Flexible Dual Busbar Layout for Vibration and EMI Control
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Solution Overview
Problem
Conventional double busbar systems lack flexibility and adaptability in installation spaces with limited dimensions and curved surfaces, failing to effectively dampen vibrations and maintain electromagnetic compatibility.
Innovation Solution
Incorporating a flexible electrical conductor element between sections of the busbars, which is adapted to the geometric dimensions of the double busbar, allowing for increased flexibility and vibration damping while maintaining electrical insulation and current-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a continuously rigid double busbar is used, then electrical insulation and current-carrying capacity are maintained, but flexibility and adaptability in installation spaces are insufficient
Solution Approach 1:
The double busbar system is divided into multiple sections: rigid busbar sections for stable electrical connections and a flexible conductor element section for adapting to installation spaces and dampening vibrations. This segmentation allows each part to fulfill its specific function optimally.
Solution Approach 2:
The flexible electrical conductor element introduces dynamic characteristics to the otherwise rigid busbar system, enabling it to accommodate movements and vibrations while maintaining electrical continuity. The flexible element can deform elastically to absorb mechanical stresses.
2Reliability
If a continuously rigid double busbar is used, then structural stability is maintained, but ability to dampen vibrations is insufficient
Solution Approach 1:
The flexible electrical conductor element acts as a pre-designed cushioning element that absorbs vibrations and mechanical stresses before they can propagate through the entire busbar system. This protects the rigid busbar sections from excessive vibrations.
Solution Approach 2:
The flexibility and vibration damping characteristics are adjusted by changing parameters of the flexible conductor element such as its material composition, cross-sectional area, and length. These parameter changes allow optimization of vibration damping while maintaining electrical performance.
3Object-affected harmful factors
If the double busbar is arranged at a small distance from each other, then electromagnetic compatibility is increased, but electromagnetic interference may still affect occupants and devices
Solution Approach 1:
The electromagnetic fields generated by the two busbars at small distance interfere with each other in a beneficial way, canceling out harmful emissions. The close arrangement transforms potential electromagnetic interference into electromagnetic compatibility through field cancellation.
4Power
If high currents and voltages are transmitted through the double busbar, then electrical energy transmission capacity is increased, but electromagnetic load on occupants and devices increases
Solution Approach 1:
The high current transmission capability is achieved while converting the harmful electromagnetic emissions into a beneficial cancellation effect. The close proximity arrangement of the two busbars causes their electromagnetic fields to oppose and cancel each other, reducing the net electromagnetic load despite high power transmission.
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 flexible conductor element enhances the busbar's ability to fit in compact spaces, dampen vibrations, and reduce electromagnetic interference, enabling efficient high-current transmission in vehicles without increasing electromagnetic load on occupants or devices.
Implementation Method 1
the flexible electrical conductor element is adapted to the geometrical dimensions of the double busbar... the flexible electrical conductor element enhances the busbar's ability to fit in compact spaces, dampen vibrations
Implementation Method 2
The busbars are electrically insulated from each other... the flexible electrical conductor element is arranged to carry electrical current in the double busbar... used to transmit the electrical energy of a vehicle battery of an electrically powered vehicle to the electric motor
Implementation Method 3
The busbars are electrically insulated from each other and are arranged one above the other... arranged at a very small distance from each other attenuates or even cancels out the electromagnetic field between the two busbars
Data Source
AI summary
A double busbar is disclosed comprising a first busbar and a second busbar, which are electrically insulated from one another and are arranged one above the other, the first busbar and the second busbar being stripped in a stripped region and a flexible electrical conductor element being arranged in the stripped region in place of the first busbar and the second busbar, the flexible electrical conductor element being set up to carry electrical current in the double busbar and the flexible electrical conductor element being adapted to the geometric dimensions of the double busbar.