Universal Busbar Connector Assembly for Variable Thickness
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Solution Overview
Problem
Conventional busbar connectors are limited to specific types and thicknesses, requiring different connectors for each variation, which is inefficient and costly, especially for field installations where varying busbar thicknesses may be needed.
Innovation Solution
A modular busbar connector assembly with a housing having identical sections for different thicknesses, featuring contact members with fixed and flexible ends that allow for secure and adjustable connections, enabling compatibility with any busbar type or thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors are used for specific busbar types, then connection reliability is improved, but adaptability deteriorates
Solution Approach 1:
The connector housing is designed with a universal structure that can accommodate multiple busbar types and thicknesses. The housing includes adjustable clamping mechanisms and guide sections that can adapt to different busbar dimensions, allowing a single connector design to serve multiple functions across various busbar configurations.
Solution Approach 2:
The connector employs locally adjustable features such as variable thickness clamping sections and positionable contact members. These local adjustments allow the connector to maintain reliable electrical and mechanical connections while adapting to different busbar types, resolving the contradiction between connection reliability and connector adaptability.
2Adaptability or versatility
If multiple connector types are manufactured for different busbar thicknesses, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
A single universal connector housing design replaces the need for multiple specialized connectors. The housing incorporates adjustable clamping mechanisms and guide sections that can accommodate different busbar thicknesses, thereby reducing manufacturing complexity while maintaining versatility.
Solution Approach 2:
The connector includes dynamic adjustment mechanisms such as movable clamping sections and positionable contact members that can be adjusted during installation. This dynamic capability allows one connector design to adapt to various busbar configurations without requiring multiple fixed designs, simplifying manufacturing while preserving adaptability.
3Ease of manufacture
If conventional fixed connectors are used, then manufacturing cost is reduced, but field installability deteriorates
Solution Approach 1:
The connector incorporates adjustable clamping mechanisms and positionable contact members that can be modified during field installation. These dynamic features allow the connector to adapt to different busbar types encountered in the field, improving field installability while maintaining a relatively simple manufacturing process compared to producing multiple specialized connectors.
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
Enables easy field installation and cost-effective manufacturing by allowing the same connector assembly to accommodate various busbar thicknesses, ensuring reliable electrical and mechanical connections while reducing manufacturing costs.
Implementation Method 1
The first contact member has a fixed end attached to the attachment section of the first housing portion and a flexible end that has a busbar contact surface
Data Source
AI summary
A busbar connector assembly that includes a housing having two portions facing one another that each have an attachment section and a guide section. A first receiving area of the housing receives a first busbar. A second receiving area of the housing receives a second busbar. First and second contact members are coupled to the housing portions. The first and second contact members each have a fixed end and a flexible end having a busbar contact surface. The housing has first and second open ends leading into the receiving areas. The first open end has a continuous width. The second open end includes lead-in surfaces formed in the housing guide sections. The lead-in surfaces define a largest width of the second open end converging to a smallest width thereof. The smallest width of the second open end is substantially the same as the width of the first open end.