Integrated Busbar and Signal Connector for Power Distribution
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Solution Overview
Problem
Existing busbar connection systems lack the ability to efficiently integrate power and signal connections, limiting their capability to dynamically adjust power distribution based on the demand of connected electrical devices.
Innovation Solution
A busbar connection system that combines a busbar connector for power transmission and a signal connector, allowing for both power and data connections to be established in a single mating movement, with features like open and closed cross-section openings, guiding rails, and card-edge style contacts to ensure reliable contact and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate power and signal connections are used, then reliable power transmission is achieved, but device complexity and connection time increase
Solution Approach 1:
The patent combines the power connector and signal connector into a single integrated busbar connection system. The power distribution system integrates the busbar for power transmission and the link module for signal transmission into one unified structure that connects to the electrical device through a single connection action, eliminating the need for separate connection operations.
Solution Approach 2:
The busbar connection system serves multiple functions simultaneously: it provides power transmission through the busbar, signal transmission through the link module, and mechanical support through the housing structure. This multi-functional design replaces what would otherwise require separate dedicated components for each function.
2Reliability
If separate power and signal connections are used, then clear functional separation is achieved, but connection time and productivity decrease
Solution Approach 1:
The power distribution system integrates the busbar for power transmission and the link module for signal transmission into one unified structure that connects to the electrical device through a single connection action, eliminating the need for separate connection operations.
Solution Approach 2:
The link module is pre-assembled with the busbar in the power distribution system before deployment. This preliminary integration means that during installation, the entire power and signal connection system is installed in one action rather than requiring sequential assembly of separate components.
3Manufacturing precision
If rigid connector structure is used, then manufacturing precision is improved, but adaptability to alignment deviations decreases
Solution Approach 1:
The connector components incorporate flexible elements such as spring contacts and elastic urging members that can deform to accommodate minor misalignments between the power distribution system and the electrical device. This flexibility allows the rigidly manufactured components to adapt to field installation variations.
Solution Approach 2:
The connector design allows for parameter changes in position and orientation through built-in compliance mechanisms. The urging members and spring-loaded contacts can adjust their position within certain tolerances, enabling the connector to adapt to small deviations in alignment without requiring high-precision installation.
4Device complexity
If integrated power and signal connector is used, then device complexity is reduced, but manufacturing complexity increases
Solution Approach 1:
The integrated busbar connection system is designed as modular components that can be manufactured separately and then assembled. The power connector, signal connector, and housing are distinct modules that simplify the manufacturing process while achieving integration in the final assembled product.
Solution Approach 2:
The link module is nested within or alongside the busbar structure in the power distribution system. This nesting arrangement allows both power and signal transmission components to be integrated in a space-efficient manner that simplifies the overall manufacturing process compared to separate external connections.
Data Source
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AI summary
The invention relates to an improved busbar connection system, an electrical device incorporating same, and an electrical system comprising at least one electrical device. Such a busbar connection system comprises a busbar connector (110) for receiving and for electrically contacting at least two conductors of a busbar, and a signal connector (120) for receiving and for electrically contacting a link module with a plurality of contact pads. The busbar connector has at least two, spaced apart, openings (111, 112) defined by an open cross-section along a mating direction that enable the busbar connector to partially surround, on opposite sides, each of the at least two conductors of the busbar. The signal connector has an opening (121) defined by a closed cross-section along the mating direction that enables the signal connector to guide the link module into a contacting position for electrically contacting the plurality of contact pads.