Busbar Profile With Variable Depth Grooves For Conductor Insertion
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Solution Overview
Problem
Existing busbar systems are complex and difficult to produce and electrically contact due to the lateral integration of electrical lines in contact webs, which increases production costs and complicates electrical connections.
Innovation Solution
A busbar system with a profile featuring grooves of different depths, allowing electrical lines to be inserted in the depth direction, simplifying production and electrical contacting, and incorporating a plug holder with reverse polarity protection for secure and easy connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical conductors are laterally positioned within contact bridges, then the busbar can accommodate different conductor heights, but the manufacturing becomes complex and electrical contacting becomes difficult
Solution Approach 1:
The patent transitions from lateral positioning of electrical conductors in the horizontal plane to depth-based positioning in the vertical dimension. Grooves of different depths accommodate conductors at different levels, transforming a complex lateral arrangement into a simpler vertical stacking configuration that is easier to manufacture and assemble.
2Adaptability or versatility
If electrical conductors are laterally positioned within contact bridges, then different conductor heights are accommodated, but electrical contacting becomes relatively difficult
Solution Approach 1:
The patent enables electrical contacting from a single side by using grooves of varying depths. Connectors can access conductors at different heights by inserting to appropriate depths, eliminating the need for lateral access to multiple sides and simplifying the electrical connection process.
3Ease of manufacture
If grooves of different depths are used to position electrical conductors, then manufacturing is simplified and electrical contacting is easier, but the busbar profile requires more complex groove geometry
Solution Approach 1:
The busbar profile features grooves with locally varied depths - shallower grooves for higher conductors and deeper grooves for lower conductors. This localized variation in groove geometry allows different conductor positions to be accommodated within a single standardized profile design, balancing manufacturing simplicity with functional requirements.
Data Source
Figure 1a~1b
Figure 2~3
Figure 4a~4b
AI summary
The present invention relates to a busbar system (100) comprising a busbar (1) and a plug holder (20) for holding a plug (40) electrically connected to the busbar (1). The present invention further relates to a busbar (1) comprising: a busbar profile (2) with a first and a second group (row) (4, 5) of grooves, wherein the grooves of the first group (row) (4) have a different depth compared to the grooves of the second group (row) (5), extending from the side of the busbar profile (2) through which the grooves are accessible to a bottom of the grooves, wherein a respective electrical conductor (7) is received in each of the grooves and is accessible for electrical contact via the respective groove.