An ac-dc switching connector

Abstract

An AC-DC switching connector comprises an upper cover plate and a lower cover plate, a spacing structure arranged between the upper cover plate and the lower cover plate, and a connecting piece connecting the upper cover plate, the spacing structure and the lower cover plate; the spacing structure comprises a spacer detachably sleeved on the connecting piece in sequence, and the spacer is an insulating structure or a conductor; by replacing the insulating structure or the conductor as the spacer, AC power supply and AC power supply switching adaptation are realized. The utility model solves the problems that the traditional connector cannot conveniently and quickly realize AC-DC power supply switching and cannot guarantee the power supply continuity of key scenes under the mixed power distribution mode of AC mains and DC backup power supply; the switching can be completed by replacing the detachable spacer, without overall disassembly, so that the switching cost and operation and maintenance difficulty are greatly reduced.

Description

Technical Field

[0001] This utility model belongs to the field of power transmission, and in particular relates to an AC / DC switching connector. Background Technology

[0002] In power transmission and distribution systems, busbar trunking, as a highly efficient power distribution medium, is widely used in high-power scenarios such as data centers, industrial parks, and commercial buildings. Busbar trunking typically consists of a metal shell, insulation components, and busbar conductors. It can replace traditional cables to achieve centralized power supply for multiple devices. It offers advantages such as high current carrying capacity, flexible wiring, and convenient maintenance. The power supply path can be flexibly expanded or adjusted according to power demand, effectively solving problems such as poor heat dissipation, difficult laying, and inconvenient expansion associated with traditional cables in high-power transmission. It has become a key component in modern power distribution systems connecting transformers, distribution cabinets, and electrical equipment.

[0003] In a power distribution system composed of busbar trunking, connectors serve as the core connection between busbar trunking sections and between busbar trunking sections and electrical equipment, playing a crucial role in power transmission and circuit on / off control. Their performance directly affects the stability, safety, and power supply efficiency of the entire power distribution system. They must meet basic requirements such as low current transmission loss, high connection reliability, and convenient installation and maintenance, while also being adaptable to different power supply modes and equipment needs in various scenarios.

[0004] With the rapid development of the digital economy and industrial intelligence, critical scenarios such as data centers and industrial parks are facing increasingly stringent requirements for power supply continuity and reliability. To address power outages caused by fluctuations or faults in the mains power, a hybrid power distribution mode of "AC mains power + DC backup power (such as battery packs)" has become the mainstream configuration: Under normal operating conditions, the system supplies power to the load through AC mains power to ensure stable equipment operation; when the AC mains power fails, voltage fluctuations exceed thresholds, or maintenance is required, the system must quickly switch to DC backup power to ensure uninterrupted power supply to core loads such as data center servers and critical production equipment in industrial parks, avoiding significant losses such as data loss and production stoppages due to power outages.

[0005] However, most busbar connectors currently on the market are designed for a single power supply mode, meaning they are only compatible with AC or DC power supplies, failing to meet the dual-power switching requirements of mixed power distribution modes. Specifically, in data center scenarios, if the AC mains power suddenly fails, the original AC connector must be manually removed and replaced with a DC connector to connect to the backup power supply. This process typically takes several minutes or even longer, far exceeding the server's allowable power outage tolerance time, which can easily lead to server downtime. In industrial park scenarios, the switching operation of traditional connectors is not only time-consuming but also requires on-site operation by professional personnel, increasing maintenance costs and safety risks. Furthermore, frequent disassembly and assembly can easily cause problems such as poor connector contact and decreased insulation performance, further affecting the stability of the power distribution system. Utility Model Content

[0006] The purpose of this invention is to provide an AC / DC switching connector to solve the technical problem of convenient switching of AC / DC power supply in busbar connections.

[0007] To achieve the above objectives, the specific technical solution of this utility model for an AC / DC switching connector is as follows:

[0008] An AC / DC switching connector includes an upper cover plate and a lower cover plate, a spacer structure disposed between the upper cover plate and the lower cover plate, and a connector connecting the upper cover plate, the spacer structure and the lower cover plate;

[0009] The spacer structure includes spacers that are detachably sleeved on the connector in sequence. The spacers are either insulating structures or conductors. Switching between AC power supply and AC power supply can be achieved by replacing the insulating structure or the conductor as the spacer.

