Rigid Busbar Winding for Compact Vehicle Chokes
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Solution Overview
Problem
High-current chokes for DC networks in vehicles are typically large and heavy due to the requirement for high inductance, making them bulky and difficult to manufacture, and existing solutions for busbar winding are complex and prone to vibration issues.
Innovation Solution
A choke design using rigid busbar members that form multiple turns around an annular core, with a housing that secures the busbars and optimizes heat evacuation, allowing for a more compact and lighter construction, and a connection method using self-tapping threaded bolts or solder paste for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high inductance is achieved using traditional semi-wound chokes with straight busbars enclosed in annular cores, then the choke can handle high currents, but the volume and weight increase significantly
Solution Approach 1:
The busbar winding is divided into multiple separate rigid busbar members (first busbar members and second busbar members) that are connected together. This segmentation allows the winding to achieve high inductance through multiple turns while using thinner individual busbars with smaller cross-sections, reducing overall volume and weight compared to traditional single-piece semi-wound designs
Solution Approach 2:
The invention transitions from traditional planar busbar arrangements to a three-dimensional winding structure where rigid busbar members are bent and connected to form multiple turns around the core. This dimensional change enables compact winding configurations that achieve high inductance in a smaller volume with reduced weight
2Power
If high inductance is achieved using semi-wound chokes with straight busbars, then the choke can handle high currents, but the volume increases significantly
Solution Approach 1:
The busbar winding is divided into multiple separate rigid busbar members (first busbar members and second busbar members) that are connected together. This segmentation allows the winding to achieve high inductance through multiple turns while using thinner individual busbars with smaller cross-sections, reducing overall volume and weight compared to traditional single-piece semi-wound designs
Solution Approach 2:
The invention transitions from traditional planar busbar arrangements to a three-dimensional winding structure where rigid busbar members are bent and connected to form multiple turns around the core. This dimensional change enables compact winding configurations that achieve high inductance in a smaller volume
3Strength
If traditional screw connections are used to connect busbar members in a winding, then the connection is mechanically strong, but the device becomes complex and vulnerable to vibration
Solution Approach 1:
The invention extracts and removes the complex screw connection elements from the busbar winding assembly. Instead of using traditional screw connections that require threading and fastening operations, the design uses simplified connection methods such as welding or pressing connections between busbar members, significantly reducing assembly complexity and eliminating vibration-related loosening issues while maintaining mechanical strength
Solution Approach 2:
The invention replaces the mechanical screw connection system with alternative joining methods such as welding or pressing connections. This substitution eliminates the need for threaded fasteners and complex assembly operations, reducing device complexity and improving vibration resistance while maintaining adequate connection strength for high-current applications
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 design achieves a compact, lightweight choke with improved heat dissipation and reduced manufacturing complexity, while maintaining high inductance and current-carrying capacity, suitable for high-current applications in vehicles.
Implementation Method 1
the coil windings are wound about the core such that magnetic fields generated in the core by differential-mode currents cancel each other out
Implementation Method 2
at least one turn of the coil winding comprises at least one rigid first busbar member and a rigid second busbar member
Data Source
AI summary
A choke comprising a core and a first power conductor, wherein the first power conductor comprises a first coil winding, having at least one complete turn about the core, characterized that at least one of the least one turns of the first coil winding comprises a rigid first busbar member and a rigid second busbar member.