Busbar Connector Shaft Geometry for Multi-Current Busbar Joints
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Solution Overview
Problem
Existing busbar connectors are limited to specific rated currents and require different types for varying current requirements, leading to increased costs and complexity due to the need for multiple designs.
Innovation Solution
A busbar connector with a housing and connection arrangement featuring a fastener element and counter element, designed to accommodate different rated currents by optimizing the shaft section dimensions and mass distribution, allowing for a single connector to handle currents ranging from 250A to 355A.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a busbar connector is designed for a specific rated current, then it can reliably conduct that current, but it cannot be used for different rated currents requiring multiple connector types
Solution Approach 1:
The busbar connector is designed with a universal shaft section that can accommodate different busbar thicknesses (12x5mm for 250A and 2x12x5mm for 355A) through a single connector type. The shaft section's dimensional tolerances and geometric features enable it to function across multiple current ratings, eliminating the need for current-specific connector variants.
Solution Approach 2:
The invention utilizes parameter ranges rather than fixed values, particularly in the shaft section dimensions. By defining dimensional tolerances that span the range of busbar thicknesses for different current ratings, the connector can adapt to various configurations without requiring design changes, thus achieving multi-current compatibility.
2Reliability
If different busbar connector types are used for different rated currents, then each connector is optimized for its specific current, but manufacturing costs and inventory complexity increase
Solution Approach 1:
By designing a single universal busbar connector that can handle multiple rated currents (250A and 355A), the manufacturer produces only one connector type instead of multiple current-specific variants. This reduces manufacturing setup changes, tooling requirements, and production complexity while maintaining reliable current conduction through the shaft section's adaptable geometry.
3Adaptability or versatility
If the shaft section thickness is reduced to fit smaller busbar spacing, then it can accommodate different busbar configurations, but the structural strength and current carrying capacity may be compromised
Solution Approach 1:
The shaft section is designed with non-uniform thickness distribution, featuring thicker regions at critical locations (such as near the busbar contact points and mounting areas) and thinner regions in non-critical areas. This local quality variation allows the shaft to maintain structural strength where needed while reducing overall thickness to accommodate different busbar spacings, thus balancing adaptability with mechanical integrity.
Data Source
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AI summary
The disclosure relates to a busbar connector (10) with a housing (100) and at least one connection arrangement (200), the housing (100) being configured to receive the at least one connection arrangement (200), and the at least one connection arrangement (200) comprising a fastener element (210) and a counter element (220) for electrically connecting a pair of collinearly arranged busbars (2), the fastener element (210) comprising a shaft (212) with a shaft section (213) for opposing ends (5) of the busbars (2), wherein: (a) the shaft section (213) comprises two opposing first portions (214) for facing the ends (5) of the busbars (2), and the shaft section (213) comprises two opposing second portions (215) adjacent to or in between the two opposing first portions (214), the shaft section (213) having a smaller thickness between the two opposing first portions (214) than between the two opposing second portions (215); and/or (b) the fastener element (210) comprises a further shaft section (214), the shaft section (213) comprising a cross-section that is narrower than a cross-section of the further shaft section (214) so that the pair of collinearly arranged busbars (2) can be spaced apart by a distance smaller than the cross-section of the further shaft section (214).