Busbar Mounting System with T-Slot Profiles for Additional Equipment
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Solution Overview
Problem
Existing mounting systems for busbars in electrical switchgear are poorly suited for adding additional equipment, as they can lead to conductive swarf causing short circuits and arc flashes when drilling into metal parts, and cable ties are inadequate for long-term stability under vibrations.
Innovation Solution
A mounting system with connection profiles featuring T-slots and self-cutting screws, allowing for flexible mounting of additional equipment like sensors without risking conductive swarf and providing stability under vibrations, using materials like aluminum and plastic for reduced electromagnetic interference and increased robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional equipment is mounted by drilling holes into metal mounting system parts, then additional equipment can be fastened securely, but conductive swarf may get into the switchgear and cause short circuits and arc flashes
Solution Approach 1:
The patent introduces slot nuts as an intermediary component between the mounting system and additional equipment. These slot nuts are mounted on the connection profiles via slots, eliminating the need to drill into metal parts. The slot nut system acts as a mediator that provides secure mounting without generating conductive swarf, thus resolving the contradiction between mounting strength and harmful conductive particles.
2Ease of manufacture
If cable ties are used to mount additional equipment, then mounting is simple and avoids conductive swarf, but the mounting capability is limited and stability under vibrations is insufficient
Solution Approach 1:
The patent segments the mounting system into multiple functional components: connection profiles with slots, slot nuts, and mounting points. This segmentation allows the system to combine the simplicity of pre-designed mounting features with the reliability of robust mechanical connections. The slot nuts provide vibration-resistant mounting while the modular design maintains ease of installation, resolving the contradiction between simplicity and reliability.
3Strength
If the mounting system uses metal components for strength, then structural integrity is improved, but the risk of conductive swarf causing short circuits increases
Solution Approach 1:
The patent extracts the drilling operation from the mounting process by introducing pre-formed slots in the connection profiles. This extraction eliminates the harmful effect of generating conductive swarf from metal drilling while preserving the structural integrity of metal components. The slots are created during manufacturing without requiring field drilling, thus removing the source of conductive swarf hazard.
4Device complexity
If the mounting system is designed for basic busbar support, then the structure is simple, but the capability to mount additional equipment is limited
Solution Approach 1:
The patent applies universality by designing connection profiles with slots that serve multiple functions: structural connection between holder rails, and mounting points for various additional equipment. The same slot infrastructure supports both the primary structural function and the secondary function of mounting sensors, indicators, or other equipment, thus achieving multi-functionality without significantly increasing structural complexity.
Data Source
Figure 1~2
Figure 3~6
Figure 7
AI summary
A mounting system (1) for busbars (L1..L3, N) of an electrical switchgear (12) is disclosed, which comprises a plurality of holder rails (2a, 2b), connection profiles (3a..3d) to interconnect the holder rails (2a, 2b) and to effect a distance between the holder rails (2a, 2b) and which comprises a plurality of busbar holders (4a, 4b), which are provided to receive the busbars (L1 ..L3, N) and which are arranged in the holder rails (2a, 2b). At least one of the connection profiles (3a..3d) has at least one slot (10) running parallel to a longitudinal extension of said connection profile (3a..3d), wherein the at least one slot (10) has an undercut in its cross-section. Further on, an arrangement (6) and an electrical switchgear (24) with a plurality of busbars (L1 ..L3, N) and a mounting system (1) for of the above kind are disclosed.