Capacitor Busbar Stress Reduction via Fixture Positioning
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Solution Overview
Problem
Capacitor devices in vehicles, such as electric and hybrid vehicles, face challenges in resisting vibrations due to the integration of capacitors and busbars, leading to increased load stress on busbars, which complicates the design and increases costs.
Innovation Solution
The capacitor device incorporates a capacitor case with first, second, and third fixture members, where the third fixture member is positioned closer to the target component than the first and second fixture members, and the busbar is located closer to the third fixture member than to a virtual line connecting the first and second fixture members, thereby reducing load stress on the busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If capacitors and busbars are integrated into a single capacitor device, then the device size and weight increase, but the busbar resistance to vibrations deteriorates due to increased load stress
Solution Approach 1:
The capacitor case is segmented into multiple fixation regions with at least three fixture members positioned at different locations. This segmentation allows the busbar to be anchored at multiple points along its length, distributing the vibration loads and reducing stress concentration, thereby maintaining vibration resistance despite the integrated design increasing device size and weight.
2Quantity of substance
If the capacitor device is made larger and heavier, then more capacity is available, but the busbar becomes more susceptible to vibration damage
Solution Approach 1:
The busbar is pre-positioned and fixed to the capacitor case at multiple locations before the device is subjected to vibration loads during operation. This preliminary fixation establishes a stable mechanical connection that prevents the busbar from becoming susceptible to vibration damage, allowing the device to accommodate larger capacitor capacity without compromising busbar durability.
3Strength
If the busbar is fixed at multiple points, then vibration resistance improves, but the device complexity increases
Solution Approach 1:
The fixture members serve multiple functions: they provide mechanical fixation for the busbar, structural support for the capacitor case, and mounting points for capacitors. This multi-functionality allows the device to achieve improved vibration resistance through multiple fixation points without proportionally increasing device complexity, as the same structural elements perform multiple roles.
Data Source
AI summary
In a capacitor device for transferring power between a power source and a target component including an electronic and/or electric component, at least one capacitor is housed in a capacitor case. A busbar is drawn out from the capacitor case. The busbar electrically connects the at least one capacitor to the target component. The capacitor case includes at least first, second, and third fixture members for fixation of the capacitor case. The third fixture member is located to be separated from a virtual line connecting between a first reference point of the first fixture member and a second reference point of the second fixture member, and located to be closer to the target component than the first and second fixture members are. The busbar is located to be closer to the third fixture member than to the virtual line.