Electrical Connector With Clamping Tabs For Busbar Coupling
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Solution Overview
Problem
The conventional method of connecting electrical busbars using bolts requires labor-intensive drilling, which is time-consuming and costly.
Innovation Solution
An electrical connector with clamping portions and coupling tabs that allow busbars to be coupled without drilling, using fasteners to secure the tabs against the busbars, forming an electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional drilling and bolting method is used to connect busbars, then reliable electrical connection is achieved, but installation time and labor cost increase
Solution Approach 1:
The connector is pre-assembled with coupling tabs and fasteners before installation. The coupling tabs are pre-formed with engagement features that align with busbar slots, eliminating the need for on-site drilling and hole alignment. This preliminary preparation significantly reduces installation time while maintaining connection reliability.
Solution Approach 2:
The invention extracts the drilling operation from the installation process entirely. By using pre-formed coupling tabs with integrated fastening features, the patent eliminates the need to drill holes in busbars during installation, removing this time-consuming step while preserving the mechanical and electrical connection function.
2Strength
If drilling holes in busbars is performed, then secure connection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The connection system is segmented into distinct functional components: the connector body, coupling tabs, and fasteners. The coupling tabs are separate elements that engage with pre-formed slots in the busbars, eliminating the need to drill holes in the busbars themselves. This segmentation allows each component to be optimized and manufactured independently, simplifying the overall manufacturing process.
Solution Approach 2:
Instead of creating holes in the busbars to receive bolts, the invention inverts the approach by providing protruding coupling tabs that insert into pre-formed slots in the busbars. This reversal eliminates the need for complex drilling and tapping operations on the busbars, simplifying their manufacture while maintaining connection strength.
3Reliability
If bolts are used to connect busbars, then electrical connection is achieved, but additional components and installation steps are required
Solution Approach 1:
The coupling tabs merge multiple functions into a single component: electrical conduction, mechanical attachment, and alignment. The tabs are electrically conductive and provide both the electrical connection path and the mechanical fastening interface, eliminating the need for separate bolts and reducing the total number of components required for a reliable electrical connection.
Solution Approach 2:
The coupling tabs serve multiple functions simultaneously: they conduct electricity, provide mechanical fastening through integrated fastener receptacles, and ensure proper alignment with the busbars. This multi-functionality reduces the number of separate components needed while maintaining reliable electrical and mechanical connections.
Data Source
AI summary
An electrical connector is provided. The electrical connector includes a first mounting portion. The electrical connector further includes a first clamping portion coupled to the first mounting portion. The first clamping portion has a first coupling tab and a second coupling tab. The first and second coupling tabs define a first gap. The first and second coupling tabs are configured to form an electrical connection with the first busbar in the first gap.