Asymmetric Contact System for High-Current Conductor Uniformity
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Solution Overview
Problem
Existing contact systems for high-current electrical conductors experience uneven current distribution due to asymmetrical geometry, leading to overheating and inefficient design, as all contact devices are designed based on the most heavily loaded one, resulting in unnecessary production effort and potential overheating.
Innovation Solution
A contact system with interlocking tooth-like contact elements, comprising two ring elements with inner and outer recesses, ensures even current distribution by engaging contact elements around the peripheral area of the conductors, allowing for uniform current transmission with minimal ohmic losses, and includes spring elements for misalignment compensation and secure radial fixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple contact devices are connected in series to handle high currents, then the current carrying capacity is improved, but the current distribution becomes uneven due to asymmetrical geometry, leading to overheating of individual contact devices
Solution Approach 1:
The patent applies asymmetry by designing contact elements with different widths - specifically, alternating between wider and narrower contact elements in a systematic pattern. This asymmetrical arrangement compensates for the natural current concentration at the edges of conductors, achieving more uniform current distribution across all parallel contact paths and preventing overheating of individual contact devices.
Solution Approach 2:
The patent implements local quality by varying the dimensions of contact elements at different positions around the conductor. Instead of using uniform contact elements throughout, the design adjusts the width and spacing of individual contact elements based on their specific location, optimizing current distribution locally at each contact point while maintaining overall system performance.
2Reliability
If contact devices are designed based on the most heavily loaded device, then overheating is prevented, but the manufacturing effort increases due to producing all contact devices to the highest specification
Solution Approach 1:
The patent reduces manufacturing effort by applying local quality - different contact elements are designed with different specifications based on their actual load requirements. Contact elements that naturally carry less current are made narrower, while those carrying more current are made wider. This allows each contact device to be optimized for its specific function rather than all being over-engineered to the highest specification.
Solution Approach 2:
The patent utilizes parameter changes by systematically varying the width parameter of contact elements based on their position in the current distribution pattern. This controlled variation in geometry parameters allows the system to achieve uniform current distribution and appropriate load sharing without requiring all contact devices to be designed to the maximum specification, thereby reducing overall manufacturing complexity and cost.
3Ease of manufacture
If symmetrical contact devices are used for ease of manufacture, then production is simplified, but current distribution becomes uneven due to current displacement effects
Solution Approach 1:
The patent deliberately introduces asymmetry into the contact element design to counteract the symmetrical current displacement effects that occur in parallel conductor arrangements. By alternating between wider and narrower contact elements in a systematic pattern, the design creates an asymmetrical current distribution pattern that balances the overall current flow, achieving uniform current sharing despite the inherent asymmetrical geometry of the arrangement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The contact system achieves uniform current distribution and reduced ohmic losses, enabling efficient high-current transmission while maintaining existing conductor geometries, suitable for both stationary and moving conductors, and reducing the risk of overheating.
Implementation Method 1
current is distributed as evenly as possible to the contact devices of the conductors over the peripheral area of the conductors to be connected to one another and as evenly as possible to the two contact devices
Implementation Method 2
current transmission through the contact system can thus be achieved as uniformly as possible and with the lowest possible ohmic losses
Implementation Method 3
A spring element or a component which has spring properties is preferably provided on the surfaces on which the respective contact elements of the conductors touch between the conductors, in order to compensate for misalignment tolerances between the conductors and to enable relative movement
Data Source
AI summary
The invention relates to a contact device for connecting conductors (21, 22), in particular current conductors for carrying high currents, wherein the contact device has a first and a second element (31, 32), in particular a first and a second ring, which have an inner recess for receiving a first conductor (21) and an outer contour for receiving in a hollow cylindrical second conductor (22), wherein the elements each have contact elements (4) surrounding the inner recess, which project from the respective element (31, 32) in a direction perpendicular to the inner recess enclosed by the elements (31, 32) and between which a recess is provided to receive the contact elements (4) of the respective other element.