Segmented Busbar Arrangement for Flexible Vehicle Wiring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional busbar arrangements have a fixed connection section, limiting their installation flexibility and requiring specialized housings, leading to unused connections in different vehicle variants.
Innovation Solution
A busbar arrangement with individually stamped sheet metal contact elements, each with a connection section for mechanical and electrical attachment of a conductor using strain relief, allowing flexible placement and attachment of electrical conductors, and enabling the busbar to be cut to a desired length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single connection section is provided in the busbar arrangement, then the manufacturing is simplified, but the installation flexibility and adaptability are reduced
Solution Approach 1:
The busbar arrangement is divided into multiple individual contact elements, each with its own connection section. This segmentation allows each contact element to be independently configured and positioned, enabling flexible installation in various locations while maintaining simple manufacturing processes for each standardized component.
Solution Approach 2:
Each individual contact element is designed as a universal module with integrated connection section that can function independently or in combination with others. This multi-functionality allows the same standardized component to be used in multiple positions and configurations, adapting to different installation requirements without requiring specialized housing features.
2Ease of manufacture
If the connection section position is predefined during manufacturing, then the manufacturing process is simplified, but the possible uses and installation locations are limited
Solution Approach 1:
The busbar is segmented into multiple identical contact elements with connection sections positioned at standardized intervals. This allows the busbar to be manufactured in a standardized way while enabling selection of different configurations by choosing which contact elements to use and where to install them.
Solution Approach 2:
The system transitions from a static, fixed configuration to a dynamic, selectable configuration. The predefined connection sections enable flexible assembly where the busbar can be adapted to different installation scenarios by selecting appropriate contact elements and positions, rather than requiring custom manufacturing for each application.
3Device complexity
If busbars with unused connections are provided in all vehicle variants, then the variety of busbar variants is reduced, but the production costs and material usage increase
Solution Approach 1:
The busbar system is segmented into individual contact elements that can be used independently. This allows each vehicle variant to use only the number of contact elements needed, eliminating waste of unused connections while maintaining a simple standardized design for each element.
Solution Approach 2:
The modular contact element design allows unused portions to be effectively discarded (not installed) while the standardized elements that are installed can be recovered and reused in other applications. This reduces material waste and production costs for each specific vehicle variant.
Data Source
AI summary
The bus bar arrangement (10) has multiple individual contact elements (12) interconnected in an electrically conductive manner and arranged side by side. The individual contact elements are made up of die cut sheet metal strips. Each individual contact element has an area that is formed as an electrical contact. Each individual contact element has a connection section (16) which is formed for mechanical and electrical fastening of an electrical conductor (38) using a cord grip (18). An independent claim is also included for a method for connecting a predetermined number of electrical inputs of an electrical device, particularly central electronics of a motor vehicle.