Bus Bar Splice Design for Compact Power Distribution
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Solution Overview
Problem
Splice joints in power distribution systems are difficult to access and assemble due to their compact nature, leading to reduced current carrying capacity and challenges in maintaining a constant cross-sectional area, which affects the efficiency and reliability of the systems.
Innovation Solution
A bus bar assembly with a splice design that includes an outer plate matching the shape of adjacent rail assemblies and inner plates with extension tabs, allowing for secure and efficient splicing of bus bars within tight confines, maintaining a constant cross-sectional area and enhancing accessibility during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional splice joints are used in compact power distribution systems, then the system structure is simple, but the splice joints are difficult to access and assemble
Solution Approach 1:
The splice joint is divided into multiple components: outer plates, inner plates, extension tabs, and bus bar segments. This segmentation allows each component to be independently manufactured and positioned, enabling assembly in compact spaces while maintaining structural integrity and electrical connectivity.
2Volume of stationary object
If splice joints are made compact to fit power distribution systems, then space is saved, but the current carrying capacity is reduced
Solution Approach 1:
The splice joint employs a nested structure where inner plates with extension tabs are positioned within outer plates, which in turn are positioned within the bus bar assembly. This nesting allows multiple functional layers to occupy the same spatial envelope, maintaining compact volume while preserving full current carrying capacity through parallel conductive paths.
3Volume of stationary object
If splice joints are made compact, then space is saved, but assembly becomes more difficult
Solution Approach 1:
The extension tabs are pre-formed on the inner plates during manufacturing, and the outer plates are pre-shaped to match the bus bar geometry. These preliminary actions enable the components to self-align and interlock during assembly, reducing the skill level and time required for installation in compact spaces.
4Ease of manufacture
If traditional splices are used, then manufacturing is simple, but the cross-sectional area is reduced at splice points
Solution Approach 1:
The splice joint employs different plate configurations at different locations: outer plates at the ends providing structural support and electrical connection, and inner plates with extension tabs in the middle section maintaining full cross-sectional area. This local differentiation ensures the cross-sectional area is maintained at critical locations while keeping manufacturing processes standard.
Data Source
AI summary
A bus bar assembly includes a first rail assembly including a first end and an adjacent first main body and a second rail assembly including a second end and an adjacent second main body. A splice splices the first end to the second end. The splice includes an outer plate wherein a portion of the outer plate is adjacent the first main body and a portion of the outer plate adjacent the second main body. The splice includes one or more inner plates, each having two or more extension tabs, wherein a first extension tab is adjacent the first rail assembly and a second extension tab is adjacent the second rail assembly. Power distribution system and methods of splicing are also disclosed.