Vehicle Electric Drive Lug Assembly Using Laser-Welded Connections
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Solution Overview
Problem
Existing methods for electrically connecting components in vehicle electric drives, such as power electronics modules and electric driving machines, are not quick, reliable, or robust, especially under vibrations and temperature fluctuations, and often require complex clamping mechanisms.
Innovation Solution
The use of thermal joining seams, specifically laser welding, to connect connecting lug pairs, allowing for rapid, precise, and durable electrical connections with a compact design and low inductance, while maintaining accessibility and incorporating insulating layers and pressure elements for secure and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If clamping mechanisms (bolt and abutment element) are used to connect connecting lugs, then the connection is mechanically secure, but the connection process is time-consuming and the structure is complex
Solution Approach 1:
The patent replaces the mechanical clamping system (bolt and abutment element) with a thermal joining process. The connecting lugs are thermally joined directly to the busbar, eliminating the need for complex mechanical fastening components and significantly reducing assembly time and structural complexity.
Solution Approach 2:
The patent extracts and removes the intermediate clamping components (bolt head, abutment element) from the connection system. By directly joining the connecting lugs to the busbar through thermal processing, the solution eliminates unnecessary mechanical elements, simplifying the overall structure and accelerating the connection process.
2Reliability
If clamping mechanisms are used to connect connecting lugs, then the connection can be assembled, but the connection is not robust under vibrations and temperature fluctuations
Solution Approach 1:
The patent replaces the mechanical clamping connection with a thermal joining process that creates a metallurgical bond between the connecting lugs and the busbar. This thermal bond is inherently more robust against vibrations and temperature fluctuations compared to mechanical fastening, as it forms an integrated structure without moving parts or stress concentration points.
3Ease of operation
If connecting lugs are positioned at a larger distance for accessibility, then the electrical connection is easier to access, but the inductance increases
Solution Approach 1:
The patent positions the joining zones on the connecting lugs such that they extend beyond the busbar edges in the horizontal direction, providing accessibility from the sides. This spatial arrangement allows thermal joining while maintaining compact positioning, thus achieving both low inductance and adequate accessibility for the electrical connection.
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
The solution provides a reliable, quick, and space-efficient electrical connection that withstands vibrations and temperature fluctuations, ensuring long-lasting and safe operation of vehicle electric drive components.
Implementation Method 1
The joining zones are laser welding zones
Implementation Method 2
for electrically connecting the component by means of a thermal joining seam
Data Source
AI summary
A component for a vehicle electric drive is described, which includes at least one connecting lug pair projecting from the component for electrically connecting the component. Here, a first connecting lug and a second connecting lug of the connecting lug pair each have a joining zone for electrically connecting the component. Furthermore, an assembly for a vehicle electric drive is presented, which has at least two such components. Further presented is a method of electrically conductively connecting two components.