[0010] The busbar conductors of the two busbar trunkings enter between the upper cover plate and the lower cover plate from both sides of the connector. The corresponding busbar conductors are respectively arranged on the upper and lower sides of the spacer. The two outermost sets of busbar conductors are respectively clamped between the upper cover plate and the spacer and between the lower cover plate and the spacer. The connector passes through the upper cover plate, the spacer structure, and the lower cover plate in sequence, clamping the upper cover plate and the lower cover plate to achieve clamping connection of the busbar conductors of the two busbar trunkings.

[0011] As a further improvement of this utility model, the insulating structure is centrally located within the spacer structure, and the remaining spacers are conductors to accommodate DC power supply.

[0012] As a further improvement of this utility model, the spacer is an insulating structure to adapt to AC power supply.

[0013] As a further improvement of this utility model, the insulating structure includes an insulating plate and conductive plates disposed on both sides of the insulating plate; insulating grooves for placing the conductive plates are provided on both sides of the insulating plate, and the conductive plates realize electrical connection between the two sides corresponding to the busbar conductors.

[0014] As a further improvement of this utility model, the thickness of the conductive plate is adapted to the depth of the insulating groove, and the edge of the conductive plate is in contact with the inner wall of the insulating groove. The surface of the conductive plate away from the insulating plate is flush with the surface of the insulating plate to ensure the flatness of the busbar conductor when it contacts the conductive plate.

[0015] As a further improvement of this utility model, the connecting member includes a bolt and a nut, wherein the bolt passes through the upper cover plate, the spacer structure, and the lower cover plate in sequence and is then threadedly connected to the nut.

[0016] As a further improvement of this utility model, an upper insulating plate is provided between the upper cover plate and the spacer, and an upper insulating groove is provided on the side of the upper insulating plate facing the spacer, and an upper conductive plate is provided in the upper insulating groove; a lower insulating plate is provided between the lower cover plate and the spacer, and a lower insulating groove is provided on the side of the lower insulating plate facing the spacer, and a lower conductive plate is provided in the lower insulating groove.

[0017] As a further improvement of this utility model, the outer surfaces of both the upper cover plate and the lower cover plate are integrally formed with heat dissipation teeth.

[0018] As a further improvement of this utility model, the connector of this utility model also includes a housing covering the upper cover plate and the lower cover plate, the two ends of the housing forming a sealed connection with the ends of the busbar grooves on both sides, and the two ends of the housing are connected to the threaded holes of the busbar grooves by fastening bolts.

[0019] Beneficial effects:

[0020] When converting AC to DC power, some insulating spacers in the partition structure are replaced with conductive spacers. This allows the originally independent multi-phase busbar conductors to be electrically connected and merged into a single phase, adapting to the unipolar current transmission characteristics of DC power. This design abandons the traditional method of requiring additional complex conversion circuits to achieve multi-phase AC-DC conversion. It directly relies on the material replacement of the spacers to complete the conduction conversion from multiple phases to one phase, ensuring that the DC current can be stably transmitted along the merged single path. This avoids DC power interruption or uneven current distribution caused by ineffective conduction of multiple phases, meeting the power supply requirements of DC backup power in scenarios such as data centers and industrial parks.

[0021] When multi-phase busbar conductors are combined into a single phase via conductor spacers, the clamping structure firmly secures the combined busbar conductor to the conductor spacers, preventing loosening of the conductive contact between the multiple phases due to stress on the busbar conductors or equipment vibration. Simultaneously, the single conductive path after merging reduces current transmission nodes, lowers contact resistance, and reduces power loss and localized heat generation during DC power supply. Compared to traditional multi-node DC paths, this significantly improves the stability and safety of DC power supply, ensuring the continuous and stable operation of core loads such as servers and industrial equipment in DC power supply mode.

[0022] This design achieves multi-phase AC to DC conversion as a single-phase switch, requiring only the targeted replacement of certain spacer components in the alternating structure (replacing insulators with conductors). It eliminates the need for disassembly or modification of core structures such as the upper and lower covers and connectors, and also eliminates the need for additional independent AC-DC conversion modules. Compared to traditional methods that require replacing all connectors or adding complex conversion circuits, this design significantly simplifies the multi-phase conversion process, shortens switching time, and avoids the increased costs and failure risks associated with additional conversion components. This allows businesses to switch to DC backup power with lower barriers to entry and at a lower cost when dealing with mains power failures, reducing business interruptions caused by complex switching.

