Flexible HV Busbar Interconnect for Multi-Orientation Inverter Packaging
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Solution Overview
Problem
Current high-voltage (HV) inverters have non-configurable battery input/output connections, limiting their applications and compatibility with hybrid electric and battery electric vehicles due to different design restraints and packaging requirements.
Innovation Solution
A busbar interconnect system with flexible connection options, including two busbars, an insulator housing, and fasteners, allowing multiple orientations and connections between an HV DC battery and inverter, suitable for various packaging requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed connection configuration is used between DC connectors and inverter, then the connection structure is simple, but the adaptability to different vehicle applications is limited
Solution Approach 1:
The busbar interconnect assembly is designed with multiple connection configurations, allowing the same assembly to serve multiple vehicle applications and packaging requirements. The assembly can accommodate different orientations and connection points between DC connectors and inverter, making it a universal solution for various hybrid electric and battery electric vehicle designs.
Solution Approach 2:
The busbar interconnect assembly incorporates flexible mounting features that allow it to be installed in different orientations and positions. The assembly can be configured to connect at various locations on the inverter housing, providing dynamic adaptability to different vehicle packaging requirements without requiring multiple specialized components.
2Adaptability or versatility
If multiple connection configurations are provided, then the adaptability to different vehicle applications is improved, but the device complexity increases
Solution Approach 1:
Multiple connection configurations are integrated into a single busbar interconnect assembly design. Rather than using separate assemblies for different connection types, the invention combines multiple mounting options, connection points, and orientations into one unified assembly that can be adapted to various vehicle applications.
Solution Approach 2:
The busbar interconnect assembly is designed as a universal component that can accommodate different vehicle applications through its multiple connection configurations. The same assembly can be used across various hybrid electric and battery electric vehicle models, reducing the need for application-specific customizations.
3Weight of moving object
If the busbar bearing surface is minimized, then the weight is reduced, but the current load capacity is compromised
Solution Approach 1:
The busbar design optimizes the bearing surface parameters by carefully controlling its dimensions, thickness, and material properties. The bearing surface is designed with sufficient area and structural characteristics to handle the required current load while maintaining minimal weight. The parameters are tuned to achieve the optimal balance between weight reduction and electrical performance.
Data Source
AI summary
A busbar interconnect system having a housing of an inverter, and an interconnect assembly mounted in the housing, where the interconnect assembly includes an insulator housing, a first busbar having first and second ends, a second busbar having first and second ends, and the first busbar, the second busbar, and a mounting bracket at least partially surrounded by the insulator housing, the mounting bracket mounted to the housing. In a first configuration, a first of a plurality of connectors is connected to the first end of the first busbar and a second of the plurality of connectors is connected to the first end of the second busbar. In a second configuration, the first of the plurality of connectors is connected to the second end of the first busbar and the second of the plurality of connectors is connected to the second end of the second busbar.