Sinusoidal Tubular Busbar for Skin and Proximity Effect Losses
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Solution Overview
Problem
Existing busbars suffer from material inefficiency due to the skin effect and proximity effect, leading to increased material usage and heat dissipation challenges in high-voltage applications.
Innovation Solution
A sinusoidal tubular busbar design that reduces material usage by optimizing the conductor perimeter, enhancing heat dissipation, and attenuating the proximity effect, while maintaining mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cross-sectional area of solid busbars is increased to reduce skin effect, then the electrical conductivity is improved, but the material usage and manufacturing cost increase
Solution Approach 1:
The busbar employs a sinusoidal tubular shape instead of a conventional rectangular solid profile. This curved, wave-like geometry increases the effective perimeter and surface area for current flow, reducing the skin effect without requiring a larger cross-sectional area. The tubular configuration with optimized wall thickness provides sufficient mechanical strength while using less copper material.
Solution Approach 2:
The invention changes the geometric parameters of the busbar by transitioning from a solid rectangular profile to a sinusoidal tubular profile. This involves optimizing the amplitude, wavelength, and wall thickness parameters of the sinusoidal shape to achieve the desired balance between electrical performance, mechanical strength, and material efficiency.
2Loss of energy
If the perimeter of the busbar is increased to reduce skin effect losses, then the heat dissipation is improved, but the complexity of the conductor shape increases
Solution Approach 1:
The sinusoidal tubular shape provides a naturally curved profile that increases perimeter and surface area for heat dissipation. The wave-like geometry creates multiple surfaces exposed to cooling air, enhancing convective heat transfer without requiring additional cooling mechanisms or complex multi-component structures.
Solution Approach 2:
The sinusoidal shape creates local variations in the busbar geometry, with peaks and valleys that provide different thermal exposure characteristics. These local geometric features enhance heat dissipation at critical areas where current density is highest, while the overall structure remains a single integrated component.
3Power
If multiple conductors per phase are used to increase current capacity, then the supported current is improved, but the proximity effect increases causing additional losses
Solution Approach 1:
The sinusoidal tubular shape breaks the symmetry of conventional rectangular busbars, creating an asymmetric current distribution pattern. When multiple such busbars are placed in proximity, the asymmetric geometry reduces the coupling between adjacent conductors, thereby minimizing the proximity effect and associated energy losses while maintaining high current capacity.
4Quantity of substance
If the wall thickness of the tubular busbar is reduced to use less material, then the material cost is reduced, but the mechanical strength decreases
Solution Approach 1:
The tubular configuration with optimized wall thickness provides sufficient mechanical strength to withstand electromagnetic forces and thermal stresses. The curved sinusoidal profile distributes mechanical loads more effectively than flat surfaces, allowing for thinner walls while maintaining structural integrity. The sinusoidal shape also provides inherent flexibility to accommodate thermal expansion and contraction.
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 sinusoidal tubular busbar achieves higher current density with less material, improved heat dissipation, and enhanced mechanical resistance, optimizing space usage and reducing production costs.
Implementation Method 1
the skin effect, that is, the useful area for conducting electricity is reduced, since the alternating current tends to be concentrated in the periphery of the conductor, decreasing the current density inside it
Implementation Method 2
losses caused by a phenomenon whose principle is the same as skin effect are also generated; however, like the interaction occurring among different conductors, the phenomenon is called proximity effect
Implementation Method 3
increasing the conductor perimeter if compared to conventional systems, then obtaining an greater area for heat dissipation
Data Source
AI summary
“SINUSOIDAL TUBULAR CONDUCTING BUSBAR” refers to an electric conductor busbar, more specifically a conductor busbar, with a sinusoidal tubular shape, applied to electric cabinets to control and switchgear assemblies for low and high voltage and prefabricated power lines. The busbar has an initial crimping tab connecting to a first sinusoid, which in turn connects to a junction tab, which in turn connects to a second sinusoid, so that said first sinusoid and second sinusoid form a tubular region between them, wherein there is no contact between said first sinusoid and second sinusoid. Said second sinusoid is connected to a final crimping or even a second junction tab, which is connected to a third sinusoid, with the said third sinusoid being connected to a final crimping tab.