Busbar Coupling Alignment for Tolerance and Vibration Compensation
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Solution Overview
Problem
Existing busbar units and connecting arrangements struggle with 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 for 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 vibration damping through a screw connection, and a robust mechanical and electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid connecting device is used to connect the busbar body to the module connecting element, then the mechanical strength of the connection is improved, but the connection becomes sensitive to installation and manufacturing tolerances, leading to unstable electrical connections
Solution Approach 1:
The connecting device incorporates a flexibility portion that enables elastic bending, allowing the rigid connecting ends to accommodate tolerance variations while maintaining stable electrical connections. This flexibility portion acts as a compliant element that absorbs dimensional deviations without compromising connection integrity.
Solution Approach 2:
The connecting device changes its geometric parameters through elastic deformation of the flexibility portion, allowing the coupling position to be variably aligned relative to the busbar body. This enables the connection to adapt to different tolerance conditions while maintaining mechanical strength and electrical contact stability.
2Manufacturing precision
If a fixed coupling position is used in the connecting device, then the manufacturing precision is improved, but the device cannot compensate for installation tolerances or vibrations, reducing reliability
Solution Approach 1:
The coupling position is made dynamically adjustable through the flexibility portion, which allows the connecting device to adapt its configuration after manufacturing. The flexibility portion enables the coupling position to move within a certain range, compensating for installation tolerances and vibrations while maintaining precise electrical connections.
3Reliability
If the connecting device is made rigid to maintain stable electrical contact, then the electrical conductivity is improved, but the device cannot damp vibrations, leading to loose connections over time
Solution Approach 1:
The flexibility portion serves as a vibration damping element that absorbs vibrational energy through elastic deformation. This protects the rigid connecting ends and electrical contacts from vibration-induced loosening, maintaining stable electrical contact while reducing the harmful effects of vibrations.
Solution Approach 2:
The flexibility portion is designed beforehand to provide cushioning against vibrations and shocks. This pre-engineered compliance element protects the connection from vibration damage before it can cause loosening, ensuring long-term reliability of the electrical contact.
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 stable connection that compensates for installation and manufacturing tolerances, maintains electrical contact, and absorbs vibrations, ensuring reliable and efficient electrical transmission.
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
Implementation Method 2
movements of the busbar body, possibly due to vibrations, relative to the module connecting element and/or to the further busbar unit, which are connected to the busbar body via the connecting device, can be compensated for by corresponding movement of the coupling position relative to the busbar body. This allows the vibrations of the busbar body to be damped by the connecting device
Data Source
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AI summary
The invention relates to a busbar unit (100) comprising a busbar body (101) and a connecting device (103) for connecting the busbar body (101) to a module connecting element and/or to a further busbar unit (303), wherein the connecting device (103) has a connecting body (107) which projects from a connecting end (105) of the busbar body (101) and has a first coupling end (109) and a second coupling end (111) opposite the first coupling end (109), wherein the connecting device (103) is formed on the connecting end (105) of the busbar body (101) via the first coupling end (109), wherein the connecting body (107) comprises a coupling unit (113) at the second coupling end (111) for coupling the connecting device (103) to the module connecting element and/or the further busbar unit (303), wherein a coupling position (P) of the connecting device (103) is defined via the coupling unit (113), and wherein the coupling position (P) of the connecting device (103) can be variably aligned relative to the busbar body (101) of the busbar unit (100) with respect to a direction of translation (T) and/or an axis of rotation (R). The invention also relates to a module connecting arrangement (200) with a busbar unit (100) and a coupling arrangement (300) for connecting busbar units (100).