Laminated Busbar Assembly for AC Motor Controller
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Solution Overview
Problem
The existing manufacturing processes for AC motor controllers in battery-operated electric vehicles are labor-intensive and inefficient due to the time-consuming insertion and soldering of elements, leading to poor production efficiency and limited extensibility of busbar assemblies.
Innovation Solution
A laminated busbar assembly with an avoiding hole group and interference fit pins and pad holes, allowing for simultaneous lamination and compression of metal plates with one-off reflow soldering, enhancing production efficiency and modularization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elements are inserted one by one through plugging and tin soldering, then reliable electrical connections are achieved, but the insertion process becomes time-consuming and laborious, reducing production efficiency
Solution Approach 1:
Multiple individual insertion and soldering operations are merged into a single lamination and compression process. The metal plates with pre-configured pins are laminated together and compressed simultaneously, achieving multiple electrical connections in one operation rather than sequentially plugging and soldering each element individually.
Solution Approach 2:
Pins are pre-configured on metal plates before assembly. The avoiding holes are pre-positioned on each metal plate, and pins are attached at predetermined locations, allowing the subsequent lamination and compression to proceed rapidly without on-site insertion operations.
2Ease of manufacture
If traditional busbar structures are used, then simple manufacturing is achieved, but the extensibility of the busbar assembly is poor
Solution Approach 1:
The busbar assembly is segmented into multiple independent metal plates (positive metal plate, negative metal plate, output current metal plate) that can be independently designed and manufactured. Each plate can be customized with specific pin configurations and avoiding hole patterns, enabling easy adaptation to different circuit requirements while maintaining simple individual manufacturing processes.
Solution Approach 2:
The lamination and compression structure serves multiple functions simultaneously: it provides electrical connections through pins, ensures insulation through avoiding holes and insulation layers, enables mechanical strength through compression, and allows for extensibility by accommodating different numbers and configurations of metal plates for various circuit designs.
Data Source
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AI summary
An AC motor controller, a laminated busbar assembly, and a manufacturing method thereof relate to the field of electrical devices. The AC motor controller includes laminated busbar assembly (1), controllable switching element assembly (400), and filter element assembly (500). The laminated busbar assembly includes a substrate (110), a positive current metal plate (120), a negative current metal plate (130), and an output current metal plate (140) which are arranged in a laminated manner. In the insertion and tin soldering process, the processing of the AC motor controller is completed by two steps: passing the first pin (121) of the positive current metal plate, the second pin (131) of the negative current metal plate, the third pin (141) of the output current metal plate, the controllable switching element assembly, and the filter element assembly through the pad hole group of the substrate, and then performing soldering in one-off manner, so the production is efficient. As a result of the modularization arrangement of the laminated busbar assembly, the present invention has good expansibility and can be widely applied to other electronic control devices.