High-Power Busbar With Controllable Resistance
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Solution Overview
Problem
Existing busbars in high-power applications lack effective shunt-based current monitoring solutions, which are robust and simple but have not been successfully upscaled for high-power use.
Innovation Solution
A busbar with a machined pattern defining a meandering conductive path is introduced, increasing the resistance in a controlled manner without altering the outer dimensions, allowing for current monitoring by measuring the voltage drop along the path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional straight conductive path is used in the busbar, then the resistance is kept small to limit thermal losses, but current monitoring capability is insufficient for high-power applications
Solution Approach 1:
The conductive path is segmented into multiple sections by introducing machined patterns (slots, grooves, or recesses) that divide the current flow path into sequential segments. This segmentation increases the effective path length and resistance without requiring a completely separate monitoring component, thereby enabling current monitoring capability while maintaining the busbar's integrated structure
Solution Approach 2:
The conductive path is extended from a simple straight line to a meandering three-dimensional path by utilizing the vertical dimension through machined patterns. The slots, grooves, or recesses create a path that winds through the busbar material in multiple directions, increasing the effective length and resistance without significantly increasing the busbar's external footprint, thus enabling current monitoring while minimizing space usage
2Measurement precision
If the conductive path length is increased to enable current monitoring, then resistance increases for monitoring purposes, but the outer dimensions of the busbar would need to increase
Solution Approach 1:
The conductive path is extended from a simple straight line to a meandering three-dimensional path by utilizing the vertical dimension through machined patterns. The slots, grooves, or recesses create a path that winds through the busbar material in multiple directions, increasing the effective length and resistance without significantly increasing the busbar's external footprint, thus enabling current monitoring while minimizing space usage
Solution Approach 2:
The machined patterns (slots, grooves, or recesses) are nested within the existing busbar structure, utilizing the available internal space and cross-sectional area. The conductive path winds through these nested features, effectively packing a longer path length into the same external dimensions by utilizing the busbar's internal volume and cross-sectional geometry
3Reliability
If shunt-based current monitoring is implemented in high-power applications, then robust and simple monitoring is achieved, but scaling from low-power to high-power applications has not been successful
Solution Approach 1:
The busbar is designed to serve multiple functions simultaneously: it acts as the primary current conductor for high-power transmission and also functions as an integrated current sensor through its machined patterns. The same conductive path that carries the high-power current also provides the voltage drop measurement capability, eliminating the need for separate monitoring components and enabling scalable application from low-power to high-power systems
Solution Approach 2:
The current monitoring function is merged with the current conduction function by integrating the measurement path directly into the busbar's conductive structure. The machined patterns create a dual-purpose feature where the same physical structure performs both power transmission and current sensing, thereby achieving scalability across different power levels while maintaining structural simplicity and robustness
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables efficient current monitoring in high-power applications by increasing resistance while minimizing inductance, allowing for accurate voltage drop measurements without the need for delicate measuring components.
Implementation Method 1
the machined pattern increases the resistance of the conductive path in a controlled fashion
Implementation Method 2
By providing the busbar with a desired resistance, it becomes possible to monitor the current flowing through the busbar by monitoring a voltage drop along the conductive path
Data Source
Figure 1~2
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AI summary
A busbar (100) for connecting power electronic components comprises at least one conductive layer. On a first conductive layer (10), there is a machined pattern (13) which defines a meandering conductive path between the input area (11) and output area (12). By the design of the pattern (13), the conductive path may be given a resistance and/ or impedance suitable for shunt-based monitoring of a current in the busbar (100). In embodiments, the first conductive layer (10) further comprises connection sites (15,16) for a voltmeter.