Electrical Bus Bar Sensor Unit Integration

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Solution Overview

Problem

Existing bus bars in motor vehicles face challenges due to the weight and size of current transformer units, which are cumbersome and prone to issues with vibrations and impacts, and shunt-based solutions pose safety and reliability concerns with high current loads.

Innovation Solution

Integration of a sensor unit with a fastening surface into the bus bar, allowing for the measurement of physical parameters like current, temperature, and mechanical stress without the need for external measuring units, using a compact design that can be securely attached and potentially powered wirelessly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If current transformer units are used to measure bus bar parameters, then measurement capability is provided, but weight and size increase significantly

Engineering Contradiction:

Improvemeasurement capabilityVSAvoidweight

Core Design Contradiction:

Measurement precisionVSWeight of stationary object

Solution Approach 1:

The patent integrates the sensor unit directly into the bus bar structure, merging the measurement function with the conductor itself. The sensor unit is embedded within the bus bar body, eliminating the need for separate external measuring units and reducing overall weight while maintaining measurement capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sensor unit is nested within the bus bar structure, with the sensor element positioned inside the conductor body. This nesting approach allows the measurement system to be contained within the existing bus bar geometry, minimizing additional weight and space requirements.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Measurement precision

If current transformer units are used to measure bus bar parameters, then measurement capability is provided, but susceptibility to vibrations and impacts increases

Engineering Contradiction:

Improvemeasurement capabilityVSAvoidsusceptibility to vibrations and impacts

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

By merging the sensor unit with the bus bar structure, the measurement system becomes an integral part of the conductor. This integration reduces the number of separate components that could be affected by vibrations and impacts, improving reliability in harsh environments.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sensor element is surrounded by electrically insulating material that also provides mechanical protection and cushioning. This insulating material acts as a buffer against vibrations and impacts before they reach the sensitive sensor element, enhancing reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Measurement precision

If shunt-based solutions are used for measurement, then current measurement is enabled, but safety and reliability concerns arise with high current loads

Engineering Contradiction:

Improvecurrent measurement capabilityVSAvoidsafety and reliability with high current loads

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The sensor element is integrated directly into the bus bar conductor, allowing current measurement without requiring separate shunt connections. This eliminates the safety risks associated with high current loads on external shunts, as the measurement is taken within the conductor itself where the current path is already established.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sensor element acts as an intermediary that measures current through electromagnetic induction or other non-contact methods, allowing current measurement without direct electrical connection to the high current path. This intermediary approach maintains safety while enabling accurate measurement.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Measurement precision

If external measuring units are used, then measurement functionality is provided, but device complexity increases

Engineering Contradiction:

Improvemeasurement functionalityVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The sensor unit is merged with the bus bar structure, combining the conductor and measurement functions into a single integrated component. This reduces device complexity by eliminating separate external measuring units, connection wiring, and mounting hardware.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bus bar is designed to serve multiple functions simultaneously: current conduction and parameter measurement. This multi-functionality reduces the need for separate dedicated measurement devices, simplifying the overall system architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10340494B2Electrical bus bar comprising a sensor unit

Publication Date: 2019.07.02 AUDI AG

AI summary

An electrical bus bar for conveying an electric current from a first electrical device to a second electrical device, with a base body, which is formed from an electrically conductive material, and which has a first terminal for connection to the first electrical device and a second terminal for connection to the second electrical device. A sensor unit with a fastening surface has at least one sensor element for detecting or recording a physical parameter of the bus bar. The base body has a support surface, to which the sensor unit is fastened by its fastening surface.