Busbar Connection Device with Segmented Insulating Housing
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Solution Overview
Problem
Existing connection devices for conductors and busbars are limited in their ability to securely and efficiently connect multiple conductors to busbars, often requiring complex mechanisms and lacking in space-saving designs while providing adequate electrical insulation and safety.
Innovation Solution
A connection device with multiple connection elements and a first insulating material housing that allows for easy and secure plugging onto parallel busbars, featuring a pivot mechanism and reinforcement elements for secure mechanical and electrical connections, along with a closure system for secure busbar engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple connection elements are accommodated in the same insulating housing, then space efficiency is improved, but device complexity increases
Solution Approach 1:
The connection device is divided into multiple independent connection elements (first connection element, second connection element, etc.), each capable of connecting a conductor to a busbar. These segmented elements are accommodated within a single insulating housing, allowing space-efficient installation while maintaining functional independence of each connection point.
Solution Approach 2:
Multiple connection elements are merged into a single insulating housing structure, creating a unified device that occupies less space when installing multiple conductor-to-busbar connections. The housing integrates support sections, connection terminals, and insulation functions into one consolidated unit.
2Reliability
If the connection device is designed for secure mechanical and electrical connection, then connection reliability is improved, but ease of installation deteriorates
Solution Approach 1:
The connection elements are pre-configured within the insulating housing with conductor terminals and busbar terminals in predetermined positions. The support sections are pre-formed to provide lever support, and the insulating housing is pre-assembled to protect all components. This preliminary arrangement ensures reliable connections while simplifying installation, as the device requires minimal on-site assembly.
3Reliability
If the busbar terminal has legs projecting into the insertion groove, then electrical contact reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The busbar terminal is designed with legs that can change their spatial configuration - projecting into the insertion groove for reliable electrical contact, or being positioned otherwise during manufacturing. This parameter change in leg position allows the same structure to serve both manufacturing and operational requirements.
Data Source
Figure 1
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AI summary
The invention relates to a connection device (10) comprising at least two connection elements (20) for connecting a conductor (100) to a busbar (200) and a first insulating housing (40) surrounding the connection elements (20). The connection elements (20) have a conductor terminal (22) and a busbar terminal (24) electrically connected to the conductor terminal (22). The connection device (10) can be attached to at least two busbars (200) that run approximately parallel to a direction of extension (E) by a movement in an insertion direction (A). The first insulating housing (40) comprises a first housing section (45) which has a insertion groove (42) for each connection element (20) suitable for receiving a section (202) of one of the busbars (200).The busbar terminal (24) of each connection element (20) has at least one leg (26) which projects into the mounting groove (42) and is suitable to be brought into contact with the section (202).