| CPC H02K 11/33 (2016.01) [B60L 53/22 (2019.02); H01B 13/0036 (2013.01); H02P 27/06 (2013.01); B60L 2210/30 (2013.01); B60L 2210/40 (2013.01)] | 20 Claims |
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1. An electric drive system, comprising:
two rigid bus bars;
a power electronics module configured to transform direct current power carried by the bus bars into alternating current power, the power electronics module including a capacitor connected between the two rigid bus bars; and
a molded bleed resistor comprising fine carbon particles bonded directly to the bus bars such that the molded bleed resistor rigidly fastens the two bus bars to one another, the bleed resistor configured to dissipate energy from the capacitor.
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9. A method of fabricating a bus bar assembly for an electric drive system, the method comprising:
holding two rigid conductive bus bars in a predetermined position relative to one another but not in contact with each other; and
injecting a substance between the two bus bars which bonds to the bus bars and hardens, thereby rigidly attaching the two bus bars together in the predetermined relative position;
wherein the substance contains fine carbon particles such that it forms a bleed resistor.
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14. A method of assembling an electric drive system, comprising:
connecting a DC bus bar assembly to a power electronics module, wherein the power electronics module includes a capacitor and an inverter, and wherein the DC bus bar assembly includes a positive bus bar and a negative bus bar rigidly fastened to one another by a molded bleed resistor comprising fine carbon particles, the molded bleed resistor bonded to the positive bus bar and the negative bus bar prior to connection to the power electronics module.
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