Soft-Annealed Phase Busbar for Inverter Alignment Tolerance
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Solution Overview
Problem
Existing phase connections between inverters and electric machines face challenges in aligning electrical connections due to manufacturing tolerances, leading to increased costs and potential damage from misalignment.
Innovation Solution
A phase connection using a load busbar formed from soft-annealed copper with flexible sections and a housing part made of insulating material, allowing for tolerance compensation and reduced stress through deformability, and featuring a fastening mechanism with a distal end section for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional rigid busbars are used for connecting inverter and electric machine, then manufacturing precision can be maintained, but tolerance compensation becomes difficult and assembly costs increase
Solution Approach 1:
The busbar material undergoes a parameter change from rigid to flexible through soft-annealing treatment. This changes the physical state of the copper material to allow elastic deformation, enabling the busbar to adapt to tolerance variations during assembly while maintaining good electrical conductivity and mechanical strength.
Solution Approach 2:
The busbar is designed with dynamic flexibility through soft-annealed copper sections that can elastically deform during assembly. This allows the connection to adapt to misalignments and tolerance variations, transforming a static rigid connection into a dynamic adaptable one that compensates for manufacturing tolerances.
2Adaptability or versatility
If lamellar conductors are used to enable flexibility and tolerance compensation, then adaptability improves, but manufacturing complexity and costs increase
Solution Approach 1:
Instead of making the entire busbar lamellar or flexible throughout, only specific sections are designed with soft-annealed copper properties to provide localized flexibility where needed for tolerance compensation. The rest of the busbar maintains its standard structure for structural integrity and electrical performance, avoiding unnecessary complexity.
Solution Approach 2:
The busbar is segmented into different functional sections: rigid sections for structural support and electrical conduction, and flexible soft-annealed sections for tolerance compensation. This segmentation allows each part to perform its specific function optimally without requiring the entire structure to be complex.
3Strength
If rigid connections are used to maintain structural strength, then mechanical strength is ensured, but stress concentration and potential damage to stator winding increase
Solution Approach 1:
The soft-annealed copper sections act as cushioning elements that absorb and distribute mechanical stresses before they reach the stator winding. These flexible sections deform elastically to compensate for misalignments, preventing stress concentration and potential damage to the brittle stator winding insulation and conductors.
Solution Approach 2:
The material parameters of the busbar are changed in specific sections to soft-annealed copper, which has higher ductility and lower yield strength. This allows these sections to deform plastically or elastically under stress, absorbing energy and preventing stress concentration at critical points like the stator winding connection.
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 solution provides cost-effective tolerance compensation and reduced mechanical stress, ensuring precise alignment and durability while minimizing damage to the stator winding, with the option for non-destructive repair and media-tight sealing.
Implementation Method 1
the load busbar being formed at least in sections from soft-annealed copper. Owing to the load busbar being formed from soft-annealed copper, tolerances in the region of the electrical connection may be compensated for in a simple manner
Implementation Method 2
provides a certain minimum cross section of the electrical conductor. Known phase connections are this kind are expensive to manufacture
Data Source
AI summary
A phase connection for electrically conductively connecting an inverter to a busbar of an electric machine, having a housing part having a housing wall, the housing wall having a first side and a second side that is different from the first side, and an opening extending between the first side and the second side being formed in the housing wall, and having a load busbar which is routed through the opening and has a first connecting section which is routed beyond the first side and is formed at least in sections from soft-annealed copper and/or contains soft-annealed copper.