Voltage Converter Busbar Layout for Laser Weld Beam Blocking
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Solution Overview
Problem
Existing electronic units for voltage converters of rotating electric machines require complex covers to block laser beams during welding, which adds complexity and cost, and may lead to degradation and the need for additional fume treatment devices.
Innovation Solution
The electronic unit design includes busbars with extensions that block laser beams without additional covers, using extensions that are integrated with the busbars to prevent beam reflection and allow the laser to pass through free areas, simplifying manufacturing and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a cover is added to block the laser beam during welding, then the laser beam is blocked effectively, but the device complexity increases and manufacturing cost increases
Solution Approach 1:
The busbar structure is merged with the laser beam blocking function. The extension of the busbar serves dual purposes: electrical conduction and laser beam blocking, eliminating the need for a separate cover structure. This integration resolves the contradiction by combining multiple functions into a single component.
Solution Approach 2:
The busbar extension is designed to perform multiple functions simultaneously: it provides electrical connection and acts as a laser beam block. This multi-functionality approach eliminates the need for additional dedicated blocking components, thereby reducing device complexity while maintaining effective laser beam blocking.
2Object-affected harmful factors
If a cover is added to block the laser beam, then the laser beam is blocked, but manufacturing cost increases due to additional components and assembly
Solution Approach 1:
The busbar is designed with an extension that combines electrical conduction and laser beam blocking functions into a single component. This eliminates the need for separate blocking covers and their associated assembly operations, directly reducing manufacturing cost while maintaining effective laser beam blocking.
Solution Approach 2:
The busbar extension serves multiple purposes including electrical connection and laser beam blocking. By making the existing busbar multi-functional rather than adding dedicated blocking components, the invention reduces part count, material cost, and assembly complexity, thereby improving ease of manufacture.
3Productivity
If the laser beam passes through the housing area, then the welding can be performed, but the housing degrades and fume treatment devices are required
Solution Approach 1:
The laser beam path is extracted and redirected to pass through a dedicated opening in the housing rather than through the housing material itself. The busbar extension blocks the laser at a location that prevents housing exposure to high-intensity laser radiation, thereby eliminating housing degradation and associated fume generation while maintaining welding capability.
Solution Approach 2:
The busbar extension acts as an intermediary element that blocks the laser beam before it can reach the housing. This intermediate blocking structure prevents direct laser-housing interaction, avoiding housing degradation and the generation of harmful fumes, while still allowing the welding process to proceed.
4Object-affected harmful factors
If the laser beam is interrupted before reaching the blocking structure, then housing degradation is prevented, but the welding process is complicated
Solution Approach 1:
The busbar extension is positioned to block the laser beam in advance, before the laser can reach and degrade the housing. This preliminary blocking action is built into the structure design rather than requiring active control systems to interrupt the laser beam, thereby preventing housing degradation without complicating the laser control system.
Solution Approach 2:
The busbar structure itself provides the laser beam blocking function through its geometric design. The extension of the busbar automatically serves as the blocking element, eliminating the need for separate active control mechanisms to interrupt or redirect the laser beam, thus preventing housing degradation while maintaining system simplicity.
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 design simplifies manufacturing, reduces costs, and avoids the need for complex covers and fume treatment devices, while minimizing degradation and fume production during laser welding.
Implementation Method 1
a first connection surface able to be welded to a second connection surface, facing the first connection surface, of a third busbar of a power electronics module by a laser weld using a laser beam passing at the interface between the first connection surface and the second connection surface
Implementation Method 2
the first busbar or the second busbar comprises a first extension extending in line with the first connection surface, the first extension being able to block the first laser beam
Data Source
AI summary
An electronic unit for a voltage converter of a rotating electric machine includes a first busbar including a first plate, a first connection portion projecting from the first plate, on a first side of the first plate. A first connection surface is able to be welded to a second connection surface of a third busbar of a power electronics module by a first laser weld using a first laser beam. A second busbar separate includes a second plate parallel to and located on a second side of the first plate, opposite the first side. The first or second busbar includes a first extension extending in line with the first connection surface, the first extension being able to block the first laser beam. A voltage converter can include the electronic unit, and the electrical assembly can include the voltage converter and a rotating electric machine.