Wrap Around Bus Bar for Vehicle Power Distribution
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Solution Overview
Problem
Traditional bus bar designs in power distribution devices are limited by their simple configuration, making it difficult to provide battery power to complex systems like hybrid-type power distribution boxes that include both a relay block and a module, often requiring multiple bus bars.
Innovation Solution
A wrap around bus bar with multiple sides, including a battery side, module side, and relay block side, designed to securely connect and provide power to these components, allowing for efficient current distribution and configuration flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple one-sided or two-sided bus bar design is used, then the manufacturing process is easier and the structure is simpler, but the design options for complex power distribution devices are limited and multiple bus bars are required
Solution Approach 1:
The bus bar is divided into multiple functional sides (first side for battery connection, second side for module connection, third side for relay block connection) that can be independently designed and configured. This segmentation allows each side to be optimized for its specific connection requirements while maintaining overall structural integrity.
Solution Approach 2:
The multi-sided bus bar design serves multiple functions simultaneously: it provides electrical connections to the battery, module, and relay block while also serving as a structural support element. This universal design eliminates the need for separate connection components and enables complex power distribution configurations with a single bus bar.
2Ease of manufacture
If traditional simple bus bar designs are used in hybrid-type power distribution boxes, then the manufacturing cost is lower, but providing battery power to both module and relay block becomes difficult and requires multiple bus bars
Solution Approach 1:
Multiple bus bars that would traditionally be used separately to connect the battery, module, and relay block are merged into a single multi-sided bus bar structure. This consolidation maintains manufacturing simplicity while dramatically improving electrical connection capability, as the bus bar can now serve multiple connection points simultaneously.
Solution Approach 2:
The bus bar design transitions from a one-sided or two-sided planar structure to a multi-sided three-dimensional configuration. This dimensional expansion allows the bus bar to access and connect to multiple components (battery terminal, module, relay block) that are positioned at different locations and orientations within the power distribution box.
3Productivity
If a multi-sided wrap around bus bar design is implemented, then design options and current distribution efficiency are improved, but the manufacturing process becomes more complex
Solution Approach 1:
Different sides of the bus bar are designed with locally optimized characteristics: the first side is configured for high-current battery connection with appropriate contact area and material properties, while the second and third sides are designed for module and relay block connections with their specific electrical and mechanical requirements. This local quality approach allows each region to be optimized for its function.
Solution Approach 2:
The bus bar employs asymmetric design where each side has different geometries, connection configurations, and dimensional characteristics tailored to its specific connection requirements. This asymmetry enables optimal electrical contact and mechanical fit for each component (battery, module, relay block) without requiring symmetric simplification that would compromise performance.
Data Source
AI summary
A wrap around bus bar that provides battery power (also referred to as B+ power) to components within a power distribution device for a vehicle electrical system, such as a hybrid-type power distribution box (PDB). The power distribution device routes or distributes power throughout a vehicle electrical system and may include a lower cover, a wrap around bus bar, a relay block assembly, a module with a printed circuit board (PCB), an array of relays and fuses, and an upper cover. Battery power is provided from a vehicle battery and/or alternator to a terminal connection, from the terminal connection to the wrap around bus bar, and from the wrap around bus bar to the relay block assembly, the module and potentially other components within the power distribution device.