Press-Formed Busbar With Selective Connection Bars

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The conventional production process for busbars requires changing the shape of the press die for different vehicle specifications, leading to inefficiency, high costs, and time-consuming processes.

Innovation Solution

A busbar design with a uniform shape press-formed busbar configuration, including main and auxiliary terminals connected through cut-off connection bars, allowing for various circuit configurations without changing the die shape, and enabling the selection of different rated currents by altering the connections post-pressing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the shape of the press die is changed according to different vehicle specifications, then different busbar configurations can be produced, but production efficiency deteriorates due to troublesome work, increased costs, and time consumption

Engineering Contradiction:

Improvebusbar configuration varietyVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The busbar is divided into a base busbar structure and separate connection bars that can be selectively removed. This segmentation allows a single press die to produce a standardized base structure, while different circuit configurations are achieved by selectively removing specific connection bars after pressing, eliminating the need to change die shapes for different specifications.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the approach from modifying the die shape parameter to modifying the connection bar configuration parameter. By keeping the die shape uniform and changing which connection bars are removed, the system achieves different busbar configurations without sacrificing production efficiency.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If the shape of the press die is changed for different specifications, then various busbar designs can be achieved, but manufacturing costs increase due to die replacement and setup

Engineering Contradiction:

Improvebusbar design varietyVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single press die is designed to produce a universal base busbar structure that can serve multiple vehicle specifications. The versatility is achieved not by changing the die, but by selectively removing different connection bars from the same base structure, making the die multi-functional for producing various busbar configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Connection bars are intentionally designed to be removed after pressing to create different circuit configurations. This discarding approach allows the same base busbar to be adapted to different specifications by removing specific connection bars, avoiding the cost of producing multiple specialized dies.

Inventive Principle:

Principle #34Discarding and recovering

3Adaptability or versatility

If the shape of the press die is changed according to vehicle specifications, then correct busbar configurations can be produced, but production time increases due to die changing and setup

Engineering Contradiction:

Improveconfiguration accuracyVSAvoidproduction time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

All possible connection bars are pre-formed and attached to the base busbar during a single pressing operation. The specific configuration is then determined by selectively removing the appropriate connection bars, eliminating the need for time-consuming die changes and setups that would otherwise be required to produce different configurations.

Inventive Principle:

Principle #10Preliminary action

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 approach enhances production efficiency and cost-effectiveness by standardizing the die shape, enabling the production of multiple busbar variations with reduced costs and improved workability, while preventing unnecessary deformation during handling.

Implementation Method 1

the busbar being press-formed in an integrated manner

Methodology Applied

Scientific EffectPress-forming: Plasticity

Data Source

PatentUS10283308B2Busbar

Publication Date: 2019.05.07 YAZAKI CORP

AI summary

A busbar includes a plurality of main terminals (upstream side terminal, downstream side terminals) and one auxiliary terminal conductively connected to one of the main terminals and is press-formed in an integrated manner. The auxiliary terminal is connected to the main terminals through connection bars which are all cut off, except for one, in a cutting process after a pressing process, and the circuit configuration can be changed by selectively cutting off the connection bars. Therefore, there is no need to change the shape of a press die, and the production efficiency can be improved using a die having a uniform shape.