Bus Bar Clamp with Movable Plate and Lever
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Solution Overview
Problem
Conventional bus bar connections in electrical power distribution systems are permanent, making it difficult to rearrange server trays within a rack without replacing the entire bus bar assembly, and they often result in high contact resistance and heat generation.
Innovation Solution
A bus bar clamp system with a movable plate and lever that allows for secure, removable connections between main and branch bus bars, reducing contact resistance and enabling tray repositioning without damaging the main bus bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent connections are used to affix branch bar to main bus bar, then electrical connection reliability is improved, but adaptability deteriorates
Solution Approach 1:
The connection system is divided into two independent parts: a permanent main bus bar and a removable branch bar with clamp assembly. This segmentation allows the main bus bar to remain fixed while the branch bar can be independently installed or removed, resolving the contradiction between connection reliability and tray repositioning capability.
Solution Approach 2:
The connection system transitions from a static permanent connection to a dynamic removable connection. The clamp assembly with movable plate and lever enables the branch bar to be securely connected when needed and easily removed when tray repositioning is required, providing adaptability while maintaining reliability during operation.
2Stability of the object's composition
If permanent connections are used to affix branch bar to main bus bar, then connection stability is improved, but device complexity deteriorates
Solution Approach 1:
The connection function is segmented into the clamp assembly (fixed to branch bar) and the main bus bar (fixed to rack). This allows the complex clamping mechanism to be localized to the branch bar end, keeping the main bus bar simple and reducing overall assembly complexity while maintaining connection stability.
Solution Approach 2:
The clamp assembly acts as an intermediary between the branch bar and main bus bar. It provides the complex connection functionality (movable plate, lever, engagement features) without requiring the main bus bar to have corresponding complex features, thus maintaining connection stability while minimizing added complexity.
3Adaptability or versatility
If removable connections are used to allow tray repositioning, then adaptability is improved, but connection reliability deteriorates
Solution Approach 1:
The connection system uses a dynamic clamp assembly that can transition between locked and unlocked states. When locked, it provides reliable electrical connection comparable to permanent connections. When unlocked, it enables tray repositioning. This dynamic capability resolves the contradiction between adaptability and reliability.
Solution Approach 2:
The clamp assembly is designed as a consumable component that can be easily installed and removed multiple times without damaging the main bus bar. While the clamp itself may eventually wear or need replacement, the main bus bar and electrical connection infrastructure remain intact and reusable, providing cost-effective adaptability.
4Reliability
If high mating forces are applied to reduce contact resistance, then electrical conductivity is improved, but damage to main bus bar increases
Solution Approach 1:
The high mating forces are extracted from the main bus bar and applied instead to the branch bar through the clamp assembly. The movable plate and lever mechanism generate substantial clamping force that is transmitted to the branch bar, ensuring low contact resistance at the mating interface without subjecting the main bus bar to damaging forces.
Solution Approach 2:
The clamp assembly serves as an intermediary that isolates the main bus bar from high mating forces. It provides the necessary clamping force to reduce contact resistance at the electrical interface while protecting the main bus bar from mechanical damage through its structural design and force distribution mechanisms.
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 bus bar clamp system provides efficient, reliable, and non-damaging connections, allowing for tray repositioning without increasing contact resistance, which reduces heat generation and energy consumption in server racks.
Implementation Method 1
Pivoting movement of the lever in a locking direction forces linear movement of the movable plate relative to the first bus bar towards the fixed base such that the inner sides of the movable plate and the fixed base sandwich the second bus bar therebetween to secure the second bus bar in engagement with the first bus bar
Data Source
AI summary
An electrical power distribution system includes a first bus bar and a clamp mounted to the first bus bar. The clamp includes a fixed base and a movable plate that define a track therebetween along a broad face of the first bus bar. The track receives a second bus bar therein such that the broad face of the first bus bar engages a corresponding broad face of the second bus bar. The clamp includes a lever connected to both the movable plate and the first bus bar. Pivoting movement of the lever in a locking direction forces linear movement of the movable plate relative to the first bus bar towards the fixed base such that respective inner sides of the movable plate and the fixed base sandwich the second bus bar therebetween to secure the second bus bar in engagement with the first bus bar.