Bus Bar Unit with Inclined and Bent Portions for Insulation
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Solution Overview
Problem
Conventional bus bar units with long bus bars are prone to manufacturing errors leading to deformation and potential short circuits due to adjacent bus bars coming into contact, and existing solutions that prevent contact, such as molding with resin, are costly and complex.
Innovation Solution
A bus bar unit design featuring first and second bus bars with specific geometric configurations, including straight, inclined, and bent portions, arranged to ensure an insulation distance between them, allowing for stress distribution in multiple directions and preventing contact, even with manufacturing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the bus bar length is increased to connect rotary electric machine and control device, then the electrical connection capability is improved, but the manufacturing error influence increases causing deformation and potential short circuits
Solution Approach 1:
The bus bar is divided into multiple straight line portions, inclined portions, and bent portions rather than being a single continuous straight bar. This segmentation allows each portion to independently accommodate manufacturing errors and stresses, preventing cumulative deformation that would compromise insulation distance.
Solution Approach 2:
The bus bar features asymmetric geometry with inclined portions at specific ends and bent portions creating non-uniform spacing. The distance between adjacent bus bars varies along their length, being larger at critical insulation regions and smaller where structural connection is needed, optimizing both reliability and space utilization.
2Reliability
If a mold portion with resin is added to prevent bus bar contact, then the insulation distance is ensured, but the manufacturing cost and process complexity increase
Solution Approach 1:
The resin mold portion is completely removed from the structure. Instead of adding an external insulating component, the bus bar itself is designed with geometric features (inclined and bent portions) that inherently maintain insulation distance, eliminating the need for separate molding processes and reducing manufacturing complexity.
Solution Approach 2:
The bus bar structure serves its own insulation function through its asymmetric geometry. The inclined and bent portions automatically maintain safe distances between adjacent bus bars without requiring external insulating materials or additional protective structures.
3Ease of manufacture
If the bus bar is made straight and simple, then the manufacturing process is simplified, but the stress distribution capability is reduced leading to deformation
Solution Approach 1:
The bus bar is segmented into straight line portions for easy manufacturing and inclined/bent portions for stress management. Each segment can be independently formed using standard fabrication processes, while the combination of segments provides superior stress distribution compared to a completely straight bar.
Solution Approach 2:
Different portions of the bus bar have different geometric qualities optimized for their specific functions. Straight portions provide structural simplicity and ease of manufacture, while inclined and bent portions locally provide stress distribution and insulation capabilities where needed.
Data Source
AI summary
A bus bar unit related to one aspect includes: a first bus bar and a second bus bar. The first bus bar and the second bus bar are arranged side by side in a second direction orthogonal to a first direction as viewed from the first direction. The first bus bar includes, as viewed from the first direction, a first straight line portion, a first inclined portion, and a first bent portion. The second bus bar includes, as viewed from the first direction, a second straight line portion, a second inclined portion, and a second bent portion. In an end surface on a second bus bar side of the first bent portion, a distance between the first bent portion and the second inclined portion is longer than a distance between the first bent portion and the second straight line portion.