Movable DC Busbar Adapter for Low-Arcing Contact Engagement
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Solution Overview
Problem
DC power supplies pose challenges such as the risk of spark gaps or arcing when contacts are close to conductors during contact or disengagement in busbars, which are not present in AC power supplies.
Innovation Solution
A system with a holding adapter designed for DC voltage, featuring multiple contacts that establish electrical connection with DC voltage-carrying conductors through a plugging or pushing movement, utilizing mechanisms like springs, insulators, or magnets to minimize the risk of sparking or arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contacts are brought close to conductors during plugging movement to establish electrical connection, then electrical connection is established, but the risk of spark gaps or arcing increases
Solution Approach 1:
The electrical connection process is segmented into multiple phases: initial mechanical engagement, intermediate contact establishment, and final electrical connection. The adapter and busbar are designed with segmented contact points that engage sequentially, allowing the connection to be established in controlled steps rather than all at once, thereby reducing sparking risk during the transition.
Solution Approach 2:
Mechanical contact is established preliminarily before electrical contact. The adapter is mechanically engaged with the busbar first, ensuring proper positioning and alignment, and only then are the electrical contacts brought into full engagement. This preliminary mechanical action prepares the system for safe electrical connection by eliminating air gaps and ensuring stable contact geometry before high-voltage DC engagement.
2Object-affected harmful factors
If contacts are quickly brought into contact with conductors to reduce sparking duration, then sparking duration is reduced, but mechanical force and wear increase
Solution Approach 1:
The engagement mechanism incorporates dynamic elements such as spring-loaded contacts and movable bridge structures that allow controlled acceleration and deceleration during the plugging movement. The spring elements store mechanical energy during insertion and release it to accelerate contact closure, reducing the time contacts remain in the critical intermediate state while distributing mechanical force over time through the elastic deformation of spring components.
Solution Approach 2:
A movable bridge structure acts as an intermediary between the adapter contacts and the busbar conductors. This bridge can be independently actuated to bring contacts into rapid engagement with the conductors, separating the high-force mechanical insertion motion from the high-speed electrical contact closure. The bridge absorbs and transforms mechanical energy, enabling fast contact closure without requiring excessive insertion force.
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
Reduces the duration and likelihood of sparking or arcing by ensuring controlled and rapid contact establishment with DC conductors, enhancing safety and reliability in DC-powered busbar systems.
Implementation Method 1
the insertion movement of the adapter (1) occurs against the spring force of the spring element (6)
Implementation Method 2
the insertion movement of the adapter (1) is supported by the magnetic force of one or more magnets (40, 40') mounted in the housing of the adapter
Implementation Method 3
an insulator (30) is arranged between the conductor (3) and the contact (2) of the adapter (1)
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3c
AI summary
A system comprises: - a DC voltage supply with an amplitude in the range from 200 V to 1000 V, - a busbar (5) supplied by the DC voltage supply, - a holding adapter (1) with a plurality of contacts which are designed for the detachable electrical connection to conductors (3) carrying DC voltage in the busbar (5), wherein the holding adapter (1) can be mounted in the busbar (5) by a plug-in movement. A holding adapter (1) with a plurality of contacts is proposed which are designed for the detachable electrical connection to conductors carrying DC voltage in a busbar (5), wherein the holding adapter (1) can be mounted in the busbar (5) by a plug-in movement.