Expandable Conductor Connection for Busbar Tolerance Compensation
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Solution Overview
Problem
In high-voltage applications, such as electric vehicles, connecting rigid electrical conductors like busbars poses challenges due to varying tolerances in spatial position and orientation, requiring a connection system that can compensate for these differences while ensuring easy assembly and robustness to maintain high current transmission with low impedance.
Innovation Solution
An electrical connection arrangement featuring a connecting element with a pressing section for radial or lateral contacting and a contact section for non-positive connection, allowing for axial and radial expansion to accommodate varying distances, combined with fastening means for secure mechanical and electrical linkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid electrical conductors are connected using conventional connection methods, then mechanical strength and electrical conductivity can be ensured, but the connection becomes sensitive to tolerances in spatial position and orientation between conductors
Solution Approach 1:
The pressing section is designed to be expandable in the radial direction, transforming a rigid connection structure into a dynamic one that can adapt to varying distances and misalignments between conductors. When the pressing section is radially expanded by the fastening means, it creates frictional contact with the inner lateral surface of the contact recess, enabling tolerance compensation while maintaining reliable electrical and mechanical connection.
2Adaptability or versatility
If the connection arrangement is designed to compensate for variable distances between conductors, then adaptability improves, but assembly complexity increases
Solution Approach 1:
The connecting element is segmented into distinct functional sections: a pressing section with lateral contact surfaces for radial expansion and frictional contact, and a contact section with a contact surface for axial contact. This segmentation allows each section to perform its specific function independently, simplifying the overall design while achieving both distance compensation and easy assembly through the combining of two fastening means.
3Strength
If a secure mechanical connection is established to withstand high mechanical loads, then connection robustness improves, but assembly difficulty increases
Solution Approach 1:
The connecting element features a connecting bore that accommodates two fastening means (first and second fastening means), allowing them to be nested within the same structural component. This nesting enables both fastening means to work together to provide secure mechanical connection and high load capacity, while maintaining ease of assembly as both fasteners can be installed through the same bore without requiring separate mounting operations.
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
This solution enables stable, low-resistance current transmission across conductors with varying tolerances, ensuring reliable connections even when conductors are not ideally aligned, while maintaining ease of assembly and robustness.
Implementation Method 1
radial or lateral expansion of the pressing section (9) in order to bring about a non-positive connection between the at least one lateral contact surface (11) and the inner circumferential surface (12)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to an electrical connection arrangement (4) for electrically and mechanically connecting a first electrical conductor (2) to a second electrical conductor (3), comprising an electrical connecting element (8) with a first end and with a second end, wherein a pressing section (9) is arranged at the first end, which has at least one lateral contact surface (11) for electrically contacting an inner sheath surface (12) of a contact recess (13) of the first electrical conductor (2), and wherein a contact section (10) is arranged at the second end, which has a contact surface (14) for force-fit connection with a side surface (15) of the second electrical conductor (3).A connecting bore (16) extends at least between the contact section (10) and the press section (9), such that the connecting element (8) is able to receive a first fastening element (17) or itself forms a first fastening element (17), and is able to receive a second fastening element (18) that can be connected to the first fastening element (17), thus establishing a force-fit connection between the contact surface (14) of the contact section (10) and the side surface (15) of the second electrical conductor (3). It is provided that the press section (9) can be radially expanded by the first fastening element (17) and/or by the second fastening element (18) to effect a force-fit connection between the at least one lateral contact surface (11) and the inner surface (12) of the contact recess (13) by connecting the two fastening elements (17, 18) to each other.