Modular Busway Splice Connector Assembly
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Solution Overview
Problem
Existing busway splice connectors are not easily replaceable, leading to costly downtime when busbars need to be replaced, and they are not quick or inexpensive to assemble.
Innovation Solution
A busway splice connector design featuring a first and second connector with housings and an insulator for easy assembly and replacement, allowing the connector to function as both a splice connector and an end feed coupler, with a cover to restrict access and facilitate quick assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional busway splice connectors are used, then the busway can be assembled, but the assembly process is time-consuming and costly, and replacement of busbars is difficult
Solution Approach 1:
The splice connector is divided into separate modular components including a housing, insulator, and connector elements that can be independently assembled and replaced. This segmentation allows for quick replacement of individual busbars without replacing the entire connector assembly, significantly reducing downtime and assembly time.
Solution Approach 2:
The connector design incorporates movable or adjustable elements that allow for dynamic assembly and disassembly operations. The connector can be quickly opened, adjusted, and reconfigured to facilitate rapid busbar replacement while maintaining secure electrical connections during operation.
2Ease of manufacture
If traditional busway splice connectors are used, then the busway can be assembled, but the assembly process is complex and expensive
Solution Approach 1:
The housing and insulator are combined into a single integrated component that provides both mechanical support and electrical insulation functions. This merging reduces the number of separate parts that need to be assembled, simplifying the assembly process while maintaining the necessary structural complexity for safe operation.
Solution Approach 2:
The splice connector is designed with universal features that allow it to accommodate different busbar configurations and sizes. The standardized housing and connector elements can be used across various busway assemblies, reducing complexity by using the same components for multiple applications rather than requiring specialized parts for each configuration.
3Ease of operation
If the busway splice connector is designed for quick replacement, then downtime is reduced, but the connector may lack proper insulation or safety features
Solution Approach 1:
The insulator is pre-positioned and integrated into the housing structure before the connector is assembled. This preliminary placement ensures that proper insulation is established before any electrical connections are made, maintaining insulation integrity while allowing for quick subsequent replacement operations without compromising safety features.
Data Source
AI summary
A busway splice connector can include a first connector and a second connector. Each of the first connector and the second connector can define a busbar volume for receiving a portion of two busbars. The busway splice connector can also include a first housing that defines a first compartment for receiving the first connector. The busway splice connector can also include a second housing that defines a second compartment for receiving the second connector. The busway splice connector can also include an insulator configured to be positioned between the first housing and the second housing and to insulate the first connector from the second connector when the busway splice connector is assembled.