Intermediate Circuit Busbar with Variable Cross-Section Lug Sections

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Solution Overview

Problem

Existing drive systems face challenges in cost-effectiveness and inductance management due to the need for separate adapter parts for high and low current sections in intermediate circuit busbars, leading to increased complexity and potential energy losses.

Innovation Solution

The implementation of an intermediate circuit busbar with adaptable lug sections of varying cross-sections and a low-inductance design, utilizing plate-shaped busbar parts and insulation to minimize inductance while allowing for efficient current transition between high and low current regions, along with a simple connection technology using recesses for screws.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate adapter parts are used for high and low current sections in intermediate circuit busbars, then the drive system can accommodate different current requirements, but the device complexity and production cost increase

Engineering Contradiction:

Improveadaptability to different current requirementsVSAvoidcomplexity of busbar assembly

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The busbar adapter part is designed with multiple lug sections having different cross-sections, allowing a single adapter to serve multiple current requirements. The adapter includes a first lug section with a first cross-section and a second lug section with a second cross-section, enabling connection to both high current and low current components without requiring separate adapter types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The adapter part is segmented into multiple lug sections with different cross-sectional areas, each capable of connecting to busbars with corresponding current ratings. This segmentation allows the single adapter body to provide multiple connection points with varying current handling capabilities.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple separate adapter parts are used for high and low current sections, then different current requirements can be met, but the production cost increases

Engineering Contradiction:

Improveadaptability to different current requirementsVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Multiple adapter functions are merged into a single adapter part. Instead of producing separate adapter components for high current and low current sections, the invention combines these functions into one integrated adapter with multiple lug sections of different cross-sections, reducing the total number of parts to be manufactured and assembled.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single adapter part serves multiple purposes by providing lug sections with different cross-sections, replacing the need for multiple specialized adapter components and thereby reducing production costs through simplified manufacturing and inventory management.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of energy

If busbar adapter parts are placed close together, then inductance is reduced, but electrical insulation becomes more difficult to maintain

Engineering Contradiction:

Improveinductance lossVSAvoidelectrical insulation

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

An insulating element is introduced as an intermediary component between the first and second busbar adapter parts. This insulating element maintains electrical isolation between the adapters while allowing them to be positioned in close proximity, thereby achieving low inductance without compromising insulation reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables a cost-effective drive system with reduced inductance, allowing for efficient energy transfer and feedback, while maintaining protection and simplicity in assembly and operation.

Implementation Method 1

One of the two lug sections has a larger cross-section, in particular a line cross-section, in particular a line cross-section for carrying current, than the other one of the two lug sections

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

Electrical insulation may be provided between the two busbar adapter parts and touches both of them

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS10790759B2Drive system with an intermediate circuit busbar

Publication Date: 2020.09.29 SEW EURODRIVE GMBH & CO KG

AI summary

A drive system includes an intermediate circuit busbar, the intermediate circuit busbar having at least one first busbar adapter part on which two lug sections, i.e. in particular lug areas, are formed, which are set apart from each other, one of the two lug sections having a larger cross-section, in particular a larger line cross-section, in particular a line cross-section for carrying current, than the other one of the two lug sections.