[0023] The multi-phase busbar conductors of the two busbar trunkings can be symmetrically connected between the upper and lower cover plates. The corresponding phases on both sides are connected and merged through the intermediate conductor spacer, forming a bidirectional symmetrical DC transmission path. This symmetrical multi-phase conduction design eliminates the need for connectors to distinguish the connection direction of the busbar trunking, adapting to the layout requirements of busbar trunking in different installation scenarios. At the same time, the symmetrical conduction structure on both sides can balance the force and current distribution during DC current transmission, further improving the stability of DC power supply, avoiding local current overload problems caused by single-sided connection, and enhancing the adaptability flexibility of connectors in different DC power distribution scenarios. Attached Figure Description

[0024] Figure 1 A schematic diagram of an AC / DC switching connector for AC power supply.

[0025] Figure 2 A schematic diagram of an AC / DC switching connector for DC power supply.

[0026] The markings in the diagram are as follows: 1. Upper cover plate; 2. Lower cover plate; 3. Spacing structure; 31. Spacing member; 32. Insulation structure; 321. Insulation plate; 322. Conductive plate; 33. Conductor; 34. Upper insulation plate; 35. Upper conductive plate; 36. Lower insulation plate; 37. Lower conductive plate; 4. Connector; 5. Busbar trunking; 51. Busbar conductor. Detailed Implementation

[0027] To enhance understanding of this utility model, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. These embodiments are only used to explain the present utility model and do not constitute a limitation on the scope of protection of the present utility model.

[0028] Implementation example:

[0029] like Figure 1-2The AC / DC switching connector shown connects two four-phase busbars in a busbar trunking system. It includes an upper cover plate 1, a lower cover plate 2, a spacer structure 3, and a connector 4. The components work together to stably clamp and fix the busbar conductors 51 in the busbar trunking system, and to flexibly switch between AC and DC power supply modes through the alternating use of the spacer 31. The overall structure is compact, and installation and subsequent maintenance are relatively convenient.

[0030] The upper cover plate 1 and lower cover plate 2 adopt a symmetrical design, both integrally formed from metal plates with good thermal conductivity. The thickness and width of the plates are determined according to the specifications of the busbar conductor 51 of the busbar trunking, leaving sufficient space for installation and protection. The upper surface of the upper cover plate 1 and the lower surface of the lower cover plate 2 are integrally formed with heat dissipation teeth, which are evenly distributed along the length of the cover plate, with an isosceles trapezoidal cross-section. The tooth tips are rounded to reduce stress concentration. Mounting holes adapted to the connectors are opened at both ends of the cover plates to avoid scratching the connectors during assembly. The upper cover plate 1 and lower cover plate 2 serve as supporting components for the connector, and together with the connector 4, they form a clamping force to stably fix the busbar conductor 51 of the busbar trunking. Relying on the thermal conductivity of the metal material and the surface heat dissipation tooth structure, the heat generated by the busbar conductor 51 during current transmission is quickly conducted and dissipated, avoiding excessive local temperature that affects performance. The design of a width greater than that of the busbar conductor 51 provides physical protection for the edges of the busbar conductor 51, reducing damage caused by external collisions.

[0031] In this embodiment, the connector 4 uses a combination of high-strength bolts and anti-loosening nuts. The bolt specifications and length are determined based on the total thickness of the upper cover plate 1, the spacer structure 3, and the lower cover plate 2, ensuring sufficient thread engagement length after the nut is tightened to guarantee connection stability. The bolt shank is treated with rust prevention, and an anti-loosening washer is provided on the inner side of the nut to prevent loosening due to vibration during long-term use. As a through-type fixing component, the bolt passes through the mounting hole of the upper cover plate 1, the through hole of the spacer structure 3, and the mounting hole of the lower cover plate 2 in sequence, forming a threaded connection with the nut. The axial force generated by tightening the nut causes the upper cover plate 1 and the lower cover plate 2 to move closer to each other, thereby clamping and fixing the busbar conductors 51 of the two busbar trunkings, ensuring that the busbar conductors 51 are in close contact with the spacer structure 3, preventing loosening due to vibration, external forces, or other factors, and ensuring the continuity and stability of current transmission.

