NEV Three-Electric System

Battery System

Cell interconnection, module-to-module connection, and high-voltage output of battery packs

Solutions:

  • Flexible Copper/Aluminum Busbars: Absorb expansion stress during charge/discharge, preventing weld joint failure caused by rigid connections.

  • Laser Welding / Ultrasonic Welding: Applied for cell terminal-to-aluminum busbar joining, ensuring low resistance and high reliability.

  • Powder Coating / PVC Dip Insulation: Resistant to electrolyte corrosion, suitable for high-voltage platforms (up to 800V), with thin and uniform insulation layers.

Copper Busbar|Aluminum Busbar|Flexible Bus Bar - RHI Electric

Motor System

Three-phase AC connection between motor controller and motor

Solutions:

  • Hybrid Rigid-Flexible Busbar Design: Rigid copper busbars for fixed ends; flexible busbars to absorb vibration and prevent weld cracking.

  • Insert Injection Molding: Copper busbars are overmolded with engineering plastics (e.g., PA66/PPS) to ensure precise phase positioning, gap filling, and short-circuit prevention.

Copper Busbar|Aluminum Busbar|Flexible Bus Bar - RHI Electric

Power Electronics System (Inverter / PDU)

(IGBT module interconnection and high-voltage power distribution for fixed, high-current applications)

Applications:

  • Copper busbars for MCU DC-link, IGBT modules, and DC-link capacitor connections

  • Insulated (dip-coated / powder-coated) copper busbars for PDU/BDU main circuits, fast charging, and HV distribution

  • Extruded rigid copper busbars for battery pack main circuits and high-current module interconnections

Solutions:

  • Insert Injection Molding: Integrates busbars into an insulated plastic frame for precise positioning and space-saving design.

  • Brazing: Enables reliable Cu–Al transition joints, mitigating galvanic corrosion.

High-voltage Busbar for Electrical Control

Custom Busbars for NEV Three-Electric System