Flat Bus Bar Power Line for Vehicle EMC and Space Constraints
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Solution Overview
Problem
High-voltage electrical systems in vehicles require efficient power transmission with minimal installation space and electromagnetic compatibility (EMC) while avoiding the high costs and complexity of large shielded circular conductors, which have significant field propagation issues.
Innovation Solution
The use of double bus bars with a foil shield and stranded drain wires, along with flexible conductors, to reduce field propagation and meet EMC requirements, allowing for installation in both interior and exterior vehicle spaces without mechanical protection, and enabling continuous shielding and insulation monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If shielded circular conductors are used for high-voltage power transmission, then electromagnetic compatibility is improved, but field propagation increases causing thermal overloading and eddy current losses
Solution Approach 1:
The patent changes the geometric parameters of the conductors from circular cross-section to flat bus bar configuration. This parameter change reduces the magnetic field propagation while maintaining EMC compliance, thereby resolving the contradiction between EMC requirements and field propagation effects.
Solution Approach 2:
The patent employs a composite structure combining flat bus bars with metallic shielding layers. This composite approach provides effective electromagnetic shielding for EMC compliance while the flat geometry minimizes field propagation, thus resolving the contradiction between the two harmful effects.
2Power
If large cross-section circular conductors are used for high-voltage transmission, then power transmission capability is improved, but installation space requirements increase and mechanical protection becomes complex
Solution Approach 1:
The patent changes the cross-sectional geometry from circular to flat bus bar configuration. This parameter change allows achieving the same power transmission capability with reduced cross-sectional area, thereby reducing installation space requirements and simplifying mechanical protection.
3Adaptability or versatility
If circular conductors are used for flexible connection and vibration absorption, then adaptability is improved, but field propagation and shield thermal overloading occur
Solution Approach 1:
The patent changes the conductor geometry to flat bus bars with reduced field propagation characteristics. This parameter change allows maintaining flexibility and vibration absorption capability while significantly reducing the magnetic field intensity that causes thermal overloading of shield connections.
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 configuration reduces thermal overloading, eddy current losses, and disturbance injections, allowing for cost-effective, compact, and EMC-compliant power transmission in vehicles, including high-voltage applications, while accommodating vibrations and conventional plug connections.
Implementation Method 1
a foil shield surrounding the bus bars from a first of the opposite ends to a second of the opposite ends
Implementation Method 2
eddy current losses caused by the high alternating magnetic fields in the auto body sheet may be reduced
Implementation Method 3
a stranded drain wire running between the bus bars and the foil shield in the longitudinal direction from the first of the opposite ends to the second of the opposite ends, wherein the first stranded drain wire is in electrical contact with the foil shield
Implementation Method 4
The bus bars are respectively insulated from each other
Implementation Method 5
For electromagnetic compatibility (EMC) reasons, the circular conductors are thus provided with a shield
Data Source
AI summary
A line for supplying electrical units with power of more than 3 kW in vehicles, comprising: at least two electrically conducting, oblong bus bars having a flat cross-section and two opposite ends in the longitudinal direction, the bus bars each being insulated from and extending parallel to each other; a foil shield surrounding the bus bars from a first of the ends to a second of the ends; a stranded drain wire running between the bus bars and the foil shield in the longitudinal direction from the first end to the second end; a pair of flexible electrical conductors at one of the ends of the bus bars, each surrounded by a shield and electrically connected at a first end to a respective one of the bus bars, with the shield of the conductors being electrically connected in each case to the stranded drain wire.