Busbar Coupling Alignment for Tolerance and Vibration Stability
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Solution Overview
Problem
Existing busbar units and connecting arrangements face challenges in accommodating installation and manufacturing tolerances, leading to unstable electrical connections and vibrations, which affect the reliability and efficiency of electrical transmission.
Innovation Solution
A busbar unit with a connecting device that allows variable alignment along a direction of translation and/or rotation, featuring a coupling unit with a through-hole or flexibility portion, enabling tolerance compensation and damping of vibrations through a screw connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid connecting device is used to ensure stable electrical connection, then electrical contact reliability is improved, but installation and manufacturing tolerances cannot be accommodated, leading to connection instability
Solution Approach 1:
The connecting device is designed with a flexible connecting body that can dynamically adjust its position and orientation. The flexibility portion allows the connecting device to adapt to tolerance variations while maintaining stable electrical connection, resolving the contradiction between rigidity for stability and flexibility for tolerance accommodation.
Solution Approach 2:
The connecting device incorporates a flexibility portion that changes its physical state between rigid and flexible based on operational needs. This parameter change allows the device to accommodate tolerance variations during installation while maintaining reliable electrical contact during operation.
2Device complexity
If a fixed coupling position is used to simplify the connecting device structure, then device complexity is reduced, but vibrations and movements cause connection instability
Solution Approach 1:
The connecting device uses a flexible connecting body that can dynamically absorb vibrations and movements. This dynamic flexibility compensates for the simplified fixed coupling position, maintaining connection stability without requiring complex adjustment mechanisms.
3Manufacturing precision
If the coupling position is fixed relative to the busbar body, then manufacturing precision is improved, but installation tolerances cannot be compensated
Solution Approach 1:
The flexible connecting body allows the coupling position to be precisely manufactured while still accommodating installation tolerances through its flexibility. The dynamic adaptation capability compensates for the fixed manufacturing position, enabling both precision and tolerance accommodation.
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
The solution provides a robust and stable electrical connection that compensates for installation and manufacturing tolerances, ensuring reliable electrical contact and efficient transmission by allowing movements to accommodate variations and vibrations.
Implementation Method 1
the connecting body comprises a flexibility portion formed between the first coupling end and the second coupling end, wherein the flexibility portion enables elastic bending of the connecting device along a bending direction
Data Source
AI summary
A busbar unit includes a busbar body and a connecting device for connecting the busbar body to a module connecting element and/or to a further busbar unit. The connecting device has a connecting body which projects from a connecting end of the busbar body and a first coupling end and a second coupling end opposite the first coupling end. The connecting device is formed on the connecting end of the busbar body via the first coupling end. The connecting body includes a coupling unit at the second coupling end for coupling the connecting device to the module connecting element and/or the further busbar unit. A coupling position of the connecting device is defined via the coupling unit. The coupling position of the connecting device can be variably aligned relative to the busbar body of the busbar unit with respect to a direction of translation and/or an axis of rotation.