Elastic Plug Insert Coupling for Busbar Vibration Tolerance
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Solution Overview
Problem
Existing coupling systems for electrical connections in motor vehicles fail to withstand long-term loads due to high power transmission and vibrations, leading to unreliable connections.
Innovation Solution
A plug insert with an insulator part comprising a sleeve and washer nut, allowing for flexible alignment and compensation of tolerance fluctuations, secured by a screw through holes in the busbar, power connector, and sleeve, ensuring reliable and cost-effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid connection parts are used to ensure stable electrical connection, then connection stability is improved, but the system cannot accommodate tolerance fluctuations and vibrations, leading to connection failure under long-term loads
Solution Approach 1:
The patent applies the dynamics principle by making the insulator part flexible rather than rigid. The insulator part can dynamically adapt its shape and position to accommodate tolerance fluctuations in the busbar and power connector, while still maintaining stable electrical connection through the flexible sealing mechanism that compensates for relative movements during operation
Solution Approach 2:
The patent changes the physical parameter of the insulator part from rigid to flexible state. This parameter change allows the insulator to deform and adapt to varying positions of connection parts under vibration and thermal expansion, thereby maintaining both connection stability and tolerance compensation capability simultaneously
2Reliability
If separate connection sockets for each pole are provided, then connection reliability is improved, but device complexity and assembly cost increase
Solution Approach 1:
The patent merges multiple separate connection sockets into a single integrated plug insert that accommodates multiple busbars. The insulator part with recesses and the common screw connection combine multiple connection functions into one component, reducing device complexity while maintaining reliable electrical connection for each pole through the integrated design
3Manufacturing precision
If precise alignment features are added to ensure correct insertion orientation, then assembly accuracy is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies asymmetry by providing recesses in the insulator part with specific directional orientations that only accommodate busbars in the correct insertion position. The asymmetric recess geometry and the positioned sealing lips create a unique fit that guides correct alignment without requiring additional complex alignment features, thereby achieving high insertion accuracy with minimal added complexity
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
Enables reliable and cost-effective current feedthrough through a machine housing with simple assembly, accommodating tolerance fluctuations and vibrations, ensuring secure electrical connections.
Implementation Method 1
The insulating part is preferably made of an elastic material and can have sealing lips and a collar. The insulating part must be flexible so that the plug insert can change its position in space, thus compensating for tolerance fluctuations in the rigid busbar.
Implementation Method 2
The insulating part can have sealing lips and a collar... the plug insert is allowed to move along the central axis when the screw is tightened... with the collar being designed to be elastic enough to ensure a seal against the housing in any position.
Implementation Method 3
the busbar, the power connector, and the sleeve each have a hole through which a screw can be inserted, so that the power connector, the sleeve, and the busbar can be secured to each other between the screw and the washer nut
Data Source
Figure 1~2
AI summary
The invention relates to a coupling system for producing an electric connection between two electric components. The first component is positioned in a housing and comprises at least one busbar, and the second component is arranged outside the housing and comprises at least one current connection, wherein an electrically conductive connection can be established between the busbar and the current connection by means of the coupling system, said coupling system comprising a plug insert which can be plugged into the housing. According to the invention, the plug insert comprises an insulator part, in which a sleeve and a disc nut are fixed, said insulator part having a recess which is arranged such that the busbar can be moved between the sleeve and the disc nut through the recess.