Flexible Weld Crimp Busbar for Stress Relief
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Solution Overview
Problem
Electrical devices with traditional weld crimps face stress issues due to applied forces, which can lead to significant stress on the weld connection between the wire and the weld crimp, necessitating an improved design to relieve these stresses and enhance mechanical and electrical security.
Innovation Solution
The electrical device incorporates a busbar with a flexible weld crimp featuring a T-shaped design, including a cross-member that is physically separate from the busbar body, with stress-relieving features at intersections to allow the crimp portion to flex relative to the weld portion, reducing stress when non-axial forces are applied, and a crimp member that is permanently deformed to secure the conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crimp portion is deformed to apply sufficient clamping force to the conductor, then the mechanical security of the conductor connection is improved, but the stress on the weld connection between the wire and weld portion increases significantly
Solution Approach 1:
The weld crimp is divided into distinct functional portions: a crimp portion for mechanical clamping and a weld portion for electrical connection. This segmentation allows each portion to be optimized independently, with the crimp portion providing clamping force and the weld portion providing a stress-relieved electrical connection point.
Solution Approach 2:
The base acts as an intermediary element connecting the crimp portion and weld portion. It provides a transition zone that helps distribute and reduce stress transmission between the high-clamping-force crimp portion and the weld connection, preventing stress concentration at the weld interface.
2Stability of the object's composition
If the weld crimp is rigidly connected to the busbar body, then the structural stability is improved, but the ability to relieve stress when non-axial forces are applied is reduced
Solution Approach 1:
The weld crimp is designed with flexible connections at the intersections between the base and busbar body, and between the crimp portion and weld portion. These flexible joints allow the structure to dynamically adapt to non-axial forces by flexing rather than rigidly resisting, thereby relieving stress while maintaining overall structural stability.
Solution Approach 2:
The base and its connections to the busbar body incorporate flexible design elements that allow controlled bending and flexing. This flexibility enables the weld crimp to accommodate non-axial forces without transmitting excessive stress to the weld connection, while still maintaining structural integrity through the flexible but load-bearing base structure.
3Reliability
If the cross-member is physically separate from the busbar body, then the stress relief capability is improved, but the device complexity increases
Solution Approach 1:
The base serves as a merged structural element that combines multiple functions: it connects the physically separate cross-member to the busbar body, provides stress relief through its flexible connection, and creates the necessary geometric configuration for both crimping and welding operations. This merging reduces the need for additional separate components.
Solution Approach 2:
The base performs multiple functions simultaneously: it acts as a connector between the cross-member and busbar body, provides stress relief through flexible connection, defines the spatial relationship between crimp and weld portions, and serves as a structural support element. This multi-functionality reduces overall device complexity despite the physically separate cross-member design.
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 weld crimp design effectively relieves stress in the weld connection, enhancing the durability and reliability of the electrical device by allowing the crimp portion to flex before the weld fails, thus improving the mechanical and electrical security of the conductor connection.
Implementation Method 1
The crimp member is permanently deformed about the conductor so as to apply a clamping force to the conductor
Implementation Method 2
The conductive element is welded to the weld portion
Data Source
AI summary
An electrical device according to the principles of the present disclosure includes a frame, a conductor having a conductive element and an electrically insulating cover disposed about at least a portion of the conductive element, and a busbar mounted to the frame. The busbar includes a busbar body and a weld crimp. The weld crimp has a base, which extends from the busbar body, and a cross-member that is coupled to the base on a side of the base that is opposite the busbar body. The cross-member has a weld portion and a crimp portion. The weld portion intersects the base. The crimp portion intersects the weld portion and has a crimp member that receives the conductor. The crimp member is permanently deformed about the conductor so as to apply a clamping force to the conductor. The conductive element is welded to the weld portion.