Electric Machine Busbar Connection Pad for Compact HV Assembly
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Solution Overview
Problem
The engine compartment of hybrid electric vehicles is overcrowded due to the close arrangement of electrical components like the traction/propulsion electric motor, power electronics module, and high-voltage battery, necessitating compact and easily accessible electrical connections that are complicated by multiple connections, especially when the electric machine has two stators.
Innovation Solution
An electrical connection device with phase and power supply conductor bars, using conductive pads and retaining elements, allows for compact and easy assembly/disassembly by passing through machine walls, eliminating the need for overlapping connections and facilitating access with insulating overmolding and centering means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connection pieces are used for each phase conductor, then reliable electrical connection is achieved, but device complexity and number of components increase
Solution Approach 1:
The patent combines multiple separate connection pieces (first, second, and third connection pieces for different phases) into a single integrated connection piece that accommodates all phase conductors. This merging reduces the total number of components while maintaining reliable electrical connections through multiple connection points within the unified structure.
Solution Approach 2:
The connection piece is designed with universal functionality to handle multiple phase conductors simultaneously. It includes multiple connection regions that can accommodate different phases (e.g., L1, L2, L3) and supports both current carrying and grounding functions within a single component, reducing the need for separate specialized pieces.
2Ease of operation
If flexible connection pieces are used to accommodate misalignment, then ease of assembly is improved, but structural stability may be compromised
Solution Approach 1:
The connection piece incorporates flexible elements that can dynamically adapt to misalignments between the electric machine and power electronics module. These flexible portions allow for positional adjustments during assembly while maintaining stable electrical connections, bridging the gap between rigidity for stability and flexibility for ease of assembly.
3Power
If connection pieces with large contact area are used, then current carrying capacity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The connection piece is segmented into multiple distinct contact regions, each optimized for specific functions (phase connections, neutral connection, grounding). This segmentation allows each region to be manufactured with appropriate precision tolerances while collectively providing large total contact area for high current carrying capacity, reducing the burden on any single manufacturing operation.
Data Source
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AI summary
The present invention relates to an electrical connection device (1) electrically connecting an electric machine and a power electronics module, the device comprising: - phase bars (U1, V1, W1, U2, V2, W2) which are connected to the electric machine; - feed bars (U, V, W) which are connected to the power electronics module, a portion (51) of a phase bar (U1, V1, W1, U2, V2, W2) and a portion (31) of a feed bar (U, V, W) being spaced apart from and parallel to one another, the portions (31, 51) comprising connection terminals (33, 53, 59); - a conductive pad electrically connecting the connection terminals (33, 53, 59) of the portions, which are held together by a retaining element (7) that passes through the conductive pad.