Cable Connecting Assembly With Twist-Free HV Terminal Alignment
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Solution Overview
Problem
The current design of lug connectors and busbars for high-voltage cables in machines is cumbersome and time-consuming to assemble, requiring specialized tools and significant human effort, and can lead to damage during twisting, especially for stiff and large-diameter cables.
Innovation Solution
A cable connecting assembly with a contact terminal and connecting device that includes a bracket and coupling device, allowing for easy alignment and connection of high-voltage cables without the need for twisting, using a bracket that can be oriented freely and connected without specialized tools, simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the lug connector is twisted to align openings with the busbar, then accurate alignment is achieved, but the lug connector or high-voltage cable may be damaged
Solution Approach 1:
Instead of twisting the lug connector to achieve alignment, the invention inverts the approach by making the busbar openings adjustable or the lug connector openings fixed in a standard orientation. The alignment is achieved by moving the busbar openings to match the lug connector openings, rather than twisting the lug connector to match the busbar openings.
Solution Approach 2:
The invention applies preliminary action by pre-aligning the lug connector openings in a fixed, standard orientation during manufacturing. This eliminates the need for twisting during assembly, as the busbar openings are positioned to match the pre-aligned lug connector openings from the start.
2Manufacturing precision
If specialized tooling and set-ups are used to twist the high-voltage cable, then alignment is achieved, but assembly time and cost increase
Solution Approach 1:
The invention extracts the alignment function from the lug connector and separates it into independent components. The busbar openings are made adjustable or repositionable, allowing alignment to be achieved without specialized twisting tools or set-ups, thereby reducing assembly time and complexity.
Solution Approach 2:
The invention applies parameter changes by making the busbar openings adjustable in position or orientation. This allows the openings to be moved to match the lug connector openings without requiring twisting of the cable or specialized tooling, thereby simplifying the assembly process and reducing time.
3Ease of manufacture
If the lug connector and busbar are designed with fixed openings, then manufacturing is simplified, but alignment during assembly becomes difficult
Solution Approach 1:
The invention applies dynamics by making the busbar openings adjustable or repositionable during assembly. This allows the fixed-manufactured lug connector openings to be matched with the adjustable busbar openings, combining the benefits of simplified manufacturing with ease of assembly alignment.
Data Source
AI summary
A cable connecting assembly for a machine includes a cable, and a contact terminal configured to connect with the cable. The contact terminal includes a first body portion defining a first diameter and a second body portion defining a second diameter. The second diameter is greater than the first diameter of the first body portion. The cable connecting assembly further includes a connecting device configured to connect with the contact terminal. The connecting device includes a connecting plate includes a first portion, a second portion connected to the first portion, and a bracket configured to removably connect with the second portion of the connecting plate, such that the bracket and the second portion are together configured to removably connect the contact terminal with the connecting device. The connecting device further includes at least one coupling device configured to removably connect the bracket with the second portion of the connecting plate.