Busbar Connection System Using Pressing Means
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Solution Overview
Problem
Existing busbar connection methods require multiple screws for connecting busbars of different potentials, leading to high assembly times and costs, and welded connections are irreversible, hindering maintenance and repair.
Innovation Solution
A busbar connection system that uses conductive bushings and insulator bushings to create a separable electrical connection between busbars of different potentials, employing a single pressing means to establish both electrical and mechanical connections, with optional eccentric clamp mechanisms for consistent force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple screw connections are used to connect busbars of different potentials, then reliable electrical and mechanical connections are ensured, but assembly time and costs increase significantly
Solution Approach 1:
The patent combines multiple separate screw connections for busbars of different potentials into a single integrated pressing means that simultaneously connects multiple busbar portions. The pressing means includes a pressing element that can press multiple busbar portions (first, second, third, and fourth busbar portions) at once, merging several connection operations into one action, thereby reducing assembly time while maintaining connection reliability.
Solution Approach 2:
The pressing means is designed as a universal connection device that can handle busbars of different potentials (first potential P1 and second potential P2) simultaneously. The insulator bushing integrates multiple functions: it provides electrical insulation between different potentials, mechanical support for the pressing element, and alignment features. This multi-functional design eliminates the need for separate connection devices for each potential, reducing assembly complexity and time.
2Reliability
If multiple screw connections are used to connect busbars of different potentials, then proper electrical and mechanical connections are ensured, but assembly costs increase due to multiple connections and torque control requirements
Solution Approach 1:
The patent merges multiple separate connection operations into a single pressing action using one pressing means. This eliminates the need for multiple torque control measurements and multiple fastening operations, directly reducing labor costs and assembly complexity while maintaining reliable electrical and mechanical connections across busbars of different potentials.
Solution Approach 2:
The patent extracts the insulation function from the mechanical connection process by introducing a separate insulator bushing. This allows the pressing means to focus solely on creating reliable mechanical and electrical connections without the added complexity of integrating insulation into each individual connection point, simplifying the manufacturing process and reducing costs.
3Reliability
If welded connections are used to connect busbars, then strong and reliable connections are achieved, but the connections become irreversible, hindering maintenance and repair
Solution Approach 1:
The patent segments the connection into separate functional components: the insulator bushing provides insulation and structural support, while the pressing element provides the mechanical and electrical connection. This segmentation allows the connection to be disassembled and reassembled, enabling maintenance and repair while maintaining connection strength during operation. The modular design facilitates easy replacement of individual components.
Solution Approach 2:
The pressing means creates a dynamic, adjustable connection that can be tightened or loosened as needed, unlike fixed welded connections. The pressing element can be adjusted to maintain optimal contact pressure throughout the busbar's operational life, and the entire assembly can be disassembled for maintenance, providing both strong connections and ease of repair.
4Productivity
If a single pressing means is used to connect busbars of different potentials, then assembly time and costs are reduced, but the complexity of ensuring proper insulation and connection increases
Solution Approach 1:
The insulator bushing is designed as a universal component that simultaneously provides electrical insulation between different potentials, mechanical support for the pressing element, alignment features for multiple busbar portions, and integration points for the pressing means. This multi-functionality consolidates multiple requirements into a single component, reducing overall system complexity while enabling fast assembly.
Solution Approach 2:
The patent employs a nested structure where the pressing element is inserted through the insulator bushing, which itself is positioned among multiple busbar portions. This nesting arrangement allows the pressing means to access and connect multiple busbar portions through a single access point, simplifying the external appearance and reducing the number of separate components visible from the outside, thereby reducing perceived complexity.
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
The present invention relates to a busbar system, a busbar assembly 1a, a busbar connection system 1 and a method for electrically connecting busbars of different potentials P1, P2, particularly for electrically connecting a first busbar portion 10 with a second busbar portion 12 and a third busbar portion 20 with a fourth busbar portion 22. The system 1 comprising a first electrically conductive bushing 30, including a through hole for providing a passage 35 through the third and fourth busbar portions 20, 22 and being configured for electrically connecting the first busbar portion 10 with the second busbar portion 12. The system further comprising a first insulator bushing 40, being configured for receiving the first electrically conductive bushing 30 at least partially and for electrically insulating busbar portions 10,12 configured for the first potential form busbar portions 20, 22 configured for the second potential P2, and a pressing means 50, comprising a shaft 52 that is configured for being received in the first electrically conductive bushing 30 so as to extend through the passage 35, wherein the pressing means 50 is configured for pressing first, second, third and fourth busbar portions 10, 12, 20, 22 in a shaft direction to electrically connect the first busbar portion 10 with the second busbar portion 12 and the third busbar portion 20 with the fourth busbar portion 22.