Bus Connector with Segmented Contact Fingers for Reduced Insertion Force
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Solution Overview
Problem
Existing bus connector designs for automatic transfer switches face challenges in withstanding high short circuit forces, requiring high insertion forces, and are not easily scalable or configurable for different current levels, leading to increased stress and complexity in assembly and installation.
Innovation Solution
A bus connector design featuring a plurality of contact fingers of different lengths arranged in parallel, which distribute the frictional force across multiple contact points, reducing the initial insertion force required and allowing for easy assembly and scalability to various bus sizes and current levels, while using a connector frame to hold these contact fingers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing bus connector designs are used to withstand high short circuit forces, then the connector can handle high current ratings, but the insertion force required becomes excessively high
Solution Approach 1:
The bus connector is segmented into multiple contact fingers (at least three) of different lengths, where each contact finger engages with the bus at a different location. This segmentation distributes the mechanical stress and insertion force across multiple points rather than concentrating it at a single interface, thereby reducing the peak insertion force while maintaining the ability to withstand high short circuit forces through the collective strength of all contact fingers
Solution Approach 2:
Different contact fingers have different lengths, creating local variations in the connector structure. The longer contact fingers engage with the bus at different positions compared to shorter fingers, allowing each contact point to contribute differently to the overall force distribution. This local quality differentiation enables optimized force distribution while maintaining high current carrying capacity
2Device complexity
If a single set of contact fingers is used, then the connector structure is simple, but the frictional force during insertion is concentrated and requires high insertion force
Solution Approach 1:
The single set of contact fingers is divided into multiple sets (first set and second set), with each set containing multiple contact fingers of different lengths. This segmentation creates multiple engagement points along the bus, distributing the frictional force that occurs during insertion. The cumulative effect of multiple contact fingers engaging at different locations reduces the peak insertion force required compared to a single concentrated contact point
Solution Approach 2:
The contact fingers are arranged in multiple sets that extend in different directions or planes relative to the bus. This multi-dimensional arrangement allows the connector to engage the bus along its length rather than at a single point, effectively distributing the insertion force across multiple spatial dimensions and reducing the force concentration at any single location
3Ease of manufacture
If contact fingers of uniform length are used, then the manufacturing process is simpler, but the frictional force is not distributed and insertion force remains high
Solution Approach 1:
Contact fingers are manufactured with different lengths, creating local variations in the connector structure. This local quality differentiation allows each contact finger to engage with the bus at a different position, distributing the frictional force that occurs during insertion. While this requires slightly more complex manufacturing compared to uniform fingers, the process remains practical through standard fabrication techniques
4Strength
If the connector is designed for high current ratings, then it can handle extreme electrical loads, but the assembly and installation become more complex
Solution Approach 1:
The high current rating capability is achieved through segmentation into multiple contact fingers rather than requiring a single massive contact structure. This segmentation allows the connector to handle high currents through the collective cross-sectional area of multiple fingers while maintaining a modular, manageable structure that is easier to assemble and install compared to a monolithic high-current connector design
Data Source
AI summary
A bus connector configured for receiving a bus is provided. An example bus connector includes a plurality of contact fingers configured to engage with the bus. The plurality of contact fingers include a first set of contact fingers and a second set of contact fingers arranged substantially parallel to one another, and the first set and second set clamp the bus when the bus is inserted between the first set and the second set. The bus connector further includes a connector frame, wherein the connector frame is configured to hold the plurality of contact fingers. The plurality of contact fingers includes contact fingers of a first length and contact fingers of a second length, wherein the second length is different than the first length.