Interlock Bus Bar Bolt Fastening for Vibration Safety
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Solution Overview
Problem
Conventional power apparatus interlock structures in eco-friendly vehicles face limitations in space and coupling force, leading to potential malfunctions due to vehicle vibrations, as they rely on small connector pins and wire connections which can be weak.
Innovation Solution
The power apparatus incorporates a robust interlock structure using bolt-fastened interlock bus bars and a safety cover to ensure secure connections between power parts, eliminating the need for interlock connections at maintenance holes and providing enhanced safety through bolt-fastening instead of wire connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If wire connections and small connector pins are used for interlock structure, then the device complexity is reduced, but the coupling force and reliability are insufficient leading to potential malfunctions due to vehicle vibrations
Solution Approach 1:
The patent combines the interlock connection function with the safety cover structure by integrating interlock terminals directly into the cover. This merging eliminates the need for separate wire connections and small connector pins, providing both structural integrity and reliable electrical connection for high-voltage interruption control.
Solution Approach 2:
The patent replaces the weak mechanical wire connection system with a robust mechanical interlock system where the safety cover itself serves as the interlock mechanism. The cover's physical attachment to the housing provides the coupling force, eliminating vibration-induced malfunctions while maintaining simplicity.
2Reliability
If multiple separate interlock connections are implemented, then the safety is improved, but the space requirement and device complexity increase
Solution Approach 1:
The safety cover serves multiple functions simultaneously: it provides physical protection, acts as the interlock mechanism, and controls high-voltage interruption. This multi-functionality eliminates the need for separate interlock connections while maintaining comprehensive safety, reducing both space requirements and device complexity.
Solution Approach 2:
The patent merges the protective cover function with the interlock control function into a single integrated structure. The interlock terminals are embedded in the cover itself, so that one component performs both safety protection and electrical interlock operations, simplifying the overall system.
3Ease of manufacture
If wire connections are used for interlock terminals, then the ease of manufacture is improved, but the coupling force is weak leading to contact failure under vibration
Solution Approach 1:
The patent replaces the wire-based mechanical connection system with a direct structural integration where interlock terminals are embedded in the safety cover itself. This substitution maintains ease of manufacture through modular assembly while providing strong coupling force through the cover's rigid structure, preventing contact failure under vibration.
Data Source
AI summary
A power apparatus includes a first power bus bar provided at a first power part, a second power bus bar provided at a second power part coupled to the first power part while communicating internally with the first power part, the second power bus bar being fastened to the first power bus bar, a first interlock bus bar provided at the first power part while being connected to an interlock terminal of a controller disposed within the first power part, a second interlock bus bar provided at the second power part while being fastened to the first interlock bus bar, and a safety cover fastened to a fastening portion between the first interlock bus bar and the second interlock bus bar while covering a fastening portion between the first power bus bar and the second power bus bar.