In some cases, manufacturers use flat braided cables instead of orange cables. Flat braided cables are welded and automatically cut into parts with specific lengths and welds on both ends. Braided cables with welds on both ends are also known as shunts. The advantage of using ultrasonic welding to make the shunt is that the least amount of heat is required to make the shunt and weld the shunt to the busbar. This prevents scoring of brittle strands and unusually thin strands due to the heat from resistance welding (another technique that can be used).
Torsion Welding Applications and Capabilities for Busbars
Flex busbar foils are laminated/plated with materials such as copper to prevent oxidation issues. For solid busbars, bolt hole connections must be plated. For aluminum solid busbars, the connecting contacts must be copper. So copper washers are used and connected to the bus bars by twist soldering.
The innovative and rapidly growing electric vehicle market requires new, developing solutions to meet future challenges. Soon, the use of high voltage bus bars will replace some current applications of high voltage cable terminations. As the industry moves to using busbars outside the battery pack, new challenges will arise until the automotive industry can establish standardization on busbar harnesses.