Charging Seat Busbar Layout for Flexible Terminal Assembly
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Solution Overview
Problem
Existing electrical connection methods for charging seats, using copper wires, are inflexible, lack compatibility, and have limited adaptability due to their single form and low compatibility.
Innovation Solution
The use of two parallel metal bars with specific structural features, including main body portions, connection end portions, and bending portions, which are connected to charging terminals via threaded connections, allowing for improved flexibility and compatibility by overlapping in the thickness direction and staggering in the width direction, and potentially using aluminum bars to reduce weight and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If copper wires are used for electrical connection, then electrical conductivity is ensured, but flexibility and adaptability are reduced
Solution Approach 1:
The electrical connection structure is segmented into multiple independent metal bars (first metal bar and second metal bar) instead of using a single copper wire. Each metal bar can be independently connected to charging terminals, allowing for flexible combinations and improved adaptability to different charging configurations.
Solution Approach 2:
The metal bars are designed with universal connection capabilities that can adapt to different charging terminal arrangements. The bars can be connected in series, parallel, or other configurations depending on the charging requirements, making the structure multi-functional and highly compatible with various charging scenarios.
2Ease of operation
If traditional copper wire connection method is used, then electrical connection is achieved, but assembly flexibility and tolerance are limited
Solution Approach 1:
The metal bars are designed with bending portions that provide dynamic flexibility during assembly. The bending portions allow the bars to deform and adapt to slight misalignments in the charging terminals, enabling easier assembly with larger tolerance ranges without requiring high manufacturing precision.
Solution Approach 2:
The structural parameters of the metal bars, particularly the bending portions, are optimized to change the mechanical properties of the connection. The bending radius and angle can be adjusted to match different assembly requirements, allowing the connection structure to accommodate varying tolerance conditions.
3Adaptability or versatility
If multiple metal bars are used to improve compatibility, then adaptability increases, but device complexity increases
Solution Approach 1:
Multiple metal bars are merged into a coordinated system where the first and second metal bars work together as an integrated connection assembly. The bars share common structural features and connection methods, reducing the overall complexity compared to using entirely separate connection components for each terminal.
Data Source
AI summary
An electrical connection assembly includes a first metal bar and a second metal bar. The first metal bar has a first main body portion, a first connection end portion, and a first bending portion connected between them. The second metal bar has a second main body portion, a second connection end portion, and a second bending portion connected between them. The first metal bar and the second metal bar are separated in a thickness direction and parallel to each other when the first metal bar and the second metal bar are electrically connected to a charging seat. The first main body portion and the second main body portion overlap with each other in the thickness direction. The first connection end portion and the second connection end portion are staggered in a width direction.