Busbars are essential components in electric vehicles (EVs), ensuring reliable and efficient connections between critical elements in high-voltage powertrain assemblies, such as inverters and motors. As the e-mobility sector expands, solutions are increasingly needed to improve assembly processes and support advanced design requirements.
Stäubli’s ZeroBolt busbar connections offer a streamlined alternative to traditional bolted systems, addressing common challenges in EV powertrain manufacturing.
These connections incorporate Stäubli’s MULTILAM contactless technology, providing high current-carrying capacity, thermal expansion compensation, and vibration resistance.
In addition, ZeroBolt enables tolerance compensation in up to three directions, achieving high performance across a broad power range while accommodating thermal expansion. The pluggable design allows for blind-mating operations, simplifying the manufacturing process and reducing assembly time and complexity.
Other key advantages of the ZeroBolt system include:
- Flexibility: Suitable for evolving EV powertrain designs while maintaining performance and reliability.
- No need for torque control: This is typically associated with bolted busbars and eyelets. ZeroBolt reduces costs and cycle times and supports potential automated assembly.
- Reduced costs and risks: By eliminating bolted connections, ZeroBolt minimizes assembly risks and associated expenses.
- Quality ensured: No quality variations based on torque related issues.
Stäubli’s ZeroBolt busbar connections offer manufacturers a solution to improve powertrain efficiency, reliability, and scalability in EVs.
Filed Under: Technology News