Busbar Socket with Cast Resin Insulating Body for High-Voltage Connections
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Solution Overview
Problem
In high-voltage applications, the large diameter of cables due to high power flow results in restricted routing and connection challenges, especially when accessing hard-to-reach components of transformers or switchgear, necessitating the use of busbars and connecting sleeves, which require additional costly and complex fastening systems to secure the connection.
Innovation Solution
A rigid conductor rail with a busbar socket firmly connected to one end, allowing direct plug-in of cable parts without the need for connecting sleeves, utilizing a screw or bolt connection for stability and featuring an insulating body made of cast resin with field control elements to manage electrical fields and prevent air pockets, eliminating the need for separate fastening systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If cables are used for high-voltage connections, then power transmission capability is improved, but routing flexibility deteriorates due to large diameter and bending radius requirements
Solution Approach 1:
The power transmission system is segmented into rigid busbar sections and flexible cable sections, allowing each component to optimize its function. The busbar provides rigid structural support and high power capacity where routing is constrained, while cables provide flexibility only where needed for connection.
Solution Approach 2:
A connecting sleeve acts as an intermediary component between the rigid busbar and flexible cable. This mediator enables the transition from rigid to flexible connection, allowing the system to achieve both high power transmission and routing flexibility without compromising either requirement.
2Adaptability or versatility
If connecting sleeves are used to connect busbar and cable, then connection versatility is improved, but device complexity increases due to additional fastening systems
Solution Approach 1:
The connecting sleeve integrates multiple functions into a single component: it provides mechanical connection, electrical connection, and positioning functions all in one element. This merging eliminates the need for separate fastening systems and reduces overall connection complexity.
Solution Approach 2:
The connecting sleeve is designed to self-position and self-secure the cable connector through its integrated structure. The sleeve's geometry and material properties enable it to automatically maintain proper alignment and secure connections without requiring additional external fastening mechanisms.
3Reliability
If locking screws are used to secure power plugs, then connection reliability is improved, but additional fastening systems are required increasing complexity and cost
Solution Approach 1:
The securing function previously requiring separate locking screws is merged into the connecting sleeve structure itself. The sleeve's design incorporates integral locking features that provide secure retention of the power plug without requiring additional fastening components.
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a busbar (1) for voltages from 1 kV to 36 kV and currents up to 2.5 kA. It comprises a rigid conductor (7) surrounded by insulation (6) and having a first and a second end (2, 4), wherein at least one of the two ends (2, 4) of the conductor (7) is provided a busbar socket (5) which includes a contact socket (10) fixedly connected to the conductor (7) and open on one side for receiving a contact head of a cable connector and an insulating body (12) surrounding the contact socket (10), wherein the insulating body (12) has an opening (13) for inserting the contact head of the cable connector into the contact socket and overlaps with the insulation (6) of the conductor (7) in the axial direction.