TMB-14 - Bal Seal Engineering, Inc.
Transcription
TMB-14 - Bal Seal Engineering, Inc.
TMB-14 Custom components that drive tomorrow’s technologies. Connecting, Conducting and EMI/RFI Shielding Solutions for the Motorsports Industry BRAKING SYSTEMS • ENERGY RECOVERY SYSTEMS • BAT TERY C ONNEC TIONS A Reputation for Innovation. When manufacturers of high-performance motorsports vehicles and systems need smart solutions to tough design challenges, they turn to Bal Seal Engineering. Our products are custom-engineered to ensure reliable, consistent fastening, shielding and delivery of current to and from batteries and other systems, and they are already at work in many of today’s top-performing vehicles and platforms. Our Bal Spring™ canted coil springs, with their unique mechanical and electrical properties, allow for the more efficient design of regenerative braking and energy recovery systems (ERS) that can intermittently increase power up to tenfold in high-performance electric and hybrid vehicles. Together with industry design engineers, we’re using these springs and other innovative components we make to accelerate advances in racing and EV technology. We’re more than just a problem-solver—we’re your innovation partner. With a vast application knowledge base, ISO 9001 and TS 16949 certified processes, and advanced manufacturing capabilities, we can help you develop standard-setting breakthroughs that give you and your team a competitive edge. The integration of Bal Spring™ canted coil spring technology into this electronic steering system is just one example of how design engineers have leveraged our products and expertise to improve vehicle reliability and performance. The Bal Spring™: Simple, Efficient & Robust. The Bal Spring™ canted coil spring is a versatile component that mechanically fastens, conducts electricity, and shields sensitive electronics from the harmful effects of electromagnetic interference (EMI), and radio-frequency interference (RFI). The spring’s independent coils, which serve as multiple contact points for optimal current carrying capability in electrical and shielding applications, ensure consistent, reliable connection—even under shock and vibration. The Bal Spring is robust enough to withstand thousands of insertion and removal cycles, and it can be precisely engineered to meet virtually any connector force requirement. Available in a broad range of wire materials, sizes, and finishes, the spring can be manufactured to inside diameters as small as 0.41 mm (0.016 in.), and can also be easily configured to serve as a “tamper-proof” connection. The spring’s compact design and multi-function capabilities help reduce system complexity and weight without compromising performance. www.balseal.com 2 For Electrical Conducting: The Bal Spring™ canted coil spring performs extremely well as an electrical contact element, enabling motorsports vehicle and system designers to effectively manage high, medium, and low current in a wide range of vehicle applications. Each coil of the Bal Spring acts independently across the mating surface interface, compensating for large tolerances and surface irregularities. Figure 1 shows derating curves for an 8 mm connector using a Bal Spring made from copper alloy. The solid line curves are based on actual test data. Also included are the cross-sectional cable areas in mm2 for comparison purposes against EU standard cable sizes. The dashed lines represent theoretical derating curves for the same 8 mm connector using 35, 25, and 16 mm2 EU standard cables. 