Integrated Choke Header Assembly With Round Busbar Bending
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Solution Overview
Problem
Existing vehicle power pack assemblies with header assemblies are costly and contribute significant resistance due to the separate assembly and installation of chokes, which complicates design and manufacturing, especially with flat stock materials that only bend easily in one axis and result in material waste and complex design changes.
Innovation Solution
A header assembly design featuring hollow cylindrical choke cores with round copper conductor busbars that minimize material volume, allow for easy bending, and eliminate the need for separate choke components, using a single conductor as both the choke and busbar, and can be manufactured with minimal waste using CNC wire benders, with the option to modify designs by changing the wire bender program.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate choke components are assembled into the lead frame, then the power pack assembly provides electrical power for steering system functions, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines the choke function and busbar function into a single integrated component. The busbar is formed with windings that create choke inductance while maintaining electrical connection functions, eliminating the need for separate choke components and reducing assembly complexity in the header assembly
Solution Approach 2:
The busbar is designed to perform multiple functions simultaneously: it provides electrical connections (busbar function) and creates magnetic inductance for noise filtering (choke function). This multi-functionality reduces the number of components needed in the power pack assembly
2Ease of manufacture
If flat stock materials are used for busbar construction, then manufacturing is simplified, but material waste increases and design flexibility decreases
Solution Approach 1:
The patent uses round wire instead of flat stock material for busbar construction. The round wire can be bent in multiple directions and formed into complex three-dimensional winding patterns, reducing material waste while maintaining ease of manufacture through CNC wire bending processes
Solution Approach 2:
The round wire busbar allows for dynamic, flexible routing and winding patterns that can be easily modified by changing CNC programming parameters. This provides design flexibility without requiring new tooling or fixtures, unlike flat stock materials that are constrained to single-axis bending
3Adaptability or versatility
If multiple separate components are assembled into the header assembly, then functional requirements are met, but production costs and assembly time increase
Solution Approach 1:
The choke and busbar are merged into a single integrated component, reducing the number of parts that need to be handled, positioned, and assembled. This directly improves assembly efficiency and productivity while maintaining all required electrical and magnetic functions
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
This design reduces production costs, improves reliability, and simplifies the manufacturing process by eliminating unnecessary welds and allowing for easier design modifications, while maintaining performance and reducing resistance in vehicle steering systems.
Implementation Method 1
a conductor busbar extending through the core and secured to the frame, wherein the conductor busbar has a round cross-section
Data Source
AI summary
A header assembly for a power pack assembly includes a frame. The header assembly also includes a core disposed on or within the frame. The header assembly further includes a conductor busbar extending through the core and secured to the frame, wherein the conductor busbar has a round cross-section.