Low-Resistance Electrical Connection for Motor Vehicle Control Units
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Solution Overview
Problem
Existing electrical connections in motor vehicle control units, particularly those with electric drives, face challenges in achieving low resistance and minimizing power loss due to high ohmic contact resistance, especially when handling currents of several hundred amperes.
Innovation Solution
An electrical connection system utilizing an electrically conductive sleeve and a bolt with a pressing device, where the bolt is guided through the sleeve to press an end section of an electrical connection cable against the sleeve's end face, creating a full-area contact and reducing ohmic resistance by generating high contact pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional electrical connections are used in control units, then the structure is simple and easy to manufacture, but the ohmic contact resistance is high leading to significant power loss
Solution Approach 1:
The electrical connection is divided into separate functional components: a conductive sleeve for electrical contact, a bolt for mechanical fastening, and a pressing device for applying contact pressure. This segmentation allows each component to be optimized for its specific function, resulting in lower contact resistance while maintaining manufacturing simplicity.
Solution Approach 2:
The invention changes the physical parameters of the connection by introducing a pressing device that applies high contact pressure (force parameter) and ensures full-area contact (surface area parameter). These parameter changes directly reduce ohmic contact resistance and power loss according to the electrical contact laws.
2Reliability
If high contact pressure is applied to reduce ohmic resistance, then the electrical conductance increases, but the mechanical stress on the connection components increases
Solution Approach 1:
The conductive sleeve acts as an intermediary component between the bolt and the electrical connection cable. It distributes the mechanical stress from the bolt over a larger area while maintaining high contact pressure at the electrical contact interface, thus protecting the bolt from excessive stress while ensuring reliable electrical contact.
Solution Approach 2:
The connection system uses composite construction with different materials optimized for specific properties: the bolt provides mechanical strength, the conductive sleeve provides electrical conductivity and stress distribution, and the pressing device provides controlled force application. This composite approach balances mechanical strength and electrical reliability.
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 configuration significantly reduces electrical power loss during operation by increasing the effective contact surface and decreasing ohmic resistance, ensuring reliable and efficient energy transfer to the inverter and other electrical components in electric vehicles.
Implementation Method 1
an electrical galvanic connection, in particular an electrical connection created by touching two contacts, increases the conductance of the connection with a high contact pressure
Implementation Method 2
the ohmic contact resistance of the contact decreases
Data Source
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AI summary
The invention relates to a control device (1) for a motor vehicle, in particular a motor vehicle comprising an electric drive, comprising a housing (2) which encloses a cavity (3), wherein the control device (1) has a power apparatus (4) arranged in the cavity (2), in particular an inverter. A housing wall (21) of the housing has an aperture (5). An electrical connection (6) of the control device (1) is passed through the aperture (5) and has an electrically conductive sleeve (7) and a bolt (8). The sleeve (7) is electrically connected detachably to the power apparatus (4). The bolt (8) is passed through the sleeve (7) and is designed to hold an end section (10) of an electrical connection cable (9) fixedly and to press the end section against a sleeve end, in the form of an end face (15, 16), of the sleeve (7) and thus to connect the electrical connection cable (9) to the connection (6).