Spring-Force Clamping Sleeve Assembly for Simpler Busbar Manufacturing
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Solution Overview
Problem
Existing spring-force clamping connections for electrical conductors are technologically demanding, complicated, and require complex tools for manufacturing, particularly when integrating a perforated collar with the busbar.
Innovation Solution
A separate sleeve is inserted into the through-opening of a busbar, allowing for independent manufacturing of the busbar and sleeve components, which can be joined using various methods such as welding, soldering, or gluing, and is designed to create a form- and force-fitting connection with the busbar to facilitate efficient clamping of electrical conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a perforated collar is integrated into the busbar using a forming method, then a spring-force clamping connection is achieved, but the manufacturing process becomes technologically demanding and complicated
Solution Approach 1:
The invention divides the busbar structure into separate components: a busbar body and a separately manufactured perforated collar. The collar is produced independently using stamping or punching processes, then mounted onto the busbar body. This segmentation eliminates the need for complex integrated forming methods while maintaining the clamping connection's reliability, as each component can be optimized and manufactured using simpler, more成熟 processes.
Solution Approach 2:
The invention combines separately manufactured components (busbar body and perforated collar) into a functional assembly. The collar is mounted onto the busbar body through insertion, pressing, or other joining methods to form a complete spring-force clamping connection. This merging approach achieves the desired functionality while avoiding the technological complexity of integrated manufacturing.
2Ease of manufacture
If a separate sleeve is inserted into the through-opening of the busbar, then independent manufacturing of busbar and sleeve is enabled, but additional assembly steps are required
Solution Approach 1:
The invention separates the busbar and the perforated collar (sleeve) into independently manufacturable components. The sleeve can be produced using standard stamping or punching processes, while the busbar is manufactured separately. This segmentation enables each component to be optimized for its specific manufacturing process and allows for parallel production, improving overall manufacturing efficiency despite requiring an additional assembly step.
Solution Approach 2:
The sleeve is inserted into the through-opening of the busbar, creating a nested structure where one component fits within another. This nesting approach allows for compact assembly while maintaining component independence. The sleeve becomes part of the busbar assembly, providing the perforated collar function without requiring complex integrated manufacturing.
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
This approach simplifies the manufacturing process, allows for the use of different materials and coatings, and ensures a reliable, low-resistance electrical connection with optimal current density distribution, while enabling modular adaptation for various conductor types.
Implementation Method 1
The sleeve wall may have an outer circumferential contour, which, in the state of the sleeve inserted into the through-opening, abuts an inner circumferential contour of the through-opening
Data Source
AI summary
A spring-force clamping connection, including a busbar, which spans a busbar plane and has a through-opening, and including a clamping spring a separate sleeve having a sleeve wall being present, which extends from an inlet to an outlet of the sleeve in a sleeve longitudinal direction. The separate sleeve being inserted into the through-opening in the sleeve longitudinal direction transversely to the busbar plane. The sleeve wall having an outer circumferential contour, which, in the state of the sleeve inserted into the through-opening, abuts an inner circumferential contour of the through-opening, and the sleeve being connected to the busbar.