Integrated Spacer Fixing Device for Tool-Free Busbar Assembly
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Solution Overview
Problem
Existing busbar systems face challenges in being produced inexpensively, having a compact design, easy tool-free installation, and ensuring long-term mechanical, electrical, and temperature-dependent stability while allowing for quick assembly and maintenance.
Innovation Solution
The busbar system features a spacer with a holding element arranged at a distance from its base via a traverse, allowing for tool-free installation of different cover elements using a single fixing device, with a locking mechanism that includes latching elements and a clamping system for secure attachment, and is designed to accommodate various dimensions and materials for enhanced stability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional busbar systems use separate fixing devices and multiple components, then assembly complexity increases and manufacturing costs rise, but structural strength and reliability are maintained
Solution Approach 1:
The patent combines the fixing device and spacer into a single integrated component. The fixing device is formed as one piece with the spacer, eliminating the need for separate fixing elements and reducing the number of parts. This merging reduces manufacturing costs by simplifying production processes and reduces assembly complexity by eliminating multiple assembly steps for separate components.
Solution Approach 2:
The integrated fixing device-s Spacer serves multiple functions simultaneously: it provides mechanical fixing, electrical insulation, and structural support. The single component performs what previously required multiple separate parts, reducing both manufacturing complexity and assembly steps while maintaining all necessary functions.
2Productivity
If busbar systems use traditional covering systems with multiple parts, then assembly time increases and tool requirements increase, but coverage and protection are ensured
Solution Approach 1:
The covering system is divided into modular cover elements that can be independently assembled. Each cover element is designed to fit specific sections of the busbar system, allowing for quick, tool-free assembly while maintaining complete coverage and protection. The segmentation enables parallel assembly operations and reduces the time required to cover the entire busbar system.
Solution Approach 2:
The cover elements are designed with self-latching mechanisms that automatically secure themselves without requiring external tools or complex assembly procedures. The covers snap into place on the busbar system, providing immediate protection and ensuring reliable continuous operation through their self-securing design.
3Adaptability or versatility
If spacers and cover elements are made from standardized components, then manufacturing cost decreases and assembly simplifies, but adaptability to different dimensions and materials is reduced
Solution Approach 1:
The integrated fixing device-s Spacer is designed with adjustable parameters and scalable dimensions that can be modified to accommodate different busbar sizes, materials, and configurations. By varying key dimensions and geometric parameters of the single integrated component, the system can adapt to different applications without requiring completely different components, maintaining manufacturing efficiency while providing versatility.
Data Source
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AI summary
The invention relates to a busbar system comprising at least one busbar (1), at least one cover element (2) and at least one spacer (3), wherein the spacer (3) has at least one locking element (4, 5), a base (30), at least one retaining element (6) and a clamping element (31), which is characterized in that the spacer (3) has at least one fixing device (8) which securely overlaps at least one free end (21, 22) of the cover element (2) and which is operatively connected to the spacer (3) via at least one fixing element (83, 84).