Busbar Connection Assembly With Homogeneous Contacts for Lower Resistance
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Solution Overview
Problem
Conventional busbar ducts experience high contact resistance and excessive temperature at the contact region due to electrical coupling, leading to increased power consumption, thermal stress, and potential safety hazards.
Innovation Solution
A busbar connection assembly using conductive plates with coupling portions made of the same material as the busbars, coupled through solid-liquid or solid-solid bonding, and a locking member to ensure low-resistance electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors are used to join busbar ducts, then the busbar duct can be assembled and connected, but the contact resistance becomes large causing excessive temperature at the contact region
Solution Approach 1:
The connector uses the same material (aluminum or aluminum alloy) for both the body and the contact portions as the busbar ducts, ensuring homogeneous material composition throughout the connection. This eliminates galvanic corrosion and reduces contact resistance, thereby lowering the temperature at the contact region while maintaining connection reliability.
Solution Approach 2:
The invention changes the material parameter of the connector to match the busbar duct material, and increases the contact area between the connector and busbars. These parameter changes reduce contact resistance and improve heat dissipation, resolving the temperature issue while maintaining reliable connection.
2Ease of manufacture
If conventional connectors are used to join busbar ducts, then the busbar duct can be assembled, but the contact resistance is large affecting power system operation efficiency
Solution Approach 1:
By using the same aluminum or aluminum alloy material for the connector and busbar ducts, the invention eliminates material incompatibility issues, ensuring easy assembly while reducing contact resistance. This homogeneous material composition prevents galvanic corrosion and minimizes energy loss at the connection point.
Solution Approach 2:
The connector design merges the connection function with the electrical conduction function by using the same material throughout, creating a unified structure that facilitates easy assembly while minimizing energy loss through reduced contact resistance.
3Adaptability or versatility
If connectors are used to join busbar ducts, then the busbar system can be extended, but the large contact resistance constitutes a safety threat
Solution Approach 1:
The connector uses the same aluminum or aluminum alloy material as the busbar ducts, ensuring homogeneous material composition that eliminates galvanic corrosion and reduces contact resistance. This resolves the safety hazard of overheating while maintaining the adaptability to extend the busbar system as needed.
Solution Approach 2:
The invention converts the potential harm of material incompatibility and galvanic corrosion into benefit by deliberately selecting the same material for the connector, thereby eliminating the harmful effects of contact resistance and overheating while enabling safe system extension.
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
Reduces contact resistance by up to 60%, lowers temperature rise by 10K, and enhances the stability and reliability of power transmission systems.
Implementation Method 1
the pair of coupling portions being respectively coupled to the body through solid-liquid coupling or solid-solid coupling by using a same material as surfaces of the connecting portions of the first busbar and the second busbar
Implementation Method 2
the pair of coupling portions being respectively coupled to the body through solid-liquid coupling or solid-solid coupling
Implementation Method 3
a locking member coupled in the positioning hole to lock and electrically connect the first busbar and the second busbar by pressing the pair of coupling portions respectively to the surfaces of the connecting portions of the first busbar and the second busbar
Implementation Method 4
since contact resistance is large, this may result in an excessively high temperature at a contact region
Implementation Method 5
an electrical coupling between the conventional busbar duct and the connector may cause the large contact resistance
Data Source
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AI summary
Embodiments of the present disclosure provide a busbar connection assembly, a busbar assembly and a busbar box assembly for connecting busbars, the busbar connection assembly comprising: a pair of conductive plates adapted to clamp and connect a first busbar and a second busbar separated from each other and extending in a same extending direction, each of the pair of conductive plates comprising: a body; a pair of coupling portions arranged at least at ends of the body in an extending direction, the pair of coupling portions being respectively coupled to the body through solid-liquid coupling or solid-solid coupling by using a same material as surfaces of the connecting portions of the first busbar and the second busbar; and a positioning hole formed in a middle portion of the body in the extending direction; and a locking member coupled in the positioning hole to lock and electrically connect the first busbar and the second busbar by pressing the pair of coupling portions respectively to the surfaces of the connecting portions of the first busbar and the second busbar. Therefore, the contact resistance of the busbar's electrical contact can be reduced, and the stability of electrical contact can be improved.