Non-conductive Busbar Fastening System Design
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Solution Overview
Problem
Existing busbar systems face challenges such as increased manufacturing and logistics costs due to multiple materials, promotion of leakage currents, and complex installation processes, while also being limited in adaptability and electrical reliability.
Innovation Solution
A busbar system featuring fastening devices made of non-electrically conductive materials with specific geometric designs that ensure secure fixation, accommodate different busbar dimensions, and meet electrical requirements by providing adequate creepage distances, along with a compact and cost-effective production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple materials (metals and fiberglass-reinforced plastic) are used in the busbar system, then mechanical strength and electrical insulation are improved, but manufacturing and logistics costs increase
Solution Approach 1:
The patent combines the mechanical support function and electrical insulation function into a single support device made of non-conductive material. The support device includes a support body with a support surface for holding the busbar and fastening means integrated into the support body, eliminating the need for separate metal fasteners and reducing material complexity.
Solution Approach 2:
The support device serves multiple functions: it provides mechanical support for the busbar, provides electrical insulation, and includes integrated fastening means for secure attachment. This multi-functional design reduces the number of separate components needed and simplifies the overall system.
2Strength
If metal fastening components are used, then mechanical fixation strength is improved, but stray current formation is promoted
Solution Approach 1:
The patent extracts the fastening function from metal components and integrates it into the non-conductive support device. The fastening means includes a fastening element that can be inserted through the support device and busbar, providing secure mechanical fixation without using metal fasteners that could conduct stray currents.
Solution Approach 2:
The non-conductive support device acts as an intermediary between the mounting structure and the busbar, providing both mechanical support and electrical insulation. This intermediary prevents direct electrical contact between metal components while maintaining secure mechanical fixation.
3Reliability
If various sections from different materials are used, then electrical requirements are met, but assembly effort and complexity increase
Solution Approach 1:
The patent merges the support function and fastening function into a single integrated support device. The support device includes a support body with integrated fastening means, eliminating the need for separate fasteners and reducing the number of assembly steps.
Solution Approach 2:
The support device is designed as a modular component that can be easily assembled and disassembled. The fastening means includes a fastening element that can be inserted through the support device and busbar, allowing for simple assembly without complex procedures.
4Volume of moving object
If a compact design is implemented, then installation space is reduced, but meeting electrical clearance distances becomes difficult
Solution Approach 1:
The support device utilizes the vertical dimension by extending downward from the busbar support surface. The fastening means includes a fastening element that extends downward through the support device, allowing for compact horizontal design while maintaining adequate electrical clearance distances in the vertical dimension.
Data Source
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AI summary
The invention relates to a busbar system comprising at least one busbar (1), at least one fastening system (2) with a first fastening device (20) and a second fastening device (30), and at least one support device (4), wherein the fastening system (2) can be fixed to the support device (4) receiving at least one busbar (1), that the fastening device (20, 30) of the fastening system (2) is made of a non-electrically conductive material, that the first fastening device (20) has a base (28) with two holding elements (25, 26) arranged opposite each other on it, which fully encircle the support device (4), that the first fastening device (20) has at least one support element (28) arranged at a distance from the base (28) via a receiving groove (22), which at least partially supports the busbar (1).The support element (21) and the first fastening device (20) have a height that is approximately twice the width of the busbar (1).