Investigation of busbar fixation for commercial electric vehicle power distribution unit

Abstract

In recent years, the trucking industry has been steadily progressing toward electrification, opening new avenues for innovation and development. A key component in this transition is the Power Distribution Unit (PDU), which plays a vital role in distributing and monitoring electrical power from the battery packs to various vehicle systems while ensuring protection against short circuits. This thesis focuses on the development of new concepts for the busbar fixation catalogue within the PDU. Busbars are conductive elements that must be both securely fixed and electrically insulated from the surrounding conductive housing. The fixation solutions must meet stringent mechanical, thermal, and electrical requirements to ensure product robustness, safety, and compliance with industry standards. The project follows a structured product development process with an emphasis on mechanical design. While customer requirements were generalized for company secrecy and to foster broader innovation, the scope was narrowed to solutions that are both space-efficient and cost-effective. A concept generation phase was conducted, resulting in multiple sub-solutions addressing the various functional demands of busbar fixation. These concepts were systematically evaluated using selection matrices based on criteria such as assembly efficiency, material cost, manufacturability, and overall performance. Three final concepts were selected for further analysis, each offering a distinct approach to fulfilling the core functional requirements. A detailed design phase followed, incorporating material selection, 3D CAD modeling, and computer-aided engineering (CAE) simulations. Special attention was given to ensuring the design met load-bearing and insulation requirements. A static structural analysis was performed to verify the chosen solution under maximum expected load conditions. Throughout the project, iterative evaluations and design refinements were carried out to ensure the quality and feasibility of the final concept.