[0032] The spacer structure 3 is the core component for switching between AC and DC power supply modes. It consists of multiple detachable spacers 31 sequentially sleeved along the axial direction of the connector 4. The number of spacers 31 is adapted to the number of phases of the busbar trunking. In this implementation, a structure of 3 layers of spacers 31 is adopted for the four-phase busbar. The spacers 31 are selected according to the power supply mode requirements, with insulation structure 32 or conductor 33.

[0033] The insulating structure 32 consists of an insulating plate 321 and a conductive plate 322. The insulating plate 321 is made of a material with excellent temperature resistance and insulation properties. Rectangular insulating grooves are formed on both sides of the insulating plate 321 for embedding the conductive plate 322. The groove size is adapted to the conductive plate 322 to ensure stable installation. The conductive plate 322 is made of a metal plate with high conductivity. Its thickness is precisely matched with the depth of the insulating groove to ensure that the surface of the conductive plate 322 remains flush with the surface of the insulating plate 321 after being embedded in the insulating groove. The edge of the conductive plate 322 fits tightly against the inner wall of the insulating groove to prevent displacement during use. The surface of the conductive plate 322 is treated with anti-oxidation and resistance reduction to reduce contact resistance, improve current transmission efficiency, and extend service life. In AC power supply mode, the insulating plate 321 can effectively block the conduction between adjacent busbar conductors and avoid phase-to-phase short circuits; the conductive plate 322 realizes the electrical connection of the same phase busbar conductors and ensures the independent transmission of each phase of AC; in DC power supply mode, the insulating structure 32 can be used in areas that require insulation isolation, and together with the conductor 33, it can meet the requirements of multi-phase conduction.

[0034] Conductor 33 is made of highly conductive copper, with its surface treated for oxidation prevention and resistance reduction. A through-hole adapted to connector 4 is provided in the center of conductor 33 to ensure smooth mounting on the bolt. The corners of conductor 33 are rounded to prevent electric field concentration. In DC power supply mode, by replacing the insulation structure 32 at the corresponding position, conductor 33 can achieve electrical connection between adjacent busbar conductors 51, thus completing the conversion from multi-phase to single-phase conduction and meeting the unipolar current transmission requirements of DC power supply.

[0035] The upper insulating plate 34 and the lower insulating plate 36 are respectively disposed between the upper cover plate 1 and the spacer structure 3, and between the lower cover plate 2 and the spacer structure 3. The upper insulating plate 34 and the lower insulating plate 36 are made of high-performance insulating material, and have an insulating groove on the side facing the spacer structure 3. The upper conductive plate 35 and the lower conductive plate 37 are respectively disposed inside the groove, and are consistent with the specifications of the conductive plate 322 of the insulating structure 32. On the one hand, this further optimizes the contact stability between the busbar conductor 51 and the spacer structure 3, ensuring smooth current transmission; on the other hand, it avoids direct conduction between the upper cover plate 1 and the lower cover plate 2 and the spacer structure 3, improving the overall insulation protection level and reducing the risk of leakage.

[0036] Simultaneously, a housing is assembled on the outside of the connector. The housing is made of bent metal sheet with a rust-proof and aesthetically pleasing surface treatment. The inner contour of the housing perfectly matches the outer contour of the busbar trunking, with a reasonable assembly gap for easy installation. Slots are provided on the inner sides of both ends of the housing for engaging and positioning with the protruding structures on the outer wall of the busbar trunking. Fastening bolt holes are provided on the side walls of both ends of the housing, aligning with the threaded holes on the side walls of the busbar trunking to ensure secure fixing with bolts. The housing achieves a sealed connection between the connector and the busbar trunking, effectively preventing external dust, moisture, and other impurities from entering the connector and avoiding their impact on the performance of core components such as the busbar conductors and spacer structures. At the same time, the fastening bolts enhance the overall connection strength between the connector and the busbar trunking, enabling the connector to adapt to complex industrial environments such as humid and dusty conditions.

