Direct Mounting Connector Busbar Segmentation for EV Inverters
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Solution Overview
Problem
Conventional direct mounting connectors for connecting three-phase alternating current motors to an inverter in electric vehicles are complex, leading to enlarged apparatus size, increased connection time, and potential errors, as well as undesired enlargement in the connecting structure when applied to busbar structures.
Innovation Solution
A direct mounting connector with six independent busbars, featuring first and second terminal parts arranged in specific sequences and configurations to simplify connections, improve workability, and integrate current sensors within insulating resin parts to reduce apparatus size and enhance stiffness, allowing for compact and efficient connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If conventional direct mounting connectors with complex wiring structures are used, then connection reliability is maintained, but apparatus size is enlarged and connection time increases
Solution Approach 1:
The connector is divided into multiple independent terminal parts (first terminal parts and second terminal parts) that can be separately connected to different phases. This segmentation allows for simplified internal wiring while maintaining connection reliability, thereby reducing apparatus size without compromising productivity
Solution Approach 2:
The patent introduces a spatial arrangement where terminal parts are positioned at different locations (first terminal parts at one end, second terminal parts at another end) along the busbar structure. This dimensional organization optimizes the wiring path and reduces the overall apparatus volume while enabling efficient connections
2Device complexity
If conventional direct mounting connectors are used, then connection reliability is ensured, but device complexity increases
Solution Approach 1:
The connector structure is segmented into distinct terminal parts that can be independently connected to different phases. This segmentation simplifies the wiring arrangement by organizing connections in a systematic manner, reducing device complexity while ensuring each connection maintains reliability through dedicated terminal pathways
Solution Approach 2:
The busbar structure serves multiple functions: it provides mechanical support, establishes electrical connections, and organizes phase relationships. This multi-functionality reduces the need for separate components, thereby simplifying device complexity while maintaining connection reliability through the integrated structure
3Volume of stationary object
If current sensors are integrated into insulating resin parts, then apparatus size is reduced, but manufacturing complexity increases
Solution Approach 1:
The current sensors are merged with the insulating resin parts to form an integrated component. This merging eliminates the need for separate sensor housings and mounting structures, thereby reducing apparatus size. The integration is achieved through co-molding or embedding techniques that, while adding some manufacturing steps, streamline the overall assembly process
Solution Approach 2:
The current sensors are nested within the insulating resin parts, with the sensors positioned inside the resin housing. This nesting arrangement maximizes space utilization, reducing apparatus size. The nested structure is manufactured by first forming the resin part and then embedding the sensors, a process that adds precision but reduces the number of separate assembly operations
Data Source
AI summary
A direct mounting connector includes: six independent busbars for connecting the apparatus to two auxiliary machines for three-phase alternating current; two U-pole first terminal parts, two V-pole first terminal parts and two W-pole first terminal parts The six first terminal parts are connected to the apparatus at first ends of the respective six busbars, the two first terminal parts of the same pole are arranged adjacently to each other; and two sets, each set of which consists of a second U-pole terminal part, a second V-pole terminal part and a second W-pole terminal part The six second terminal parts are connected to the two auxiliary machines at second ends of the respective six busbars, the two sets arranged adjacently to each other having a distance therebetween. Busbar parts extend between the two sets of the second terminal parts.