Integrated Bus Bar Fuse Structure for Inverter EMI Reduction
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Solution Overview
Problem
In electrified vehicles, noise introduced into the inverter due to the structure of the current flow path can distort or amplify, affecting electromagnetic performance, and there is a need to reduce electromagnetic waves and integrate fuses within the inverter to prevent damage from excessive current.
Innovation Solution
A bus bar assembly is designed with an integrated structure of an electromagnetic wave reduction core and a fuse, which includes a first and second bus bar with a narrowing portion, an arc-blocking portion, a magnetic core, and a housing to accommodate these components, allowing for reduced volume and improved space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromagnetic wave reduction devices and fuses are installed separately in the inverter, then the electromagnetic performance and safety are improved, but the spatial constraint and device complexity increase
Solution Approach 1:
The patent combines the electromagnetic wave reduction device and fuse into a single integrated bus bar assembly. The magnetic core surrounds the bus bar to reduce electromagnetic waves, while the narrowing portion of the bus bar acts as a fuse element. This merging eliminates the need for separate installations, reducing spatial constraints while maintaining both electromagnetic performance and safety functions.
Solution Approach 2:
The bus bar assembly performs multiple functions simultaneously: it conducts electrical current, reduces electromagnetic waves through the magnetic core, and provides fuse protection through the narrowing portion. This multi-functionality allows a single component to replace what would traditionally require separate devices, addressing the spatial constraint issue while maintaining reliability.
2Reliability
If electromagnetic wave reduction devices and fuses are installed separately, then the protective functions are improved, but the manufacturing cost and installation complexity increase
Solution Approach 1:
By merging the electromagnetic wave reduction device and fuse into a single bus bar assembly, the patent reduces the number of separate manufacturing processes and installation steps. The integrated structure allows for simplified production where the magnetic core and bus bar with narrowing portion are manufactured as a unified component, reducing overall manufacturing cost and installation complexity while maintaining both protective functions.
3Productivity
If the bus bar has a uniform cross-section, then the current flow is simplified, but the fuse function and space utilization are reduced
Solution Approach 1:
The bus bar features a uniform cross-section in most areas for efficient current flow, but includes a localized narrowing portion that creates high resistance for fuse functionality. This local quality change allows the bus bar to maintain good current conduction properties overall while providing the necessary fuse protection at a specific location, balancing productivity and reliability requirements.
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 integrated bus bar assembly effectively reduces electromagnetic waves and provides a compact structure that is easily applicable to the inverter, improving space utilization and reducing costs while preventing damage from excessive current.
Implementation Method 1
an electromagnetic wave reduction core and fuse are integrated
Implementation Method 2
High-voltage fuses may prevent damage to the vehicle caused by fire or the like by physically disconnecting the bus bar carrying the current when an excessive current is abruptly generated
Data Source
AI summary
A bus bar assembly includes a first bus bar including a narrowing portion with a reduced cross-sectional area in a first direction between the end portions thereof, a second bus bar spaced from the first bus bar, an arc-blocking portion disposed to surround the narrowing portion at the least, a magnetic core disposed on the outside of the arc-blocking portion, and a housing accommodating respective portions of the first bus bar and the second bus bar, the arc-blocking portion, and the magnetic core.