Busbar Support Riveting for Misalignment Without Over-Molding Cracks
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Solution Overview
Problem
Existing busbar connections in electrical machines face issues due to misplacement and bending, leading to over-molding cracks when insulating the busbars from the environment.
Innovation Solution
The use of busbars with fixation holes and a support structure featuring grooves and flexible tabs, allowing for flexible attachment via riveted pins, enabling movement and reducing stress on the busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If busbars are bent to compensate for misplacement, then connection adaptability is improved, but over-molding cracks occur due to stress concentration
Solution Approach 1:
The busbar support structure incorporates flexible tabs that can bend to accommodate misalignment between busbars and connection points, while the busbars themselves remain straight and rigid. This dynamic flexibility is localized to the support structure rather than the busbars, preventing stress concentration in the over-molded regions of the busbars while still providing the necessary adaptability for connection.
2Strength
If busbars are made rigid for structural strength, then mechanical strength is improved, but misalignment compensation becomes difficult
Solution Approach 1:
The system is segmented into rigid components (busbars, fixation pins, grooves) and a flexible component (tabs). The rigid busbars maintain their structural strength and electrical integrity, while the flexible tabs provide the necessary misalignment compensation. This segmentation allows each component to perform its optimal function without compromising the other.
3Ease of manufacture
If fixation holes are made larger to accommodate pin insertion, then ease of assembly is improved, but fixation precision deteriorates
Solution Approach 1:
The fixation holes are designed with specific dimensional parameters that balance ease of assembly and fixation precision. The holes are larger than the pins to allow for simple insertion without precise alignment, but the overall geometry and positioning of the holes in the flexible tabs maintain adequate fixation precision. The flexible nature of the tabs compensates for any dimensional variations.
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
The solution provides a stable and flexible connection that minimizes over-molding cracks and accommodates misalignment, enhancing durability and reliability of electrical connections.
Implementation Method 1
two fixation pins projecting from a bottom of the groove, designed for being respectively received in the fixation holes of the busbar received in the groove and for being riveted to fix the busbars to the support
Data Source
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AI summary
The electrical connection (110) comprises: - several busbars (202U-W) designed for connecting an inverter to an electrical machine, each busbar (202U-W) having two fixation holes (212U-W, 214U-W); - a support (216) designed for supporting the busbars (202U-W), the support (216) comprising: • grooves (218U-W) designed for respectively receiving the busbars (202U-W), and • for each groove (218U-W), two fixation pins (220U-W, 222U-W) projecting from a bottom (306) of the groove (218U-W), designed for being respectively received in the fixation holes (212U-W, 214U-W) of the busbar (202U-W) received in the groove (218U-W) and for being riveted to fix the busbars (202U-W) to the support (216); wherein each fixation hole (212U-W, 214U-W) is larger than the fixation pin (220U-W, 222U-W) received.