Integrated Bus Bar Assembly With Redundant Paths and Fault Sensing
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Solution Overview
Problem
Conventional bus bar assemblies suffer from high contact impedance, low power transmission efficiency, excessive waste material, limited power paths, and lack of real-time abnormality detection, leading to potential power interruptions.
Innovation Solution
The proposed bus bar assembly integrates a sensor for real-time temperature and voltage monitoring, features a one-piece structure with reduced waste material, and includes multiple power transmission paths to enhance efficiency and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the main bar and output part are formed by removing waste material from a metal plate, then the contacting surface is increased and contact resistance is reduced, but the volume of waste material is about 46% of the metal plate which is excessively high
Solution Approach 1:
The bus bar is divided into multiple separate components (main bar and output part) that are assembled together rather than formed from a single metal plate. This segmentation allows for reduced material waste while maintaining the necessary contacting surfaces for low contact resistance.
2Loss of substance
If the main bar and output part are assembled by screws to avoid waste material, then the waste material is reduced, but the contact impedance increases and power transmission efficiency decreases
Solution Approach 1:
The main bar and output part are merged into a single integrated component formed from a metal plate with optimized geometry. This combining ensures continuous metallic contact throughout the structure, minimizing contact impedance while reducing waste material through precise shaping.
3Device complexity
If the bus bar assembly has only one power outputting path, then the structure is simple, but it cannot provide backup power paths and has low degree of freedom in assembly application
Solution Approach 1:
The bus bar assembly is designed with multiple output parts that can serve different functions simultaneously - primary power output and backup power paths. This multi-functionality allows the same structure to adapt to various power distribution configurations and failure scenarios without increasing complexity.
4Device complexity
If no detection device is installed in the bus bar assembly, then the device complexity is low, but temperature abnormalities or voltage abnormalities cannot be detected immediately
Solution Approach 1:
The bus bar assembly incorporates built-in detection devices (temperature sensors and voltage sensors) that automatically monitor their own operational status. These self-monitoring capabilities enable immediate detection of abnormalities without adding significant complexity, as the system serves its own diagnostic needs.
Data Source
AI summary
A bus bar assembly is provided and includes a first linking bus bar, a second linking bus bar and plural power connectors. The first linking bus bar includes a first main bar, a first bending part and a first conducting part. The first bending part connects between the first main bar and the first conducting part. The second linking bus bar is disposed corresponding to and isolated from the first linking bus bar, and includes a second main bar, a second bending part and a third conducting part. The second bending part connects between the second main bar and the third conducting part. The power connectors are electrically coupled with the first main bar and the second main bar, respectively.