Hybrid Power Control Housing With Busbar Grounding
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Solution Overview
Problem
The housing of hybrid power control devices in eco-friendly vehicles, typically made of conductive materials like aluminum, is heavy, increasing costs and reducing fuel efficiency, and requires post-processing, which is not ideal for lightweight and cost-effective designs.
Innovation Solution
The housing is made of a non-conductive material, such as a mixture of polyamide-based resin with 35% carbon filler, and includes a grounding port and multiple grounding busbars connected via screws to ensure effective grounding and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing is made of conductive material like aluminum, then grounding performance and noise shielding are improved, but weight increases and fuel efficiency decreases
Solution Approach 1:
The grounding function is segmented from the housing material itself and implemented through separate grounding busbars that can be selectively positioned and connected to components requiring grounding, allowing grounding functionality without requiring the entire housing to be conductive
Solution Approach 2:
Grounding busbars act as intermediary conductive elements between the non-conductive housing and the components requiring grounding, enabling effective grounding performance while maintaining the lightweight advantage of non-conductive housing material
2Object-affected harmful factors
If the housing is made of conductive material like aluminum, then noise shielding performance is improved, but weight increases and manufacturing costs increase
Solution Approach 1:
The noise shielding function is segmented and implemented locally through grounding busbars and grounding ports at specific locations rather than requiring the entire housing to be made of conductive material, achieving noise shielding where needed while maintaining overall lightweight construction
Solution Approach 2:
The housing uses composite construction combining non-conductive lightweight material for the main structure with conductive grounding busbars strategically placed for noise shielding and grounding functions, optimizing both weight and electromagnetic performance
3Reliability
If the housing is made of aluminum with die casting method, then grounding performance is improved, but manufacturing costs increase due to post-processing operations
Solution Approach 1:
The grounding system is segmented into separate busbar components that can be manufactured independently and assembled to the housing, eliminating the need for complex die casting and post-processing operations on the housing itself while maintaining effective grounding performance
Solution Approach 2:
The grounding busbars serve as intermediary conductive elements that can be easily manufactured and assembled separately from the non-conductive housing, avoiding the need for expensive conductive housing manufacturing processes while achieving the required grounding performance
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 achieves a lightweight design with equivalent grounding performance, reducing costs and maintaining noise shielding, thus enhancing fuel efficiency and cost-effectiveness.
Implementation Method 1
a non-conductive material, such as a mixture of polyamide-based resin with 35% carbon filler
Data Source
AI summary
A hybrid power control device which is lightweight by changing a material of a housing and has improved grounding performance, includes: a housing formed of a non-conductive material and including a grounding port on an external surface of the housing; and a plurality of grounding busbars disposed inside or outside the housing and including a first side connected directly or indirectly to the grounding port and a second side connected to a component mounted inside or outside the housing.