Busbar Connector Joint With Spherical Washers for Alignment
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Solution Overview
Problem
Existing technologies face challenges in achieving proper mechanical alignment and electrical connection between stiff busbars and connectors, which affects the transfer of current.
Innovation Solution
A connecting arrangement using fasteners with inner and outer washers having spherical cap mating surfaces allows for flexible positioning and angling of the busbar relative to the electrical connector, facilitated by through holes and press-fitting mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a stiff busbar is connected to a stiff connector using conventional fastening methods, then mechanical strength is ensured, but proper mechanical alignment becomes difficult to achieve
Solution Approach 1:
The patent employs spherical cap mating surfaces on washers instead of conventional flat surfaces. The first and second washers each have a mating surface shaped as a spherical cap that mates with corresponding spherical cap surfaces on the connector and busbar respectively. This curvature enables the stiff busbar to be adjusted to the position and angle of the electrical connector, achieving proper mechanical alignment while maintaining structural strength.
2Adaptability or versatility
If conventional flat mating surfaces are used, then manufacturing is simplified, but the busbar cannot be adjusted to the position and angle of the electrical connector
Solution Approach 1:
The spherical cap geometry provides inherent adaptability for position and angle adjustment while using standard machining operations. The mating surfaces are shaped as spherical caps with defined radii of curvature, allowing the busbar to be oriented in various positions including 360° rotation about the fastener axis and tilting at different angles, without requiring complex adaptive mechanisms.
3Ease of operation
If the busbar is made flexible to achieve alignment, then ease of connection is improved, but structural integrity and current transfer capability deteriorate
Solution Approach 1:
The patent maintains the stiffness and structural integrity of the busbar by using spherical cap mating surfaces on rigid washer components. The curvature provides the necessary alignment capability without requiring the busbar itself to be flexible. The spherical caps enable adjustment to position and angle while the busbar remains a rigid conductor capable of proper current transfer.
Data Source
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AI summary
A connecting arrangement for providing a mechanical and electrical connection between a busbar and an electrical connector. Each one of a first and a second inner washer has a respective mating surface shaped as a spherical cap. The inner washers are configured to be provided on opposite sides of a busbar so that said mating surfaces face away from the busbar. Each one of a first and a second outer connecting portion have a mating surface for mating with the mating surface of the respective inner washer such that at least a portion of the first inner washer is stacked between the first outer connecting portion and the first side of the busbar, and such that at least a portion of the second inner washer is stacked between said opposite second side of the busbar and the second outer connecting portion. A fastener extends though the first inner washer, the busbar, the second inner washer and into the electrical connector.