Bus Bar Assembly With Gapped Core for Stable Noise Reduction
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Solution Overview
Problem
Existing bus bar assemblies in hybrid vehicles face instability in noise current reduction due to vibration-induced displacement of the magnetic core and magnetic saturation, leading to increased complexity and weight in fixing members, as well as reduced effectiveness in noise current reduction.
Innovation Solution
A bus bar assembly with a C-shaped or U-shaped section of uniform area in insertion holes, combined with a θ-shaped core and a spacer, and a fastening member with an engagement portion to prevent core displacement and enhance vibration resistance, thereby maintaining stable noise reduction and reducing material loss and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a leaf spring and ceiling structure are used to fix the core to the bus bar, then the core can be easily fixed and held at a predetermined position, but vibration or oscillation of the vehicle would vary the distance between the bus bar and the core, rendering the noise current reducing effect unstable
Solution Approach 1:
The core is divided into a first core member and a second core member that are combined together. This segmentation allows the core to be easily assembled with the bus bar while maintaining positional stability through the integrated structure of multiple core members working together.
Solution Approach 2:
The first core member and second core member are combined to form an integrated core structure that is held by the bus bar. This merging provides stable positioning without requiring additional fixing members, resolving the contradiction between ease of fixing and stability of the noise reduction effect.
2Reliability
If the core is designed as a complete closed circuit to reduce noise current, then the noise current reduction effect is maximized, but the core reaches magnetic saturation quickly when large current flows through the bus bar, losing the noise current reduction effect
Solution Approach 1:
The core is segmented into first and second core members that are combined together. This segmentation creates a magnetic circuit structure that can handle large currents without saturating, while still maintaining effective noise current reduction through the coordinated magnetic paths of both core members.
Solution Approach 2:
The core uses a composite structure of first and second core members with different magnetic path configurations. This composite design allows the core to process large currents without saturation while maintaining noise reduction effectiveness through the combined magnetic shielding action.
3Reliability
If extensive fixing members are used to suppress variations in distance between bus bar and core, then the distance variations are reduced, but the mounting procedure becomes complicated and the weight of the fixing member increases
Solution Approach 1:
The first core member and second core member are combined to form an integrated structure that is directly held by the bus bar. This merging eliminates the need for extensive separate fixing members, simplifying the mounting procedure while maintaining distance stability through the integrated design.
Solution Approach 2:
The combined core structure serves multiple functions: it provides stable positioning relative to the bus bar, maintains consistent distance without additional fixing members, and delivers noise current reduction. This multi-functionality resolves the contradiction between distance stability and mounting complexity.
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 effectively prevents core displacement, enhances vibration resistance, and maintains noise reduction efficacy by ensuring the core and bus bar remain stable, reducing noise production and manufacturing costs through improved design and assembly.
Implementation Method 1
the core is a complete closed circuit. Accordingly, the core shortly reaches a state of magnetic saturation by current flowing into the bus bar with the result that the noise current reduction effect is lost
Implementation Method 2
a leaf spring formed of an elastic material is provided with a ceiling
Data Source
Figure 1
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Figure 4
AI summary
In a bus bar assembly including a magnetic body 30 having insertion holes 33 and a bus bar 20 disposed through the insertion holes 33, the bus bar 20 is configured so that directions of electrical current E flowing therethrough are opposed to each other at least once. The magnetic body 30 includes a middle leg 34 in a middle region 40 located between portions (22) of the bus bar 20, where the directions of current E are opposed to each other and end legs 36 in end regions 60 located opposite the middle region 40 with respect to the portions 22. At least the middle leg 34 defines a gap 35 which renders a magnetic field produced by the current E discontinuous.