Busbar Joint Plate and Stud Layout to Prevent Rotation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional busbar connection systems face issues with rotational movement between connected busbars, particularly in applications with high vibration or torque, leading to potential damage and performance degradation, and existing solutions increase costs, weight, and packaging size.
Innovation Solution
A busbar connection system utilizing a plate member with higher tensile strength and stud members inserted through apertures in both the plate and busbars to securely prevent rotational movement, with configurations such as rectangular or square shapes and central or diagonal arrangements, typically using stainless steel for the plate and copper or aluminum for the busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical devices (screws or bolts) are used to connect busbars, then connection is achieved, but rotational movement between busbars occurs leading to damage and degraded performance
Solution Approach 1:
A plate member is introduced as an intermediary component between the busbars. The plate member includes apertures that receive stud members, which are inserted through aligned apertures in the busbars. This intermediary plate structure prevents direct rotational movement between busbars while maintaining secure mechanical connection through the stud members that engage with the plate and busbar apertures.
2Reliability
If larger mechanical devices and backer plates are used to prevent rotation, then rotational stability is improved, but costs, weight, and packaging size increase
Solution Approach 1:
The plate member is made from a material with higher tensile strength than the busbar materials (e.g., stainless steel for aluminum or copper busbars). This parameter change in material strength allows the use of a thinner, lighter plate with smaller stud members while still achieving the required rotational stability and connection strength, thereby reducing overall weight compared to conventional solutions.
3Reliability
If larger mechanical devices and backer plates are used to prevent rotation, then rotational stability is improved, but costs, weight, and packaging size increase
Solution Approach 1:
The connection system is segmented into distinct functional components: the plate member providing the mounting structure, and the stud members providing the fastening function. This segmentation allows each component to be optimized independently - the plate can be made thin and light while the studs provide the necessary mechanical engagement, resulting in a simpler overall system compared to conventional backer plate solutions.
Data Source
AI summary
A busbar connection system comprises a plate member formed of a first material having a higher tensile strength than second and third materials of first and second busbars, respectively, and defining first and second apertures and first and second stud members securely inserted through the first and second apertures of the plate member, respectively, the first and second stud members being configured to be securely inserted through first and second apertures, respectively, in each of the first and second busbars, wherein the first and second stud members mitigate rotational movement between the first and second busbars when connected.