Bus Bar Connector Layout for Grounding and Short-Circuit Isolation
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Solution Overview
Problem
Existing connectors for high current density applications risk short-circuiting and inadequate grounding due to manufacturing tolerances and assembly errors, leading to potential electrical failures and hazards.
Innovation Solution
A connector design featuring power terminals within a connecting channel and grounding terminals with elastic fingers and an auxiliary support member, which ensures reliable contact with the bus bar and reduces the risk of short-circuiting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If power terminals and grounding terminals are arranged in a row, then the connector structure is simple, but the risk of short-circuiting increases and grounding reliability decreases
Solution Approach 1:
The connector is divided into distinct functional zones: power terminals are housed within the connecting channel while grounding terminals are positioned outside on the side walls. This spatial segmentation isolates high-voltage power contacts from grounding contacts, eliminating the short-circuit risk present in linear arrangements while maintaining structural simplicity.
Solution Approach 2:
The grounding terminals are relocated from a linear one-dimensional arrangement to a three-dimensional configuration where they protrude from the side walls perpendicular to the connecting channel. This dimensional change creates physical separation between power and grounding terminals, ensuring grounding reliability without increasing overall device complexity.
2Ease of operation
If grounding terminals are positioned to accommodate manufacturing tolerances and assembly errors, then the connector is easier to assemble, but the contact force may be insufficient for reliable grounding
Solution Approach 1:
The grounding terminals incorporate elastic fingers that can dynamically adjust their position and exert continuous contact force. This elasticity compensates for manufacturing tolerances and assembly variations, maintaining sufficient contact force for reliable grounding while accommodating a range of alignment conditions during assembly.
Solution Approach 2:
The elastic fingers change their physical state from rigid to flexible, allowing them to deform and adapt to positional variations caused by manufacturing tolerances. This parameter change enables the grounding terminals to maintain optimal contact force across a range of assembly conditions without requiring precise alignment.
3Object-affected harmful factors
If grounding terminals are placed outside the connecting channel on side walls, then the risk of short-circuiting is reduced, but the device complexity increases
Solution Approach 1:
The side walls of the connector housing serve multiple functions: they provide structural support, define the connector boundaries, and serve as mounting surfaces for the grounding terminals. This multi-functionality allows grounding terminals to be positioned outside the connecting channel for safety without adding separate structural elements, thus avoiding increased device complexity.
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 connector design effectively reduces the risk of short-circuiting and ensures reliable grounding, enhancing safety and performance in high current density applications.
Implementation Method 1
Each of the grounding terminals have an elastic first finger
Data Source
AI summary
A connector for plugging into a bus bar comprises a housing with a first side wall, a second side wall, and a connecting channel between the first side wall and the second side wall. A plurality of power terminals each having an electrical connection part are provided inside the connecting channel and are adapted to electrically connect with the bus bar. A plurality of grounding terminals are each disposed on the first side wall and the second side wall outside the connecting channel respectively. Each of the grounding terminals have an elastic first finger. An auxiliary support member is provided and supports the first finger.