main busbar 130. The outer surface 152 of the second portion 154 may contact the second main busbar 130.
[0040] More specifically, the inner surface 151 of the second portion 154 of the second capacitor busbar 150 may be substantially coplanar with the inner surface 131 of the second main busbar 130. The inner surface 131 of the second main busbar 130 may face the capacitor 110. Thus, the second capacitor busbar 150 may be "bent" due to the orientation of the first portion 153 and the second portion 154.
[0041] As Figure 1B shown, the first capacitor busbar 140 may extend into the first cavity 160. Further, the inner surface 141 of the first capacitor busbar 140 may be connected to the first main busbar 120 via a first weld 170. For example, the first capacitor busbar 140 may be laser welded to the inner circumferential surface 161 of the first cavity 160 of the first main busbar 120, to the outer surface of the first main busbar 120, to the inner surface of the first main busbar 120, etc.
[0042] As Figure 1B further shown, the first portion 153 of the second capacitor busbar 150 may extend into the second cavity 180 of the first main busbar 120. Further, the second portion 154 of the second capacitor busbar 150 may be disposed within the second cavity 180 of the first main busbar 120. The outer surface 152 of the second portion 154 of the second capacitor busbar 150 may contact the inner surface 131 of the second main busbar 130. Further, the outer surface 152 of the second portion 154 of the second capacitor busbar 150 may be connected to the inner surface 131 of the second main busbar 130 via a second weld 200. For example, the second capacitor busbar 150 may be laser welded to the second main busbar 130.
[0043] Alternatively, in some embodiments, the first main bus bar 120 may not include the second cavity 180. In this case, the second capacitor bus bar 150 may extend around the first main bus bar 120 to avoid contact with the first main bus bar 120, and extend toward and contact the second main bus bar. For example, the second capacitor bus bar 150 may extend in the Y direction to avoid the first main bus bar 120 and contact the second main bus bar 130.
[0044] The system 100 may facilitate the connection between the first capacitor bus bar 140, the first main bus bar 120, the second capacitor bus bar 150, and the second main bus bar 130 while accommodating various size variations of the capacitor 110. That is, despite the size variations of the capacitor 110, the first weld 170 and the second weld 200 may still be formed because the second portion 154 of the second capacitor bus bar 150 extends in the X direction, which provides an overlap between the second main bus bar 130 and the second capacitor bus bar 150.
[0045] The length of the second portion 154 may be selected based on the size of the capacitor 110, the size of the first main bus bar 120, the size of the second cavity 180, the size of the second main bus bar 130, the size of the third cavity 190, etc. In any case, the length of the second portion 154 may be selected such that a threshold amount of the inner surface 131 of the second main bus bar 130 overlaps with the outer surface 152 of the second portion 154 of the second capacitor bus bar 150.
[0046] Although Figure 1A and Figure 1B the second portion 154 is depicted as being located on the lower right side of the capacitor 110, it should be understood that the second portion 154 may be disposed on any other side of the capacitor 110. For example, as Figure 2A and Figure 2B shown, the second portion 154 may be disposed on the lower left side of the capacitor 110. As another example, and as Figure 3A and Figure 3B shown, the second portion 154 may be disposed on the upper left side of the capacitor 110. As another example, and as Figure 4A and Figure 4B shown, the second portion 154 may be disposed on the upper right side of the capacitor 110. Further, although the present disclosure depicts a single curved capacitor bus bar, it should be understood that the system 100 may include two curved capacitor bus bars.
[0047] While the principles of the present disclosure have been described herein with reference to illustrative embodiments of a particular application, it should be understood that the present disclosure is not limited thereto. Those of ordinary skill in the art and the teachings provided herein will recognize that additional modifications, applications, embodiments, and equivalent substitutions are within the scope of the embodiments described herein. Accordingly, the invention should not be considered limited to the foregoing description.
Claims
1. A system (100), comprising: including: a capacitor (110) for an electronic device (400) of an electric vehicle (300); a main busbar (130); and a capacitor busbar (150) configured to connect the capacitor (110) to the main busbar (130), wherein the capacitor busbar (150) includes a first portion (153) perpendicular to the main busbar (130), and wherein the capacitor busbar (150) includes a second portion (154) that extends from the first portion (153), is perpendicular to the first portion (153), and is coplanar with the main busbar (130).
2. The system (100) according to claim 1, wherein the capacitor busbar (150) is laser welded to the main busbar (130).
3. The system (100) according to claim 1 or 2, wherein the capacitor (110) is a DC link capacitor.
4. The system (100) according to any one of claims 1 to 3, wherein the capacitor (110) is disposed above the main busbar (130) in the vertical direction, and the capacitor busbar (150) is disposed on one side of the capacitor (110) in the horizontal direction.
