Busbar Filter Cover Fastening to Reduce Stress and Abrasion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing busbar units with integrated filter devices face challenges in manufacturing complexity, size, and mechanical stability, particularly due to complex molds and processes, and conventional fastening methods cause mechanical stress and abrasion.
Innovation Solution
A positive-locking connection between a cover and busbar assembly is implemented using an elastically deformable fixing device, which engages behind the busbars, along with restoring elements to secure the filter device in place, reducing mechanical stress and allowing for automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the filter device is positively fitted into the housing to ensure mechanical stability, then the filter device is securely fixed, but the cover and busbar assembly are subjected to undesirable mechanical loads
Solution Approach 1:
A dedicated fixing device is introduced as an intermediary component between the filter device and the busbar assembly. This fixing device includes fixing elements that engage with the busbar assembly, transferring mechanical loads away from the cover and busbars to specialized fastening structures.
Solution Approach 2:
The fixing device is segmented into multiple fixing elements distributed along the filter device. This segmentation allows the mechanical loads to be distributed across multiple engagement points with the busbar assembly, reducing stress concentration on any single component.
2Stability of the object's composition
If spring elements are used to fix the common-mode filter inside the housing, then the filter is securely mounted, but abrasion occurs which can accumulate and lead to malfunctions
Solution Approach 1:
The fixing elements are designed as simple, robust structures that engage with the busbar assembly without requiring complex spring mechanisms. By using straightforward mechanical engagement features rather than reusable spring elements, the design eliminates the abrasion problem while maintaining effective mounting.
3Stability of the object's composition
If the cover is designed to bear mechanical loads to restrict movement, then the filter device is secured, but the cover structure becomes more complex and massive
Solution Approach 1:
The function of bearing mechanical loads and restricting filter device movement is extracted from the cover and transferred to a dedicated fixing device. The cover is reduced to its primary function of enclosing the filter device, while the fixing device handles the mechanical fastening and load-bearing responsibilities.
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
This solution simplifies manufacturing, reduces mechanical stress, and prevents abrasion, while ensuring stable and secure attachment of the filter device to the busbar assembly.
Implementation Method 1
The fixing device has several fixing elements which are elastically deformable when the cover is placed on top, allowing it to snap into place behind the busbar assembly
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a device (1), comprising: a bus bar assembly (2), which has two bus bars (3, 4); and a filter assembly (5), comprising a filter device (7), which surrounds the bus bars (3, 4) in a filter segment (6), and a cover (8), which covers the filter device (7), wherein the cover has a fastening device, which is designed to engage behind the bus bar assembly (2) in order to fasten the cover (8) to the bus bar assembly (2).