Drive Controller Busbar with Spring Clips for High Current
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Solution Overview
Problem
Existing drive systems face challenges in efficiently transmitting high currents due to the large and unwieldy connectors required for maximum power consumption, and complex current transmission methods that restrict current transfer and require screw fastenings, limiting their usability.
Innovation Solution
The use of long busbars with a constant cross-section and spring clips for secure contact with carrier guide plates allows for efficient transmission of high currents without the need for screw fastenings, enabling each drive controller to receive its maximum current requirement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If connectors are designed for maximum power consumption of the entire drive system, then power transmission capability is improved, but the connectors become large and unwieldy
Solution Approach 1:
The power transmission system is segmented into multiple busbar sections, each handling a portion of the total current. Instead of using a single large connector for the entire system, the current path is divided into manageable segments along the busbar length, allowing each local connection to be smaller and more manageable while collectively handling the full power requirement.
Solution Approach 2:
The power distribution transitions from a point-to-point connector approach to a distributed linear busbar system. Power is distributed along the length of the busbar rather than being concentrated at a single connector location, effectively moving the connection interface from a discrete component to a continuous structure.
2Ease of operation
If plugs are designed for lower power consumption as a compromise, then connector size is reduced, but restrictions in the use of the drive system occur
Solution Approach 1:
The busbar system serves multiple functions simultaneously: it provides mechanical support for the drive controllers, establishes electrical connections, and distributes power to multiple devices. This multi-functional design eliminates the need for separate heavy-duty connectors while maintaining full power transmission capability across the entire system.
3Reliability
If DC voltage rails are screwed to a support component and connection lugs are screwed onto the rails, then secure fastening is achieved, but the structure becomes complex and the cross-section is influenced
Solution Approach 1:
The support component and electrical connection functions are merged into a single integrated busbar structure. The busbar simultaneously provides mechanical support and electrical conduction, eliminating the need for separate support components and connection lugs. This reduces structural complexity while maintaining secure fastening through the spring-clip mechanism.
4Reliability
If screw fastenings are used for DC voltage rails and connection lugs, then secure connection is achieved, but the cross-section and current transfer behavior are influenced
Solution Approach 1:
The spring clips apply localized pressure at specific contact points on the busbar, creating high-density contact areas that optimize current transfer. The spring force is concentrated at the interface between the clip and busbar, ensuring reliable electrical connection without requiring reduction of the overall busbar cross-section.
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 solution enables reliable and efficient transmission of high currents across multiple drive controllers, simplifying the design and assembly of the drive system while maintaining a constant cross-section for the current-carrying elements, thus supporting various levels of current consumption without compromising power transfer.
Implementation Method 1
The busbar rests against the contacting of a carrier guide plate of the respective drive controller under spring force
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The propulsion system has drive controllers which are arranged one behind another in a row, and connected by current carrying elements to conduct current to each other. The current carrying element connected with a bus bar (2) extended over length of connected drive controllers.