Flexible Busbar Connectors for Conductor Spacing Tolerance
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Solution Overview
Problem
Existing busbar connection systems require high manufacturing accuracy due to limited tolerance in conductor spacing, leading to increased production costs and complexity.
Innovation Solution
A busbar connection system with flexible connectors that include contact members and urging members capable of compensating for deviations in conductor spacing, allowing for reliable electrical connections with reduced manufacturing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard busbar systems with rigid connectors are used, then manufacturing precision can be maintained within tight tolerances (0.1-0.15mm), but manufacturing costs increase due to high accuracy requirements
Solution Approach 1:
The patent changes the physical state and mechanical properties of the connector components by introducing flexibility to the contact member and urging member. This allows the system to accommodate parameter variations (conductor spacing deviations up to 1mm or more) without requiring high manufacturing precision, thereby reducing manufacturing costs while maintaining reliable electrical connections
Solution Approach 2:
The patent transforms the rigid, static connector structure into a dynamic system where the contact member and urging member can move and adjust their positions. This dynamic capability enables the connector to adapt to varying conductor spacing, eliminating the need for tight manufacturing tolerances and reducing production costs
2Ease of manufacture
If conductors are manufactured with larger tolerances (more than 1mm variation), then manufacturing costs decrease, but reliable electrical connections cannot be ensured with standard busbar systems
Solution Approach 1:
The patent modifies the mechanical parameters of the connector by introducing flexible elements that can accommodate parameter variations in conductor spacing. The flexible contact member and urging member maintain reliable electrical contact despite deviations in conductor position, ensuring connection reliability even when conductors are manufactured with larger tolerances
Solution Approach 2:
The patent incorporates a pre-designed flexible mechanism in the connector that anticipates and compensates for potential conductor spacing variations. The flexible urging member acts as a cushioning element that absorbs dimensional deviations, ensuring reliable electrical connections are maintained despite manufacturing tolerances in the conductors
3Reliability
If high manufacturing accuracy is required for conductors and connectors, then reliable electrical connections are ensured, but device complexity and production time increase
Solution Approach 1:
The patent changes the mechanical characteristics of the connector components from rigid to flexible, which simplifies the assembly process. The flexible contact member and urging member automatically adapt to conductor positioning variations, eliminating the need for complex alignment procedures and reducing assembly complexity while maintaining reliable electrical 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 cost-effective production and assembly of electrical power distribution systems by accommodating larger tolerances in conductor spacing, ensuring reliable electrical connections even in worst-case scenarios.
Implementation Method 1
The contact member and the urging member of at least one of the connectors are flexible in a direction transverse to a mating direction of the conductors to permit compensating for a deviation of the distance between the conductors from a predetermined distance
Data Source
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AI summary
The invention is related to a busbar connection system comprising at least two pluggable connectors (4) spaced apart from each other in order to respectively accommodate at least one of a least two of conductors (6) which are spaced apart from each other in a certain distance. Each of the connectors (4) comprises at least one contact member (8) for contacting the respective conductor (6) and at least one urging member configured to clasp the contact member for providing contact force between the contact member (8) and the conductor (6). The contact member (8) and the urging member (10) of at least one of the connectors (4) are flexible in a direction transverse to an mating direction of the conductors (6) to permit compensating for a deviation of the distance (D1) between the conductors (6) from a predetermined distance (Do).