Busbar Assembly Collar Structure for Secure Inverter Fastening
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Solution Overview
Problem
Existing busbar assemblies in electric drives for vehicles are prone to fastening errors during assembly, leading to potential mechanical damage and electric short-circuits due to misplaced fastening means, necessitating reassembly and increasing risks for human workers.
Innovation Solution
A busbar assembly design featuring insulating bodies with collars surrounding busbar openings to prevent unintentional detachment of fastening means, ensuring secure assembly and reducing the risk of mechanical damage and electric shocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or automatic fastening is used to connect busbars to high-voltage components, then assembly efficiency is improved, but the risk of fastening means flipping away from intended position increases
Solution Approach 1:
The insulating body acts as an intermediary structure that guides the fastening means into the correct position and prevents it from flipping away. The collar formed by the insulating body surrounding the busbar serves as a physical constraint that ensures the fastening means remains at the intended connection position during assembly operations.
Solution Approach 2:
The collar structure provides self-guiding and self-constraining functionality for the fastening means. The physical limitation created by the collar automatically prevents the fastening means from departing from the busbar assembly unintentionally, without requiring additional active control mechanisms.
2Object-affected harmful factors
If comprehensive reassembly is performed to remove lost fastening means, then mechanical damage and electric short-circuits are prevented, but manufacturing time and costs increase
Solution Approach 1:
The collar structure is pre-formed as part of the insulating body before assembly operations. This preliminary structural preparation ensures that the fastening means cannot fall into the housing during assembly, thereby preventing the need for subsequent reassembly operations to remove lost fastening means.
3Object-affected harmful factors
If reassembly is performed by human workers to remove lost fastening means, then safety risks are reduced, but the complexity of the assembly process increases
Solution Approach 1:
The collar structure provides automatic protection against fastening means loss without requiring human intervention or complex assembly procedures. The physical limitation inherent in the collar design self-regulates the fastening process, eliminating the need for additional safety protocols or complex procedural steps.
Data Source
AI summary
A busbar assembly includes at least two busbars each having a current flow direction and a cross-sectional area with regard to the current flow direction, the cross-sectional area having opposing first and second long sides and two opposing small sides, each busbar having a through-hole extending from the first long side to the second long side. An insulating body surrounding the long sides and the small sides of each busbar along a part of the current flow direction and forming an opening for each busbar on the first long side so as to allow access to the through-hole. The insulating body forms a collar extending away from the first long side and surrounding the openings.