[0037] During assembly, insert the four-phase busbar conductors of the two busbar trunking 5 into the space between the upper cover plate 1 and the lower cover plate 2 from both sides of the connector, ensuring that each phase busbar conductor is precisely aligned with the corresponding insulation structure 32. Pass the connector bolts sequentially through the mounting holes of the upper cover plate 1, the through holes of the upper insulation plate 34, the through holes of each phase insulation structure 32, the through holes of the lower insulation plate 36, and the mounting holes of the lower cover plate 2. After installing the anti-loosening washers, tighten the nuts. Clamping the upper and lower cover plates ensures tight contact between the busbar conductors and the conductive plates 322 of the insulation structure 32. Install the outer casing, engaging the slots at both ends of the casing with the protrusions of the busbar trunking. Align the bolt holes and tighten the bolts to complete the sealed assembly. When switching between AC and DC modes, first loosen the connector nuts and remove the lower cover plate 2. Disassemble the spacer to be replaced and replace it with the required insulation structure 32 or conductor 33. Reinstall the lower cover plate 2, insert the connector bolts back in, and tighten the nuts to ensure tight contact between the busbar conductor 51, conductor 33, and the retained conductive plate 322 of the insulation structure.

[0038] The connector of this utility model relies on a detachable spacer design. Only the combination of insulation structure and conductor needs to be adjusted to achieve AC / DC power supply mode switching. There is no need to disassemble the entire connector, which greatly simplifies the switching operation and shortens the switching time. By replacing some of the insulating spacers in the spacer structure with conductor spacers, the multi-phase busbar conductors that were originally independent in AC power supply are electrically connected through the conductor spacers and merged into one phase to adapt to the unipolar current transmission characteristics of DC power supply.

[0039] It is understood that this utility model has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this utility model. Furthermore, under the teachings of this utility model, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of this utility model.

Claims

1. An AC / DC switching connector, characterized in that, It includes an upper cover plate and a lower cover plate, a spacer structure disposed between the upper cover plate and the lower cover plate, and a connector connecting the upper cover plate, the spacer structure and the lower cover plate; The spacer structure includes spacers that are detachably sleeved on the connector in sequence. The spacers are either insulating structures or conductors. Switching between AC power supply and AC power supply can be achieved by replacing the insulating structure or the conductor as the spacer. The busbar conductors of the two busbar trunkings enter between the upper cover plate and the lower cover plate from both sides of the connector. The corresponding busbar conductors are respectively arranged on the upper and lower sides of the spacer. The two outermost sets of busbar conductors are respectively clamped between the upper cover plate and the spacer and between the lower cover plate and the spacer. The connector passes through the upper cover plate, the spacer structure, and the lower cover plate in sequence, clamping the upper cover plate and the lower cover plate to achieve clamping connection of the busbar conductors of the two busbar trunkings.

2. The AC / DC switching connector according to claim 1, characterized in that, The insulating structure is centrally located within the spacer structure, and the remaining spacers are conductors to accommodate DC power supply.

3. The AC / DC switching connector according to claim 1, characterized in that, The spacer is an insulated structure to accommodate AC power supply.

4. The AC / DC switching connector according to claim 1, characterized in that, The insulation structure includes an insulating plate and conductive plates disposed on both sides of the insulating plate; insulating grooves for placing the conductive plates are provided on both sides of the insulating plate, and the conductive plates realize electrical connection between the two sides corresponding to the busbar conductors.

5. The AC / DC switching connector according to claim 4, characterized in that, The thickness of the conductive plate is adapted to the depth of the insulating groove, and the edge of the conductive plate is in contact with the inner wall of the insulating groove. The surface of the conductive plate away from the insulating plate is flush with the surface of the insulating plate to ensure the flatness of the busbar conductor when it contacts the conductive plate.

6. The AC / DC switching connector according to claim 1, characterized in that, The connector includes a bolt and a nut. The bolt passes through the upper cover plate, the spacer structure, and the lower cover plate in sequence before being threadedly connected to the nut.

7. The AC / DC switching connector according to claim 1, characterized in that, An upper insulating plate is provided between the upper cover plate and the spacer. An upper insulating groove is provided on the side of the upper insulating plate facing the spacer, and an upper conductive plate is provided in the upper insulating groove. A lower insulating plate is provided between the lower cover plate and the spacer. A lower insulating groove is provided on the side of the lower insulating plate facing the spacer, and a lower conductive plate is provided in the lower insulating groove.

8. The AC / DC switching connector according to claim 1, characterized in that, The outer surfaces of both the upper and lower cover plates are integrally formed with heat dissipation ridges.

9. The AC / DC switching connector according to claim 1, characterized in that, It also includes a housing covering the upper cover plate and the lower cover plate, the two ends of the housing forming a sealed connection with the ends of the busbar grooves on both sides, and the two ends of the housing being connected to the threaded holes of the busbar grooves by fastening bolts.

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