Bent Capacitor Bus Bar Layout for Reliable EV Laser Welding
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Solution Overview
Problem
The existing connection between capacitor bus bars and main bus bars in electric vehicles is prone to errors due to dimensional variance, leading to ineffective welding and potential gaps, which can compromise the electrical connection.
Innovation Solution
A bent capacitor bus bar design that includes a first portion perpendicular to the main bus bar and a second portion extending perpendicularly and planar with it, allowing for laser welding to accommodate dimensional variations and ensure a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a straight capacitor bus bar is used, then the structure is simple and manufacturing is easy, but gaps may exist between the bus bar and main bus bar due to dimensional variance, leading to ineffective welding
Solution Approach 1:
The capacitor bus bar is designed with a bent configuration instead of a straight form. The bus bar includes a first portion extending from the capacitor and a second portion that is bent relative to the first portion, allowing the bus bar to conform to the cavity geometry and eliminate gaps between the bus bar and main bus bar, ensuring reliable laser welding connection.
2Reliability
If the capacitor bus bar is bent to accommodate dimensional variance, then welding reliability is improved, but the bus bar structure becomes more complex
Solution Approach 1:
The capacitor bus bar is divided into multiple portions: a first portion extending from the capacitor and a second portion that is bent relative to the first portion. This segmentation allows each portion to serve a specific function - the first portion provides electrical connection while the bent second portion accommodates dimensional variance and enables proper alignment for welding, thus improving connection reliability with minimal added complexity.
3Adaptability or versatility
If dimensional variance of the capacitor is accommodated, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The capacitor bus bar incorporates a bent configuration that provides geometric flexibility to accommodate dimensional variance in the capacitor. The bent shape allows the bus bar to adapt to different capacitor dimensions and positions without requiring high manufacturing precision, as the bent geometry can compensate for variations in capacitor size and alignment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bent capacitor bus bar design effectively addresses dimensional issues, enabling reliable laser welding and maintaining a stable electrical connection between the capacitor and main bus bars, even with varying dimensions, thus enhancing the reliability of the electrical system in electric vehicles.
Implementation Method 1
The capacitor bus bar may be laser welded to the main bus bar.
Data Source
AI summary
A system may include a capacitor for an electronic device of an electric vehicle; a main bus bar; and a capacitor bus bar configured to connect the capacitor to the main bus bar, wherein the capacitor bus bar includes a first portion that is perpendicular to the main bus bar, and wherein the capacitor bus bar includes a second portion that extends from the first portion, that is perpendicular to the first portion, and that is planar with the main bus bar.