Busbar Connector Assembly With Variable Cable Lengths
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increasing current demand in electrical systems necessitates various connectors with fixed specifications, leading to higher production and inventory costs due to the need for different current ratings, resulting in a variety of connectors.
Innovation Solution
A connector assembly comprising a busbar connector, first and second cable-end connectors, and cables of differing lengths, with specific terminal configurations and structural features to reduce resistance and enhance user convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different current ratings require different connector specifications, then current demand is met, but production and inventory costs increase
Solution Approach 1:
The busbar connector is designed with a universal structure that can accommodate multiple current ratings through interchangeable cable-end connectors. The main busbar connector body remains the same, but different cable-end connectors can be attached to meet different current requirements, allowing one connector design to serve multiple functions and current ratings.
Solution Approach 2:
The connector assembly is divided into separable components: a main busbar connector body and interchangeable cable-end connectors. This segmentation allows the system to maintain a standardized main body while swapping out the cable-end portions to match different current ratings, reducing the need for entirely different connector designs for each current level.
2Reliability
If the number of conductive terminals increases to meet current demand, then current capacity increases, but connector size increases
Solution Approach 1:
The connector design allows for dynamic configuration by enabling the attachment of different cable-end connectors to the main busbar connector body. This dynamic adaptability means the same physical connector can be configured for different current capacities without permanently increasing its size, as the appropriate cable-end connector is selected based on current requirements.
3Adaptability or versatility
If cables of different lengths are used, then system configuration flexibility increases, but interference between connectors may occur
Solution Approach 1:
The connector assembly utilizes spatial arrangement in multiple dimensions to accommodate cables of different lengths. By designing the connector layout and cable routing to operate in three-dimensional space, the system can accommodate length variations without cables interfering with each other, as longer and shorter cables can be routed through different spatial paths.
Data Source
AI summary
A connector assembly includes a busbar connector, a first cable-end connector, a second cable-end connector, a first cable, and a second cable. The first cable-end connector is electrically connected to the busbar connector. The second cable-end connector is electrically connected to the busbar connector. The first cable is connected between the busbar connector and the first cable-end connector. The second cable is connected between the busbar connector and the second cable-end connector. A length of the first cable is different from a length of the second cable.