Sliding Busbar Insulation Cover for Confined EV Module Spaces
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Solution Overview
Problem
Conventional insulating housings for busbars in electric vehicles are bulky and unsuitable for confined spaces, particularly around the end portions where busbars are fixed to modules, posing a risk of high-voltage contact and complicating installation.
Innovation Solution
An electrical insulation device comprising a support made of insulating material with orifices and guide slots for removable covers, allowing easy access and secure closure, featuring guide members, retaining members, and poka-yoke mechanisms to ensure correct positioning and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulating housings with folding flaps or caps are used, then electrical insulation is provided, but the housing becomes bulky and unsuitable for confined spaces
Solution Approach 1:
The cover is designed to be movable between a first position (allowing access to the orifice for screw-fastening) and a second position (providing electrical insulation). This dynamic configuration allows the housing to adapt its volume and function based on operational requirements, resolving the contradiction between providing insulation and maintaining compact size.
Solution Approach 2:
The insulating housing is segmented into a support structure and a removable cover. This segmentation allows the cover to be moved independently between positions, enabling the housing to provide insulation when needed while maintaining a compact form factor when the cover is retracted, thus resolving the volume contradiction.
2Reliability
If insulating housings are used around busbar end portions, then electrical insulation is provided, but accessibility for screw-fastening is compromised
Solution Approach 1:
The cover can be moved between a first position that provides full accessibility to the orifice for screw-fastening operations and a second position that provides electrical insulation. This dynamic positioning resolves the contradiction by allowing the housing to switch between accessibility and insulation modes as needed.
Solution Approach 2:
The cover is designed to be moved to the first position before screw-fastening operations to ensure accessibility, and then moved to the second position after fastening to provide insulation. This preliminary positioning action resolves the contradiction by ensuring the correct state is established before each operation.
3Reliability
If folding flaps or caps are used for insulation, then electrical insulation is provided, but the mechanism becomes complex and requires space for opening/closing
Solution Approach 1:
The cover is designed with simple guide members that guide movement along a defined path between two positions. This dynamic but simplified mechanism reduces complexity compared to traditional folding flaps while maintaining the insulation function, resolving the contradiction between reliability and complexity.
Solution Approach 2:
The complex folding flap mechanism is extracted and replaced with a simpler removable cover that slides or moves along guide members. This extraction of the overly complex mechanism while retaining the essential insulation function resolves the contradiction between providing reliable insulation and reducing device complexity.
Data Source
AI summary
An insulation device for a busbar includes a support and at least one cover made of electrically insulating material and attached to the support. The at least one cover is slidably mounted on the support by at least one guide member.