Segmented Bus Bar Assembly for Tight-Radius Routing
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Solution Overview
Problem
Existing bus bar manufacturing methods, such as press working and forming processes, are complex and costly, and can result in cracking when forming bent portions with small radii, making it difficult to accommodate various wiring pathway shapes.
Innovation Solution
A bus bar design comprising multiple members with different characteristics, connected by laser joining, allowing for easy adaptation to various shapes and reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If press working is used to form the wiring pathway, then the member can be formed into complex shapes, but the manufacturing process becomes complicated and costly
Solution Approach 1:
The bus bar is divided into multiple straight members that are connected end-to-end to form the wiring pathway. Each member maintains a straight shape without complex bending, while the overall pathway achieves the required complex geometry through the arrangement and connection of multiple segments. This segmentation eliminates the need for complex press working dies and processes.
2Shape
If forming process is used to create bent portions, then the member can follow the wiring pathway, but the member cracks when the bending radius is small
Solution Approach 1:
Instead of forming bent portions in a single member, the bus bar is segmented into multiple straight members connected at joints. The bends are achieved through the angular arrangement of connected members rather than plastic deformation of a single piece, eliminating cracking issues associated with small bending radii.
Solution Approach 2:
Connection members serve as intermediaries between adjacent bus bar members, providing the necessary angular transitions to achieve bent pathway shapes. These connection members allow the system to achieve curved or angled pathways without subjecting the conductive members to high-stress forming operations.
3Device complexity
If a single plate shaped member is used, then the structure is simple, but it cannot easily adapt to various wiring pathway shapes
Solution Approach 1:
The bus bar system uses multiple simple straight members that can be easily manufactured and handled. By connecting these simple segments in different configurations, the system can adapt to various wiring pathway shapes while maintaining the simplicity of individual components.
Solution Approach 2:
The bus bar system achieves adaptability through the dynamic arrangement and connection of multiple straight members. The same set of straight members can be configured in different patterns to accommodate various wiring pathways, providing versatility without requiring complex individual member geometries.
4Adaptability or versatility
If multiple members with different characteristics are connected, then the bus bar can optimize properties for specific functions, but the connection process becomes more complex
Solution Approach 1:
The patent replaces traditional mechanical connection methods (such as bolting or riveting) with laser welding for joining bus bar members. This substitution simplifies the connection process by eliminating the need for holes, fasteners, and complex assembly procedures, while enabling reliable connections between members with different characteristics.
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 enables efficient production of bus bars that can accommodate diverse wiring pathways with improved electrical connection reliability and reduced manufacturing costs by using members with optimal properties for specific functions.
Implementation Method 1
The members adjacent to each other are connected to each other by laser joining
Data Source
AI summary
A bus bar includes a wiring pathway made from a conductive material and having bent portions bending at at least two sites of the wiring pathway. The wiring pathway includes members consecutively arranged to form a plate shape. At least two of the members have different characteristics. The members adjacent to each other are connected to each other by laser joining.