Bus Bar Sensor Assembly With Cooling for High-Current Loads
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Solution Overview
Problem
Existing electrical assemblies often fail to provide sufficient functionality for large electrical currents, inadequate cooling, and require complex assembly processes, which limits their effectiveness in high-current applications.
Innovation Solution
The proposed electrical assembly includes a bus bar assembly, a sensor assembly, a bracket, and a cooling member, where the cooling member is configured to dissipate heat generated by high currents, and the assembly method involves connecting a shunt resistor with the bus bar assembly, circuit board with the bus bar assembly, and the cooling member with the bracket to facilitate efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing electrical assemblies are used, then the assembly structure is simple, but they cannot handle large electrical currents and provide insufficient cooling
Solution Approach 1:
The patent combines multiple functional components into an integrated electrical assembly: bus bar assembly for current conduction, sensor assembly for monitoring, bracket for structural support, and cooling member for thermal management. This merging of previously separate components enables the system to handle large currents (up to 2500 Amps) while providing adequate cooling, resolving the contradiction between improved reliability and increased device complexity.
Solution Approach 2:
The electrical assembly is designed as a multi-functional integrated system where a single assembly performs multiple functions: the bus bar assembly conducts electricity, the sensor assembly monitors electrical parameters, the bracket provides mechanical support, and the cooling member dissipates heat. This multi-functionality allows the assembly to handle large currents and provide sufficient cooling within a unified structure, addressing the contradiction between enhanced reliability and structural complexity.
2Adaptability or versatility
If existing electrical assemblies are used, then the assembly process is simple, but they provide insufficient functionality for high-current applications
Solution Approach 1:
The electrical assembly is divided into distinct functional modules: bus bar assembly, sensor assembly, bracket, and cooling member. Each module is designed and assembled separately then integrated into the complete system. This segmentation approach enables the assembly to provide sophisticated functionality for high-current applications (up to 2500 Amps) while maintaining a manageable assembly process through modular construction.
Solution Approach 2:
The individual components (bus bar assembly, sensor assembly, cooling member) are prepared and pre-assembled into functional modules before final integration. This preliminary action allows each subsystem to be optimized independently for high-current functionality while simplifying the final assembly process, as pre-assembled modules can be integrated more efficiently than individual components.
3Temperature
If existing electrical assemblies are used, then the design is simple, but they do not provide sufficient cooling for large electrical currents
Solution Approach 1:
The cooling member acts as an intermediary component between the heat-generating bus bar assembly and the environment. It is specifically positioned to receive and dissipate heat from the bus bar assembly, providing dedicated thermal management for high-current applications. This intermediary cooling system enables effective heat dissipation without requiring complete redesign of the entire assembly configuration.
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
This configuration enables the electrical assembly to handle high currents of up to 2500 Amps for extended periods while effectively dissipating heat, improving functionality and simplifying the assembly process, thus addressing the limitations of existing assemblies.
Implementation Method 1
a cooling member connected to the bracket... configured to dissipate heat generated by high currents
Implementation Method 2
cooling member... effectively dissipating heat
Implementation Method 3
connecting a shunt resistor with a bus bar assembly... sensor assembly, including a circuit board connected to the bus bar assembly, and a sensor
Data Source
AI summary
An electrical assembly may include a bus bar assembly, a sensor assembly, including a circuit board connected to the bus bar assembly, and a sensor, a bracket connected to the bus bar assembly, and a cooling member connected to the bracket. A method of assembling an electrical assembly may include connecting a shunt resistor with a bus bar assembly, connecting a circuit board with the bus bar assembly, connecting the bus bar assembly with the bracket, disposing the cooling member on or about the bracket, and/or connecting the cooling member with the bracket.