Elastic Busbar Plug Connector Tolerance Compensation
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Solution Overview
Problem
High-voltage battery connectors, such as RADSOK® D14, have limited tolerance compensation and allow relative movements, leading to increased wear and premature failure due to strict alignment requirements and high manufacturing costs.
Innovation Solution
A plug-in connection system with a busbar design featuring a non-elastic and elastic section, allowing for elastic deformation to accommodate transverse forces, reducing wear and enabling greater tolerance compensation, and incorporating a centering device for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If RADSOK® connectors are used with strict alignment requirements, then electrical connection reliability is improved, but manufacturing cost increases and manufacturing tolerance decreases
Solution Approach 1:
The busbar's mechanical properties are changed by introducing an elastic section with specific stiffness characteristics. This allows the busbar to deform elastically under transverse forces, accommodating misalignments while maintaining reliable electrical contact, thereby reducing manufacturing cost requirements
Solution Approach 2:
The elastic section of the busbar is designed in advance to compensate for expected misalignments and transverse forces. This pre-built flexibility cushioning mechanism absorbs stresses before they can cause connection failures or require precision manufacturing
2Stability of the object's composition
If RADSOK® connectors are used with limited tolerance compensation, then connection stability is improved, but manufacturing tolerance decreases and requires higher precision
Solution Approach 1:
The busbar is designed with dynamic flexibility through its elastic section, allowing it to adapt to misalignments during connection. This dynamic adjustment capability maintains stable electrical contact while accommodating broader manufacturing tolerances
Solution Approach 2:
The stiffness parameter of the busbar is optimized by creating distinct elastic and non-elastic sections. The elastic section provides necessary flexibility for tolerance compensation, while the non-elastic section maintains structural stability for reliable connection
3Ease of operation
If connectors allowing relative movements are used, then ease of connection is improved, but wear increases and service life decreases
Solution Approach 1:
The busbar's elastic section is designed with optimized stiffness parameters that allow controlled deformation to absorb relative movements. This parameter optimization enables easy connection while minimizing wear through controlled elastic deformation rather than rigid contact
4Manufacturing precision
If busbar with elastic section is used, then tolerance compensation is improved and manufacturing cost decreases, but structural complexity increases
Solution Approach 1:
The busbar is segmented into distinct elastic and non-elastic sections, each performing specific functions. This segmentation provides tolerance compensation capability while keeping the overall structure simple and manufacturable, avoiding excessive complexity
Solution Approach 2:
The elastic section of the busbar acts as a flexible element that can deform to accommodate misalignments. This flexible design approach achieves tolerance compensation with simple geometric modifications rather than complex mechanisms
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
The system significantly reduces manufacturing costs by allowing less accurate tolerances and minimizes relative movement between contacts, resulting in a low-wear, cost-effective connector suitable for high-voltage applications.
Implementation Method 1
the second elastic section being designed in such a way that with this transverse force transverse to the plug-in direction, in particular in the longitudinal direction of the at least one busbar, can be accommodated by elastic deformation
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a plug connection system (1) comprising a plug part (2) and a socket part (3) electrically connected to the plug part, wherein the plug part (1) comprises at least one contact element (4) with an end facing away from the socket part (3) and an end facing the socket part (3), wherein the end facing away is configured to establish an electrical connection with a plug part-side connector not included in the plug connection system in a plugging direction (S).By comprising at least one busbar (5) in the socket part (3), wherein the at least one busbar (5) has a first substantially non-elastic section (7) and a second elastic section (6), wherein the second elastic section (6) is designed such that it can absorb a transverse force transverse to the plugging direction (S), in particular in the longitudinal direction (L) of the at least one busbar (5), by elastic deformation, and wherein the at least one busbar (5) can be electrically connected to a socket-side connector not included in the plug connection system (1), a plug connection system (1) can be provided which, using the simplest possible design means, enables a higher manufacturing tolerance with regard to the connectors and reduces or compensates for relative movements of the connectors.