Joining of hybrid busbars for E-Mobility: An economic and environmental study

João PM Pragana; Miguel ST Sapage; Rui FV Sampaio; Ivo MF Bragança; Ines Ribeiro; Carlos MA Silva; Paulo AF Martins

Key information

Authors:

João PM Pragana (João Pedro da Fonseca Matos Pragana); Miguel ST Sapage (Miguel Santiago Teixeira Sapage); Rui FV Sampaio (Rui Filipe Vieira Sampaio); Ivo MF Bragança (Ivo Manuel Ferreira de Bragança); Ines Ribeiro (Inês Esteves Ribeiro); Carlos MA Silva (Carlos Manuel Alves da Silva); Paulo AF Martins (Paulo António Firme Martins)

Published in

November 1, 2023

Abstract

This paper presents a model to evaluate and analyze the costs of joining hybrid (copper-aluminum) busbars when different production processes are deployed. The process-based cost model (PBCM) is built upon the subdivision of the production cycle in three different stages related with the fabrication or purchase of auxiliary joining elements, preparation of the individual copper and aluminum conductors, and final joining of the hybrid busbars. The total cost per hybrid busbar is obtained by converting the major physical, human, and financial resources associated with the production cycle into itemized costs that make use of the expenses in materials, labor working hours, number and usage time of machines and tools, among other production costs. Application of the PBCM is illustrated with three different joining processes and enriched with a life cycle assessment (LCA) focused on the environmental performance of hybrid busbars throughout its fabrication, service use and end of life. The combined economic and environmental sustainability analysis of joining hybrid busbars allows concluding that despite conventional fastening being the cheaper process it has the highest environmental impact due to the use of bolts, nuts and washers made from galvanized medium carbon steel. Injection lap riveting arises to be the most well-balanced process in terms of production cost and environmental impact.