Laser-Joined Bus Bar Assembly With Tolerance Buffers
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Solution Overview
Problem
Existing bus bars with single-member wiring pathways face challenges in maintaining dimensional accuracy, especially when the wiring pathway design is complex, leading to reduced manufacturing tolerances.
Innovation Solution
A bus bar configuration that uses consecutively arranged plate-shaped members connected by laser joining, with tolerance buffers between the members to absorb manufacturing tolerances, thereby improving dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single member is processed to form a complicated wiring pathway, then the wiring pathway can be formed by a single component, but manufacturing tolerances are generated and dimensional accuracy is reduced
Solution Approach 1:
The bus bar is divided into multiple plate-shaped members (first plate-shaped member, second plate-shaped member, etc.) that are consecutively arranged and connected by laser joining. Each member can be manufactured separately with high precision, and then assembled to form the complete wiring pathway. This segmentation allows complicated wiring pathways to be constructed while maintaining dimensional accuracy, as each individual member can be precisely manufactured and positioned.
Solution Approach 2:
Laser joining is used as an intermediary connection method to join the plate-shaped members together. This joining technique enables precise alignment and connection of multiple members while maintaining the overall dimensional accuracy of the wiring pathway. The laser joining process allows for controlled and accurate assembly of the segmented members.
2Manufacturing precision
If multiple plate-shaped members are used to form the wiring pathway, then dimensional accuracy is improved, but the device structure becomes more complex
Solution Approach 1:
Multiple plate-shaped members are merged together through laser joining to form a complete wiring pathway. While the structure consists of multiple components, they are combined to create a unified electrical connection system. The merging of these precisely manufactured members results in a wiring pathway that achieves high dimensional accuracy while maintaining functional integration.
Solution Approach 2:
Traditional mechanical joining methods are replaced with laser joining technology. This substitution enables more precise and controlled connection of the plate-shaped members, maintaining structural integrity while achieving higher dimensional accuracy. The laser joining process provides better control over the joining parameters compared to conventional mechanical fastening methods.
3Manufacturing precision
If laser joining is used to connect plate-shaped members, then dimensional accuracy is maintained, but manufacturing process complexity increases
Solution Approach 1:
Conventional mechanical joining processes are replaced with laser joining technology. This substitution introduces a more advanced manufacturing process that provides superior dimensional accuracy and control. The laser joining process enables precise positioning and connection of plate-shaped members, maintaining the integrity of the wiring pathway geometry while achieving higher manufacturing precision.
Solution Approach 2:
The manufacturing process transitions from mechanical joining to laser joining, representing a change in the fundamental process parameters. Laser joining allows for precise control of energy input, joining speed, and positioning, enabling maintenance of dimensional accuracy throughout the assembly process. This parameter change enables the fabrication of complex multi-member structures with high precision.
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 proposed bus bar design enhances dimensional accuracy along the wiring pathway, allowing for more complex designs without compromising electrical connection reliability or increasing manufacturing costs.
Implementation Method 1
adjacent ones of which are connected to each other by laser joining
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A bus bar (1) includes members (9) made from a conductive material and consecutively arranged to form a plate shape defining a wiring pathway (7). The members (9) adjacent to each other have connection surfaces (21, 23, 25, 27, 31, 33) at which the members (9) adjacent to each other are connected to each other by laser joining. The members (9) adjacent to each other include at least one tolerance buffer (29) between the members (9) adjacent to each other. In the at least one tolerance buffer (29), the connection surfaces (21, 23, 25, 27, 31, 33) of the members (9) adjacent to each other have different widths.