High-Voltage Bus Bar Fork Prong Segmentation for Laser Welding
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Solution Overview
Problem
Existing high-voltage bus bars for electrically contacting ring conductors in electrical machines face challenges in efficiently distributing heat during the welding process, leading to increased energy requirements and prolonged process times due to dispersed thermal energy and continuous contact surfaces.
Innovation Solution
A high-voltage bus bar design that bifurcates into separate fork prongs for integral bonding to ring conductor ends, optimizing heat distribution and reducing surface area for improved welding efficiency, allowing for direct laser bonding or use of solder flux for enhanced bonding without additional material melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a continuous contact surface is used for bonding the bus bar to ring conductors, then the bonding area is maximized, but the heat input is dispersed and welding time increases
Solution Approach 1:
The bus bar is segmented into multiple fork prongs (at least two) at its second end, with each fork prong forming a separate contact face for bonding to distal end portions of ring conductors. This segmentation concentrates heat input at discrete bonding locations rather than dispersing it across a continuous surface, thereby reducing overall welding time while maintaining adequate bonding strength through focused thermal energy application.
2Strength
If a continuous contact surface is used for bonding, then the bonding area is maximized, but energy consumption increases due to dispersed heat input
Solution Approach 1:
The bus bar is segmented into multiple fork prongs (at least two) at its second end, with each fork prong forming a separate contact face for bonding to distal end portions of ring conductors. This segmentation concentrates heat input at discrete bonding locations rather than dispersing it across a continuous surface, thereby reducing overall welding time while maintaining adequate bonding strength through focused thermal energy application.
3Reliability
If multiple welding and bonding points are used to connect ring conductors to the bus bar, then connection reliability is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The bus bar design integrates multiple contact faces (at least two) formed by fork prongs directly into its structure, allowing simultaneous or sequential bonding of multiple ring conductors to different fork prongs. This merging of multiple connection points into a single integrated component reduces assembly complexity and manufacturing steps while maintaining reliable electrical connections across all phase conductors.
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 design reduces energy consumption and shortens welding times, lowering process costs and improving the overall efficiency of the bonding process while maintaining strong, integral connections.
Implementation Method 1
the heat input which is introduced locally as a result of the welding process can be better distributed so that the edge zone reaches an optimum temperature for the welding process
Implementation Method 2
The welding process requires melting of the materials to be joined, if necessary with the use of an additional solder flux, in order to obtain an integral bond
Data Source
AI summary
A high-voltage bus bar for electrically contacting an electrical, optionally insulated, line with two mutually adjacent, distal end portions of a ring conductor. The high-voltage bus bar includes, in the region of its first distal end, a terminal for connection to the electrical line, and its second distal end bifurcates into at least two prongs in such way that each of the at least two fork prongs forms a separate contact face which is provided to be integrally bonded to one of the distal end portions of the ring conductor.