Passive Busbar Cooling in High-Voltage Terminals

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Solution Overview

Problem

Existing electric machines face challenges in effectively cooling high-voltage terminals and associated busbars due to their challenging location, leading to increased heating in heavy-duty applications.

Innovation Solution

The electric machine incorporates a distribution member with a fluid inlet and outlet, guides within the high-voltage terminal to direct fluid to busbars, and uses a plastic arcuate body with funnel-shaped guides to optimize cooling, reusing fluid for multiple cooling purposes without additional pumping losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the high-voltage terminal and busbars are positioned in a challenging location, then the electrical connection from winding to power electronics is established, but the cooling effectiveness deteriorates leading to increased heating

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidbusbar temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent introduces fluid guides as intermediary structures within the high-voltage terminal that channel cooling fluid directly to the busbars. These guides act as mediators between the cooling system and the electrical components, enabling effective heat removal while maintaining the challenging positional arrangement of the terminal and busbars

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If active cooling systems are used to cool the busbars, then the temperature reduction is effective, but the system complexity and energy consumption increase

Engineering Contradiction:

Improvebusbar temperatureVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling system is designed to be self-service through passive fluid guidance. The fluid guides within the high-voltage terminal automatically direct cooling fluid to the busbars without requiring active control mechanisms, sensors, or additional energy input. The system uses the existing fluid flow to cool itself

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces active mechanical cooling systems with passive fluid guidance structures. Instead of using pumps, fans, or controlled thermal management systems, the design relies on strategically positioned fluid guides that passively direct cooling fluid to the heat-generating busbars

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 design efficiently cools the busbars, reducing their temperature and improving thermal management without active cooling systems, thereby enhancing the performance and reliability of the electric machine.

Implementation Method 1

fluid is guided from a nozzle distribution ring to cool busbars associated with a high-voltage terminal

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

fluid flows from the fluid inlet to the fluid to cool windings associated with the stator and the rotor

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4586470A1Method and apparatus to passively cool high-power phase connections on a fluid cooled electric machine

Publication Date: 2025.07.16 SCHAEFFLER TECHNOLOGIES AG & CO KG

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AI summary

An electric machine includes a housing or housing cover and a distribution member supported by the housing or housing cover. The distribution member has a fluid inlet and a fluid outlet. A high-voltage terminal is supported by the housing or housing cover. One or more busbars are associated with the high-voltage terminal. One or more guides are formed within the high-voltage terminal to direct fluid from the fluid outlet to the one or more busbars.