Intermediate Busbar Connector Assembly for Misalignment and Vibration
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Solution Overview
Problem
Existing connector assemblies for electric vehicles face challenges in compensating for position deviations between inverter busbars and electrical connectors, while also reducing static loads and being resilient to vibrations.
Innovation Solution
A connector assembly comprising a carrier with a positioning pin, an intermediate busbar with a first terminal and a first fastening element, and a third fastening element, which allows the intermediate busbar to be connected to the inverter busbar and electrical connector without applying static loads and is resilient to vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid connector assembly is used to connect inverter busbar to electrical connector, then structural stability is improved, but the assembly cannot compensate for position deviations and is sensitive to vibrations
Solution Approach 1:
The patent employs a flexible busbar design that can deform elastically to accommodate position deviations between the inverter busbar and electrical connector. The flexible busbar acts as a compliant element that absorbs vibration and misalignment stresses without compromising the structural stability of the overall connector assembly, thereby resolving the contradiction between rigidity and vibration resistance.
Solution Approach 2:
The patent utilizes elastic deformation of the busbar to change its geometric parameters dynamically. When vibrations or position deviations occur, the busbar flexes within its elastic limit, changing its shape and length to maintain electrical connection. This parameter change allows the assembly to remain stable structurally while adapting to vibrational stresses.
2Manufacturing precision
If position deviations are compensated using rigid positioning elements, then alignment precision is improved, but static loads increase on the inverter busbar
Solution Approach 1:
The flexible busbar provides alignment precision through controlled elastic deformation rather than rigid positioning elements. The busbar can bend and flex to achieve proper alignment with the electrical connector, eliminating the need for rigid positioning elements that would impose static loads on the inverter busbar.
Solution Approach 2:
The flexible busbar acts as an intermediary element between the inverter busbar and the electrical connector. It absorbs the alignment adjustments and position deviations through its flexibility, preventing these adjustments from being transmitted as static loads to the inverter busbar while still achieving precise electrical connection.
3Stability of the object's composition
If the inverter busbar is rigidly fixed to reduce position deviations, then connection stability is improved, but vibration resistance deteriorates
Solution Approach 1:
The flexible busbar design allows the connection to remain stable electrically while physically accommodating vibrations through elastic deformation. The busbar maintains reliable electrical contact through its flexibility rather than rigid fixation, thereby improving vibration resistance without sacrificing connection stability.
Data Source
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AI summary
Connector assembly for electrically connecting an inverter busbar to an electrical connector of a drive unit comprising: a carrier (3), an intermediate busbar (16, 16', 16'') comprising a first terminal (17, 17', 17'') with a hole (18, 18', 18''), and a first fastening element (21, 21', 21'') extending through the hole (18, 18', 18'') of the first terminal (17, 17', 17''), wherein the intermediate busbar (16, 16', 16'') is mounted to the carrier (3) and the intermediate busbar (16, 16', 16'') is connectable to the inverter busbar (24, 24', 24'') by the first fastening element (21, 21', 21''), wherein the carrier (3) comprises a positioning pin (15) defining a longitudinal axis (L1), said positioning pin (15) being adapted to be accommodated in a receptacle of a housing (29) of the drive unit (1) such that the carrier (3) is axially slidable in the direction of the longitudinal axis (L1); and that the first fastening element (21, 21', 21'') is arranged within the hole (18, 18', 18'') of the first terminal (17, 17', 17'') with a radial clearance relative to the longitudinal axis (L1) of the positioning pin (15).