Busbar Terminal With Slipped Abutment And Clamping Spring
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Solution Overview
Problem
The existing manufacturing processes for busbars with connecting terminals are complex and costly due to the need for multiple bending steps, increasing production expenses.
Innovation Solution
A busbar design where an abutment is slipped onto the busbar, with a U-shaped clamping spring pressing a stop surface against the busbar to create contact pressure, eliminating the need for complex bending and allowing for simpler production, using a stamped part for the abutment and busbar, and a U-shaped abutment with conical legs for conductor alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bent sections are formed on the busbar for contacting conductors, then the conductor contact function is improved, but the manufacturing complexity and production cost increase due to multiple bending steps
Solution Approach 1:
The busbar system is divided into separate functional components: a straight busbar body and separate abutments with clamping springs. The abutments are slipped onto the busbar and secured by clamping springs, eliminating the need to bend the busbar itself while maintaining the conductor contact function.
Solution Approach 2:
abutment acts as an intermediary component between the conductor and the busbar. Instead of directly bending the busbar to contact the conductor, the abutment with conical legs provides the contact interface, simplifying the busbar manufacturing while achieving the same electrical contact function.
2Reliability
If bent sections are formed on the busbar, then the conductor contact function is improved, but the production time and manufacturing cost increase
Solution Approach 1:
The busbar system is divided into separate functional components: a straight busbar body and separate abutments with clamping springs. The abutments are slipped onto the busbar and secured by clamping springs, eliminating the need to bend the busbar itself while maintaining the conductor contact function.
Solution Approach 2:
The abutments are pre-formed with the necessary geometric features (conical legs, receiving slots) in a single stamping operation, and the clamping springs are pre-formed. These components are then simply slipped onto the busbar and engaged, eliminating time-consuming bending operations during busbar assembly.
3Manufacturing precision
If the abutment is designed with conical legs, then the conductor alignment and centering is improved, but the manufacturing complexity of the abutment increases
Solution Approach 1:
The conical shape of the abutment legs provides self-centering functionality through geometric parameters. As the conductor is inserted, the conical surfaces guide it into proper alignment automatically, achieving precise positioning without complex adjustment mechanisms.
Solution Approach 2:
The conical legs of the abutment automatically center and align the conductor during insertion through their geometric shape. The system self-adjusts to achieve proper alignment without requiring external alignment tools or complex positioning mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies the production of busbars by eliminating the need for complex bending and allowing for easier assembly and disassembly, reducing manufacturing costs and enabling compatibility with different terminal types.
Implementation Method 1
a flexible end of the clamping spring presses a stop surface of the abutment against the busbar
Implementation Method 2
the legs of the U-shaped abutment are conical to each other
Data Source
Figure 1~4
Figure 5~8
Figure 9~10
AI summary
Connecting terminal (1) has an insulating housing (3), in which a busbar (5) and atleast a clamp spring (7) are arranged. The support (9) is attached to the busbar and the flexible end of the clamp spring presses an abutment surface of the support against the busbar.