450 2/0 AWG (67.23 mm) 400 Bal Spring™ Conducting Applications Current (A) 350 •Regenerative braking systems •Lithium-ion battery pack/harness connections •Kinetic MGU, heat MGU, energy storage, and control electronics •Electronic starter controls •Steering systems 1/0 AWG (53.49 mm) 300 250 2 AWG (33.62 mm) 200 150 35 mm 100 25 mm 50 16 mm 0 0 20 40 60 80 100 120 140 160 Ambient Temperature (OC) Derating Curves Figure 1. Derating curves for 8 mm Bal Spring canted coil springs in electrical contact element applications. Tests performed to DIN EN 60512-5-2 specifications. Data available upon request for other standard pin sizes. For Mechanical Fastening: Our Bal Spring canted coil springs for latching, locking, and holding applications are available in a variety of materials and surface finishes. In addition to fastening or latching, the spring can be designed to permanently lock two pieces together, or to perform a holding function. Normal working deflection Normal maximum working deflection HEAVY 20 MEDIUM LIGHT Depending on design requirements, a spring may be engineered to require as much as 900–1000 lb of tension load breakaway force. The spring can also be used to dampen vibration. Its resistance to compression set translates to consistent, repeatable service over thousands of cycles, and its controllable forces make it ideal for quick connect/ disconnect applications. Force (N) 15 O-ring 10 V-spring Ribbon spring 5 Bal Spring™ canted coil spring 0 0 Bal Spring™ Fastening Applications 10 20 30 40 50 Deflection (%) Figure 2. Unlike typical spring technologies, the Bal Spring canted coil spring provides nearly constant force across the working deflection. •Access panels •Driver safety systems •Body assembly www.balseal.com 3 For EMI/RFI Shielding: Transfer Impedance of Canted Coil Spring shields vs. Other shielding methods 500 •Driver information & safety systems •Radio, telephony & antennae •Power management (battery packs, power converters & sensors) •Vehicle performance monitoring Transfer Impedance (μΩ/m) Bal Spring™ Shielding Applications The Bal Spring’s highly conductive properties and unique 400 design enable it to provide superior shielding against EMI/RFI, particularly in high-frequency, small-package applications. As Finger Stock 300 Helical Flat Spring an interface shielding component, the spring offers designers a Wire Mesh over simple, economical means to greatly reduce radiated emissions Elastomer 200 and conducted interference. 105 Series Bal Spring™ Canted Coil Spring 100 0 10 100 Transfer Impedance Attenuation (dB) (μΩ/m) 500 Note: shielding effectiveness is highly dependent on the connector design and configuration. Finger Stock Helical Flat Spring BSE9 60 200 50 Wire Mesh BSE9 w/Agover Elastomer BSE3 105 Series Bal Spring Spring™ No Canted Coil Spring 40 100 30 100 1.0 2.0 3.0 1000 Frequency (MHz) 4.0 5.0 6.0 7.0 8.0 9.0 10.0 100 Transfer Impedance of Canted Coil Spring shields 100 MHz–1 GHz, Attenuation vs. Frequency vs. Other shielding methods 90 100 500 80 90 70 80 400 60 70 50 60 300 40 50 30 40 200 20 30 10 20 100 0 10 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 0 Frequency (GHz) 0 100 200 300 400 500 600 700 800 900 1000 10 100 1000 BSE9 BSE9 w/Ag BSE9 Finger BSE3 Stock BSE9 w/Ag Helical Flat Spring No Spring BSE3 Wire Mesh over No Spring Elastomer 105 Series Bal Spring™ Canted Coil Spring Frequency (MHz) Frequency (MHz)vs. Frequency 100 MHz–1 GHz, Attenuation Figure 4. 100 MHz–1 GHz, attenuation vs. frequency. 100 Attenuation (dB) (dB) Attenuation Compared with no spring, material type BSE3 shows greatly improved shielding effectiveness, which may be sufficient for some applications. BSE9, which shows even greater shielding effectiveness, is recommended for high-performance shielding requirements. 80 300 70 Figure 3. Transfer impedance Bal Spring canted coil Frequencyof(GHz) 1–10shielding GHz, Attenuation vs. Frequency spring vs. other methods. 90 100 80 90 70 80 60 70 50 60 40 50 30 40 20 30 10 20 0 10 0 1–10 GHz, Attenuation vs. Frequency BSE9 BSE9 w/Ag BSE9 BSE3 BSE9 w/Ag No Spring BSE3 No Spring 100 200 300 400 500 600 700 800 900 1000 Frequency (MHz) 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 Frequency (GHz) Figure 5. 1–10 GHz, attenuation vs. frequency. 100 MHz–1 GHz, Attenuation vs. Frequency 100 4 90 www.balseal.com on (dB) Figures 4 and 5 at right illustrate the Bal Spring’s shielding effectiveness at frequency ranges of 100 MHz–1 GHz and 1–10 GHz. Tests were conducted on a 50-Ω characteristic impedance coaxial connector using a copper alloy Bal Spring with 6-μm silver plating as a shielding element. The spring was shown to provide 60 db of attenuation. 