42 THE DISTRIBUTOR’S LINK PENN ENGINEERING 5190 Old Easton Road, Danboro, PA 18916 TEL 1-800-237-4736 FAX 215-766-0143 EMAIL info@pemnet.com WEB www.pemnet.com ADVANCING EMOBILITY: SPECIALIZED SOLUTIONS FOR EV BUSBARS by John O’Brien, Global Technologist currents, prompting a shift towards busbars as a more efficient alternative. eMobility is reshaping the automotive industry in unprecedented ways. Once dominated by mechanical engineers, the automotive sector now demands expertise in electrical engineering as vehicles transform into data-rich, smart machines. In the rapidly evolving eMobility sector of electric vehicles (EV), the demand for superior electrical connections continues to grow. Let’s take a deeper dive into the evolution of the EV sector and how new specialized solutions are revolutionizing busbar applications in EVs. Meeting Changing Requirements In The EV Sector: Evolution Of Electrical Pathways In EVs Initially, high current pathways in early EVs relied largely on heavy-duty cables. While these cables offered great flexibility, their performance was limited. As the EV industry advanced, so did the need for higher Copper Busbars: Benefits and Challenges Early busbars were made of copper, requiring significant material to meet the EV sector’s standards. This not only increased weight but also raised costs. To address this, companies opted to run busbars warmer, reducing the copper needed by half. Over time, busbars could operate at up to 10A/ mm², although this caused them to heat up significantly. Fortunately, the cooling systems already necessary for EV batteries could also cool busbars, maintaining their slim profile and reducing both weight and costs. Transition To Aluminum By 2022, the rising cost of copper led EV companies to explore alternative materials like aluminum. Despite needing twice the amount of aluminum, its weight was still half that of the copper required, offering both weight and cost savings. However, aluminum posed a challenge due to its rapid formation of an insulating oxide layer, complicating electrical connections. Specialized Solutions: The ECCB PEM eConnect ® Contact Bushing To overcome these challenges, PennEngineering® recently developed the ECCB PEM eConnect® Contact Bushing. TECHNICAL ARTICLE CONTINUED ON PAGE 110
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