Floating Busbar Connection Structure for EV Charging Misalignment
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Solution Overview
Problem
The electrical connection between a charging seat and a battery pack in electric vehicles is challenging due to the high rigidity and lack of flexibility of aluminum busbars or rods, leading to difficult operations and potential tensile stresses, especially with manufacturing tolerances and installation misalignments.
Innovation Solution
An electrical connection device with oblong connection holes and gaps allowing for relative movement and rotation of transmission members, combined with an elastic conductive mechanism, facilitates the connection by accommodating longitudinal, transverse, and angular misalignments, and includes copper terminals for direct electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If aluminum busbars or solid aluminum rod conductors are used to replace traditional copper-core wires, then the current-carrying capacity of wires is improved and the temperature rise of wires is lowered, but the rigidity of the conductor increases and flexibility decreases
Solution Approach 1:
The solid aluminum rod conductor is segmented into multiple aluminum rod conductors that can flex independently. This segmentation maintains the high current-carrying capacity of aluminum while introducing flexibility through the ability of individual rods to bend and adapt to misalignments during connection operations.
2Ease of manufacture
If aluminum busbars or solid aluminum rod conductors are used, then manufacturing cost is reduced, but the difficulty of electrical connection operations increases due to high rigidity
Solution Approach 1:
The connection structure incorporates dynamic adjustment capabilities through oblong connection holes that allow the aluminum rod conductors to move and align themselves during connection operations. This dynamic adjustment mechanism accommodates manufacturing tolerances and installation misalignments, making connection operations easier while maintaining the cost advantages of aluminum conductors.
3Power
If large-cross-section wire is used to increase charging current capacity, then the current-carrying capacity is improved, but the wire becomes less flexible and more difficult to connect
Solution Approach 1:
Instead of using a single large-cross-section wire, the invention segments the conductor into multiple smaller aluminum rod conductors. This segmentation achieves the required total current-carrying capacity while maintaining flexibility, as the individual rods can bend and align more easily during connection operations compared to a single large wire.
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 solution simplifies the connection process by accommodating manufacturing and installation errors, reducing the difficulty of aligning the charging seat and battery pack, and ensures reliable electrical contact.
Implementation Method 1
an elastic conductive member compressed in an axial direction of the bolt between the end of the first electrical transmission member and the end of the second electrical transmission member to enable one of the end of the first electrical transmission member and the end of the second electrical transmission member to float in the axial direction of the bolt relative to the other
Data Source
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AI summary
The present invention discloses an electrical connection device which includes: a housing having a front port, a rear port and an upper port; a first electrical transmission member having an end inserted into the housing from the front port and having a first connection hole formed in the end thereof; a second electrical transmission member having an end inserted into the housing from the rear port and having a second connection hole formed in the end thereof; a bolt assembly entering the housing from the upper port and comprising a bolt passing through the first connection hole and the second connection hole; and a nut assembly disposed in a bottom wall of the housing and threadedly connected to the bolt to fasten the first electrical transmission member and the second electrical transmission member together. The first connection hole is oblong and extends in a transverse direction of the housing to enable the end of the first electrical transmission member to move in the transverse direction. The second connection hole is oblong and extends in the longitudinal direction of the housing to enable the end of the second electrical transmission member to move in the longitudinal direction.