1–10 GHz, Attenuation vs. Frequency 100 400 90 20 0 1010 0 Transfer Attenuation Impedance (μΩ/m) (dB) (dB) Attenuation Figure 3 at right indicates the superior shielding effectiveness of the Bal Spring canted coil spring compared with other shielding options. Summary testing data shows that the spring exhibits much lower transfer impedance than finger stock, helical flat springs, or wire mesh over elastomer. 1000 Frequency (MHz) Transfer Impedance of Canted Coil Spring shields vs. Other shielding methods 80 70 60 BSE9 Typical Bal Spring™ Applications in Formula 1 and Formula E Designers of F1/FE racing vehicles and systems are leveraging the unique electrical and mechanical capabilities of the Bal Spring canted coil spring to improve performance and safety. In power management systems The Bal Spring shields against EMI/RFI, ensuring the integrity of signal/data transfer between battery packs, power converters, and sensors. In radio, telephony & antennae The Bal Spring shields against EMI/RFI and prevents system “cross-talk.” In body assembly applications The Bal Spring can be customengineered to latch and lock panels and body components for fast removal/replacement. In kinetic MGU, heat MGU, energy storage and control electronics The Bal Spring provides multi-point electrical contact, even in high vibration and shock load environments. In regenerative braking systems The Bal Spring ensures consistent power transfer to the ERS. EMI/RFI shielding Electrical conducting www.balseal.com Mechanical fastening/ connecting 5 Custom components, infinite possibilities. We are a global provider of custom sealing, connecting, conducting and EMI/RFI shielding solutions. We specialize in applying our advanced designs, unique materials and manufacturing capabilities to meet your most demanding application requirements. Whether you’re working on a new product or improving an existing one, we’re standing by to help. Call or visit us today. Americas Europe, Middle East, Africa Asia Pacific Bal Seal Engineering, Inc. 19650 Pauling Foothill Ranch, CA 92610-2610 Telephone (949) 460-2100 Toll Free (800) 366-1006 Fax (949) 460-2300 E-mail [email protected] Bal Seal Engineering Europe B.V. Jollemanhof 16, 5th floor 1019 GW Amsterdam The Netherlands Telephone +31 20 638 6523 Fax +31 20 625 6018 E-mail [email protected] Bal Seal Asia Limited Suite 901, Chinachem Century Tower 178 Gloucester Road Wanchai, Hong Kong Telephone +(852)-28681860 Fax +(852)-22956753 E-mail [email protected] www.balseal.com IMPORTANT INFORMATION The information, descriptions, recommendations, and opinions set forth herein are offered solely for Buyer/User consideration, inquiry and verification and are not, in part or in whole, to be construed as constituting a warranty, expressed or implied, nor shall they form or be a part of the basis of any bargain with Bal Seal Engineering, Inc. If any sample or model was shown to or provided by Buyer/User, such sample or model was used merely to illustrate the general description and type of goods, and such use is not to be construed as warranty that the goods will conform to the sample or model. Furthermore, THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER WARRANTIES, IMPLIED OR EXPRESSED, ARE EXCLUDED AND SHALL NOT APPLY. This document provides product options for further investigation by Buyers/Users having technical expertise. The Buyer/User, through analysis and testing, is solely responsible for making the final selection of the products and for assuring that all performance, safety and warning requirements for the application are met. It is recommended that Buyers/Users run evaluation testing under actual service conditions to determine whether proposed Bal Seal Engineering products are suitable for the intended purpose. Nothing contained herein or in any of our literature shall be considered a license or recommendation for any use that may infringe patent rights. (LE-17) Products described herein may be protected by one or more of the following U.S. patents: 5,411,348; 5,474,309; 5,545,842; 5,599,027, 8,166,623, 8,167,285, 8,297,662, 8,375,543, 8,491,345, 8,561,274 TMB-14-APG-09/15 © 2015 Bal Seal Engineering, Inc. All rights reserved.
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