Bus Bar Coupling Structure for Inverter Miniaturization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional bolting coupling methods for bus bars in high voltage inverters lead to increased size and cost due to space constraints and assembly defects, requiring additional tools and fixed element disposition.
Innovation Solution
A coupling structure using a female and male bus bar with a spring-mounted fitting mechanism, allowing direct coupling without tools, enhancing miniaturization and cooling efficiency by eliminating the need for bolting and enabling flexible power part disposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolting coupling method is used for bus bars, then connection strength is ensured, but inverter size increases and assembly complexity increases
Solution Approach 1:
The bus bar coupling structure is segmented into male and female coupling parts with distinct functional zones: a coupling部 for mechanical connection and a connection部 for electrical connection. This segmentation allows each part to be optimized independently, reducing overall size while maintaining connection strength through specialized coupling mechanisms.
Solution Approach 2:
The coupling structure employs a nested configuration where the male bus bar coupling part is inserted into the female bus bar coupling part. The male coupling part includes an insertion hole that receives the female coupling part, creating a nested arrangement that minimizes space requirements while ensuring robust mechanical and electrical connection.
2Reliability
If bolting coupling method is used for bus bars, then connection reliability is maintained, but manufacturing cost increases due to additional tools and components
Solution Approach 1:
The coupling structure merges mechanical coupling and electrical connection functions into a single integrated component. The male and female bus bars each have coupling parts that simultaneously provide mechanical attachment and electrical conductivity, eliminating the need for separate bolting hardware and reducing manufacturing steps.
Solution Approach 2:
The invention extracts and eliminates unnecessary intermediate components from the traditional bolting system. By using direct male-female coupling parts with insertion holes and connection surfaces, the design removes bolts, nuts, washers, and associated tooling, thereby reducing manufacturing complexity and cost while maintaining connection reliability.
3Stability of the object's composition
If bolting coupling method is used for bus bars, then structural stability is achieved, but assembly precision decreases due to worker deviation
Solution Approach 1:
The coupling structure employs asymmetric male and female coupling parts with specific geometric features such as insertion holes, protrusions, and recesses. This asymmetric design provides built-in alignment guidance that ensures precise mating of components, eliminating variability introduced by manual assembly and ensuring consistent structural stability.
Solution Approach 2:
The coupling parts are designed with pre-configured geometric features including insertion holes, alignment protrusions, and contact surfaces that guide the assembly process. These preliminary structural arrangements ensure that components self-align and mate precisely during assembly, eliminating the need for complex alignment procedures and ensuring consistent assembly precision.
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 solution reduces the overall size of the inverter, enhances cooling efficiency, and prevents assembly defects by allowing direct contact with coolers, while reducing production costs and manual errors.
Implementation Method 1
a spring mounted into the mounting groove or mounted on an outer surface of the male bus bar coupling part
Data Source
AI summary
Provided is a coupling structure of a bus bar equipped in a power part. The coupling structure of the bus bar includes a female type bus bar and a male type bus bar respectively coupled to different elements of the power part, wherein the female type bus bar is fitting-coupled to the male type bus bar. In the coupling structure of the bus bar, since bus bars of high voltage elements are connected to each other by a connecting method instead of a conventional bolting coupling structure, the miniaturization effect and cooling effect of an inverter may increase, and moreover, a tool used to couple bus bars may be omitted, thereby enabling power parts to be easily disposed.