Elastic Connector for Misaligned Three-Phase Power Bus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electrical connector systems for high voltage and high current applications struggle with misalignment issues and the need for easy component removal and reinstallation, particularly in three-phase power systems, where existing designs fail to maintain effective connections during servicing.
Innovation Solution
A novel connector system featuring a plug assembly with conductive extensions that are biased outwardly and compressible, allowing for elastic deformation to accommodate misalignment, and a fork-shaped receptacle that contacts and compresses these extensions for secure three-phase power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard connections with bolted or screwed bus bar components are used, then current carrying capability is maintained, but misalignment between components cannot be accommodated and alignment precision is required
Solution Approach 1:
The patent changes the physical state of the conductor from rigid to flexible by using a spring-loaded resilient conductor. This allows the conductor to deform elastically and accommodate misalignment between bus bar components while maintaining reliable electrical contact and current carrying capability
Solution Approach 2:
The resilient conductor is designed to be dynamically adjustable through spring loading, allowing it to adapt its position and shape to accommodate variations in alignment between mating components. The spring mechanism provides continuous adjustment capability to maintain optimal contact under varying alignment conditions
2Adaptability or versatility
If flexible structures like conductive wire braids are used, then misalignment can be accommodated, but current carrying capability for high power applications is insufficient
Solution Approach 1:
The patent employs a composite structure combining a resilient spring mechanism with a solid conductive bus bar material. This hybrid approach provides both the flexibility needed to accommodate misalignment and the substantial current carrying capacity required for high power applications, merging advantages of both flexible and rigid conductors
3Reliability
If sizable conductors are used for high current applications, then current carrying capability is sufficient, but flexibility for removal and reinstallation is reduced
Solution Approach 1:
The spring-loaded resilient conductor can be dynamically compressed to reduce its effective size and flexibility during installation, then expands to its full resilient state during operation to maintain both high current carrying capability and accommodation of misalignment. This dynamic behavior enables easy installation and removal while maintaining performance
4Stability of the object's composition
If AC power bus components are designed for permanent installation, then connection stability is maximized, but ease of repair and replacement is reduced
Solution Approach 1:
The connector system is segmented into separable components including the resilient conductor, bus bar sections, and mounting elements. This segmentation allows the connection to be easily disassembled for repair or replacement while maintaining stable electrical contact during normal operation, combining the benefits of permanent and removable connections
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 enables reliable high voltage and high current connections while allowing for translational and angular misalignment, facilitating easy assembly and disassembly, thus improving flexibility and reliability in high-power applications.
Implementation Method 1
the conductive extensions being biased outwardly and compressible towards the support... allowing for elastic deformation to accommodate misalignment
Implementation Method 2
a generally fork-shaped conductive receptacle having opposed sides, wherein the opposed sides contact and compress the conductive extensions
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A connector system is provided for use in power applications, such as for conveying three phase power in electrical enclosures. The system comprises plug assemblies in which a power conductor is mounted in a floating arrangement with elastically deformable conductive structures extending from either side thereof. A mating receptacle may be mounted on a bus conductor. Three such arrangements may be provided for conveying three phase power. The structures allow for plug-in mating of the system components while accommodating considerable translational and angular misalignment between the connector parts.