TY - CHAP
T1 - Busbars for e-mobility: State-of-the-Art Review and a New Joining by Forming Technology
AU - F. V. Sampaio, Rui
AU - Zwicker, Maximilian F. R.
AU - Pragana, João P. M.
AU - M. F. Bragança , Ivo
AU - Silva, Carlos M.A.
AU - Nielsen, Chris V.
AU - Martins, Paulo A. F.
PY - 2022
Y1 - 2022
N2 - The changes in the automotive market and their effects on industry are
nowadays hot topics in metal forming seminars and conferences around the
world. The rise in the number of electric vehicles will inevitably lead
to a decrease in the demand of components for combustion engines and
power drive trains. Typical forming components such as pistons,
connecting rods, valves, camshafts, crankshafts, multi-speed gear boxes
and others that exist in diesel or petrol vehicles, will no longer be
required. However, the lightweight construction requirements for the
body-in-white of electric vehicles, the production of components for
asynchronous motors and the fabrication of battery components, namely
busbars, are bringing new challenges and opportunities for the metal
forming industry. This chapter is focused on busbars, which are metallic
strips or sheets that are utilized to distribute electric power to
multiple equipment such as the electric motor, the electric power
steering unit, and the AC/DC converters. In particular, the chapter
addresses the challenge of replacing copper busbars by hybrid busbars
made from copper and aluminium, due to the expected savings in weight
and cost. For this purpose, the authors discuss the challenge of
connecting copper to aluminium in hybrid busbars by means of existing
joining technologies and introduce a new joining by forming process
aimed at connecting hybrid busbars at room temperature without giving
rise to material protrusions above and below the sheet surfaces. The
effectiveness of the new process is compared against fastening by
measuring the electric resistivities in both types of hybrid busbar
joints. Finite element analysis gives support to the presentation and
proves to be suitable for the electro-thermo-mechanical analysis of
busbar connections.
AB - The changes in the automotive market and their effects on industry are
nowadays hot topics in metal forming seminars and conferences around the
world. The rise in the number of electric vehicles will inevitably lead
to a decrease in the demand of components for combustion engines and
power drive trains. Typical forming components such as pistons,
connecting rods, valves, camshafts, crankshafts, multi-speed gear boxes
and others that exist in diesel or petrol vehicles, will no longer be
required. However, the lightweight construction requirements for the
body-in-white of electric vehicles, the production of components for
asynchronous motors and the fabrication of battery components, namely
busbars, are bringing new challenges and opportunities for the metal
forming industry. This chapter is focused on busbars, which are metallic
strips or sheets that are utilized to distribute electric power to
multiple equipment such as the electric motor, the electric power
steering unit, and the AC/DC converters. In particular, the chapter
addresses the challenge of replacing copper busbars by hybrid busbars
made from copper and aluminium, due to the expected savings in weight
and cost. For this purpose, the authors discuss the challenge of
connecting copper to aluminium in hybrid busbars by means of existing
joining technologies and introduce a new joining by forming process
aimed at connecting hybrid busbars at room temperature without giving
rise to material protrusions above and below the sheet surfaces. The
effectiveness of the new process is compared against fastening by
measuring the electric resistivities in both types of hybrid busbar
joints. Finite element analysis gives support to the presentation and
proves to be suitable for the electro-thermo-mechanical analysis of
busbar connections.
U2 - 10.1007/978-3-030-90487-6_4
DO - 10.1007/978-3-030-90487-6_4
M3 - Book chapter
SN - 978-3-030-90486-9
T3 - Materials Forming, Machining and Tribology
SP - 111
EP - 141
BT - Mechanical and Industrial Engineering. Materials Forming, Machining and Tribology
A2 - Davim, J.P.
PB - Springer
CY - Cham
ER -