Flexible Laminated Busbar for Narrow Motor Controller Assembly
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Solution Overview
Problem
Existing busbar designs for electric drive assembly systems face challenges in narrow installation spaces, leading to power loss and hindered weight, size, and integration due to additional screws or large wiring terminals, and fail to effectively manage motor vibration and current-carrying capacity.
Innovation Solution
A busbar design featuring a flat flexible strap formed of multiple stacked metal sheets, allowing adjustment during installation, with bent parts to fit narrow spaces, and incorporating rigid connectors and an insulating part for vibration damping and insulation protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a common L-shaped busbar is used, then the installation is simple, but it cannot pass through narrow installation ports
Solution Approach 1:
The busbar is divided into multiple straight segments that can be assembled together to form L-shaped or other configurations. Each segment can independently pass through narrow installation ports, and they are connected via connection pieces with screws, enabling both narrow port compatibility and installation flexibility.
2Adaptability or versatility
If a split busbar design with two perpendicular straight busbars is used, then the narrow installation port problem is solved, but additional screws are required which cause power loss and increase weight
Solution Approach 1:
Multiple busbar segments and connection pieces are integrated into a unified assembly where the connection pieces with integrated screws create rigid connections. This merging reduces the number of separate components and minimizes power loss by creating low-resistance electrical connections between segments.
3Adaptability or versatility
If a busbar in the form of a cable is used, then flexibility is improved, but the wiring terminals are large in size requiring large installation space
Solution Approach 1:
The busbar uses thin, flat metal sheets (0.3-1.0mm thick) that can be bent and shaped to fit narrow installation ports. These thin-sheet segments maintain electrical conductivity while occupying minimal space, eliminating the need for large wiring terminals associated with cable-type busbars.
4Adaptability or versatility
If additional screws are used to install perpendicular busbars, then the narrow installation port problem is solved, but weight reduction and integration are hindered
Solution Approach 1:
The connection pieces serve multiple functions: they mechanically connect busbar segments, provide electrical conductivity between segments, and enable rigid connections without requiring additional fastening components. This multi-functionality reduces the overall component count and system weight while maintaining adaptability to narrow installation ports.
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
Enables installation in narrow spaces, reduces motor vibration impact, enhances current-carrying capacity, and provides insulation protection, while maintaining system integration and versatility.
Implementation Method 1
a flat flexible strap located between the first rigid connector and the second rigid connector, wherein the flat flexible strap is formed of multiple stacked metal sheets
Implementation Method 2
the busbar having a flat flexible part which can be adjusted in the process of installation, suitable for a narrow installation port and preventing motor vibration from affecting components in the motor controller assembly
Data Source
Figure 1~2
Figure 3~4
Figure 5~6b
AI summary
The present disclosure provides a busbar, a motor controller assembly, and an electric drive assembly system. The busbar is used for electrically connecting a motor controller to a motor and includes: a first rigid joint (10) electrically connected to a corresponding output pin (16) of the motor controller, a second rigid joint (13) electrically connected to a corresponding input pin (17) of the motor, and a flat flexible strap (12) located between the first rigid joint (10) and the second rigid joint (13), wherein the flat flexible strap (12) is formed of multiple stacked metal sheets.