Bus Bar Connector Flange Structure for Vibration-Stable Insulation
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Solution Overview
Problem
Existing bus bar assemblies face issues with inadequate connections between the outer layer and the connector, leading to relative movement and potential disconnection due to vibrations, which compromises electrical insulation and moisture protection.
Innovation Solution
A bus bar assembly design featuring a conductor with a first layer fitted radially outer to a flange of a connector, secured by clamping members, and additional collar parts with flanges and sealing elements to maintain connection and protection, allowing for relative movement while ensuring electrical isolation and moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the outer layer is connected directly to the connector without a flange structure, then the assembly is simpler, but the connection stability deteriorates under vibrational conditions
Solution Approach 1:
The first layer is fitted over the first flange in a nested configuration, where the layer envelops the flange structure. This nesting arrangement allows the layer to be securely retained on the connector while maintaining relative movement capability between the conductor and layer, resolving the contradiction between simple structure and vibration resistance
Solution Approach 2:
The design permits relative movement between the conductor and the first layer while maintaining their connection. This dynamic capability allows the assembly to accommodate vibrational forces without compromising the connection between the layer and connector, thereby improving reliability under vibrational conditions
2Reliability
If clamping members are used to secure the first layer to the first flange, then connection stability improves, but device complexity increases
Solution Approach 1:
The first flange is pre-configured with features (such as circumferential grooves or engagement structures) that enable the first layer to be fitted and secured in advance. This preliminary configuration of the flange structure allows for stable connection while minimizing the need for additional complex clamping mechanisms
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
A bus bar assembly 4, comprising a bus bar 6 and a connector 8. The bus bar comprising a conductor 10, extending axially along a centerline C, a first layer 16, extending coaxially with the centerline, and radially outer to the conductor. The connector comprises a first end 12 and a second end 14, the connector extending along an axis D, between the first end and the second end. The connector further comprising a first collar part 20, extending coaxially with the axis, and radially outer to the axis, and wherein a portion of the conductor extends radially inner to the first collar part, such that the conductor extends through the first collar part via the first end of the connector. A first direction D1 acts along the axis from the second end towards the first end and the first collar part comprises a first flange 24 extending coaxially with the axis in the first direction, and radially outer to the axis, and wherein the first layer of the bus bar is fitted radially outer to the first flange.