5. The system (100) according to any one of claims 1 to 3, wherein the capacitor (110) is disposed below the main busbar (130) in the vertical direction, and the capacitor busbar (150) is disposed on one side of the capacitor (110) in the horizontal direction.
6. The system (100) according to any one of claims 1 to 5, further comprising: including: a second main busbar (120); and a second capacitor busbar (140), wherein the second main busbar (120) includes a cavity (160), and the second capacitor busbar (140) extends through the cavity.
7. The system (100) according to any one of claims 1 to 5, further comprising: including: a second main busbar (120); and a second capacitor busbar (140), wherein the second main busbar (120) includes a cavity (160), the second capacitor busbar (140) extends through the cavity, and wherein the second capacitor busbar (140) is welded to a side surface of the cavity (160).
8. The system (100) according to any one of claims 1 to 5, further comprising: including: a second main busbar (120); and a second capacitor busbar (140), wherein the second main busbar (120) includes a cavity (160), and the first capacitor busbar (150) extends through the cavity.
9. The system (100) according to any one of claims 1 to 8, wherein the capacitor busbar (150) includes an inner surface (151) facing the capacitor (110) and an outer surface (152) facing away from the capacitor (110), and wherein the outer surface (152) is welded to the main busbar (130).
10. An electric vehicle (300), comprising: including: A capacitor (110) for an electronic device (400) of the electric vehicle (300); A main bus bar (130); And A capacitor bus bar (150) configured to connect the capacitor (110) to the main bus bar (130), Wherein the capacitor bus bar (150) includes a first portion (153) perpendicular to the main bus bar (130), and Wherein the capacitor bus bar (150) includes a second portion (154) that extends from the first portion (153), is perpendicular to the first portion (153), and is coplanar with the main bus bar (130).
11. The electric vehicle (300) according to claim 10, wherein the capacitor bus bar (150) is laser welded to the main bus bar (130).
12. The electric vehicle (300) according to claim 10 or 11, wherein the capacitor (110) is a DC link capacitor.
13. The electric vehicle (300) according to any one of claims 10 to 12, wherein the capacitor (110) is disposed above the main bus bar (130) in the vertical direction, and the capacitor bus bar (150) is disposed on one side of the capacitor (110) in the horizontal direction.
14. The electric vehicle (300) according to any one of claims 10 to 13, wherein the capacitor (110) is disposed below the main bus bar (130) in the vertical direction, and the capacitor bus bar (150) is disposed on one side of the capacitor (110) in the horizontal direction.
15. The electric vehicle (300) according to any one of claims 10 to 14, which further Comprises: A second main bus bar (120); And A second capacitor bus bar (140), Wherein the second main bus bar (120) includes a cavity (160), the second capacitor bus bar (140) extends through the cavity, and Wherein the second capacitor bus bar (140) is welded to a side surface of the cavity (160).
16. The electric vehicle (300) according to any one of claims 10 to 15, wherein the capacitor bus bar (150) includes an inner surface (151) facing the capacitor (110) and an outer surface (152) facing away from the capacitor (110), and wherein the outer surface (152) is welded to the main bus bar (130).
17. A method of connecting a capacitor (110) of an electric vehicle (300) to a main bus bar (130) of the electric vehicle (300), the method Comprises: Laser welding a capacitor bus bar (150) to the main bus bar (130) to connect the capacitor (110) to the main bus bar (130), Wherein the capacitor bus bar (150) includes a first portion (153) perpendicular to the main bus bar (130), and Wherein the capacitor bus bar (150) includes a second portion (154) that extends from the first portion (153), is perpendicular to the first portion (153), and is coplanar with the main bus bar (130).
18. The method according to claim 17, further comprising: extending the capacitor bus bar (150) through a cavity of the second main bus bar (120).
19. The method according to claim 17 or 18, further comprising: laser welding a second capacitor bus bar (140) to the second main bus bar (120) to connect the capacitor (110) to the second main bus bar (120), wherein the second capacitor bus bar (140) includes an inner surface (141) facing the capacitor and an outer surface (142) facing away from the capacitor, and wherein the inner surface (141) is laser welded to the cavity of the second main bus bar (120).
20. The method according to any one of claims 17 to 19, wherein the capacitor bus bar (150) includes an inner surface (151) facing the capacitor (110) and an outer surface (152) facing away from the capacitor (110), and the outer surface (152) is laser welded to the main bus bar (130).