Overmolded Busbar Connection Element for Flexible Electric Machines
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Solution Overview
Problem
Existing connection devices for multi-phase electrical machines are not easily adaptable to various electrical machine configurations and power sources, requiring complex and costly manufacturing processes to ensure reliable connections.
Innovation Solution
A connection device featuring uncoated electrically conductive current rail elements fixed by an electrically insulating injection molding element, allowing for easy adjustment and adaptation to different electrical machine configurations, with ends coupled to the stator and inverter, and a sealing element for secure housing integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional connection devices are used for multi-phase electrical machines, then reliable electrical connections are achieved, but the manufacturing process becomes complex and costly, and adaptability to different configurations is reduced
Solution Approach 1:
The connection device is segmented into separate busbar elements that can be individually positioned and configured. Each busbar element can be independently arranged to match different phase configurations, allowing the same basic structure to adapt to various electrical machine setups without requiring complete redesign of the connection system.
Solution Approach 2:
The connection device is designed as a universal structure that can serve multiple configurations. The standardized busbar elements and modular design allow the same connection device to be used across different electrical machine types and power source configurations, eliminating the need for specialized manufacturing processes for each variant.
2Reliability
If individualized connection elements are created for each electrical machine variant, then optimal connections are achieved, but manufacturing costs and process complexity increase
Solution Approach 1:
The busbar elements are pre-configured with standardized connection points and geometries during manufacturing. This preliminary preparation allows for rapid assembly and ensures consistent, reliable connections without requiring complex custom manufacturing processes for each electrical machine variant. The standardized design enables mass production while maintaining connection reliability.
3Ease of manufacture
If uncoated electrically conductive materials are used for busbar elements, then manufacturing simplicity and cost-effectiveness are improved, but electrical conductivity and corrosion resistance may be compromised
Solution Approach 1:
The connection device utilizes composite material construction where uncoated electrically conductive busbar elements are combined with electrically insulating injection-molded material. This composite structure provides both the electrical conductivity needed for power transmission and the insulation required for safety, while maintaining manufacturing simplicity by eliminating the need for separate coating processes.
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
Enables a cost-effective, flexible, and reliable connection solution that can be easily manufactured and adapted to various electrical machine configurations, ensuring efficient energy transfer and sealing, thus addressing the need for individualized connections.
Implementation Method 1
The plurality of busbar elements are each enclosed at predetermined positions by an electrically insulating injection-molded element. This fixes the plurality of busbar elements.
Implementation Method 2
The method further comprises a step of overmolding the plurality of busbar elements with an electrically insulating material. In this way, an electrically insulating injection-molded element is formed around the busbar elements.
Data Source
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AI summary
The invention relates to a connection element for a multi-phase electric machine. The connection element is designed to be so simple that it can be produced using a basic injection molding process in which several busbar elements are overmolded. By varying the busbar elements, a high degree of flexibility for the electric machine's connection element can be achieved within a consistent injection molding process.