Floating Bus Bar Connector for Blind Plug Alignment
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Solution Overview
Problem
Conventional bus bar assemblies face issues with manual assembly errors, stress, and misalignment due to gaps and tolerances between output terminals and connection terminals, leading to potential damage and assembly failures.
Innovation Solution
A bus bar assembly with a floating connector that allows for slidably and blindly plugged connections using modular structures and conductors with protrusions to secure and align terminals, reducing manual assembly errors and stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the gap between output terminals is adjusted to fit connection terminals, then the assembly can be performed, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The floating connector allows the gap between output terminals to be dynamically adjusted within a range, enabling the assembly to adapt to different connection terminal positions without complex pre-adjustment procedures. The connector transitions from a fixed gap design to a dynamic range design.
Solution Approach 2:
The patent changes the gap parameter from a fixed value to a variable range. The floating connector is designed with a gap that can vary within specific limits, allowing it to accommodate different connection terminal positions and tolerances without requiring precise pre-adjustment.
2Ease of operation
If the gap between output terminals is made larger to accommodate assembly tolerances, then assembly becomes easier, but extreme stress is caused in the output terminals
Solution Approach 1:
The floating connector design incorporates a pre-designed gap range that acts as a cushion for assembly tolerances. This predetermined flexibility absorbs the stress that would otherwise be transmitted to the output terminals, protecting them from extreme stress while facilitating easier assembly.
Solution Approach 2:
The floating connector serves as an intermediary element between the rigid bus bar assembly and the connection terminals. It mediates the connection by absorbing dimensional variations and stress, preventing direct transmission of extreme stress to the output terminals while enabling successful assembly.
3Reliability
If bolts are used to fix the bus bar assembly, then secure connection is achieved, but manual assembly errors and misalignment occur
Solution Approach 1:
The floating connector enables self-aligning connection between the bus bar assembly and connection terminals. The design allows the components to automatically find their correct positions through the controlled gap range, eliminating the need for manual alignment and reducing assembly errors while maintaining secure connection.
4Volume of moving object
If the gap between output terminals is made smaller for compact design, then space is saved, but assembly becomes difficult or impossible
Solution Approach 1:
The floating connector transforms the static gap into a dynamic range. The gap is designed to be small for compactness but can expand within a controlled range during assembly to accommodate connection terminals, thus achieving both compact design and ease of assembly.
Data Source
AI summary
The present disclosure provides a bus bar assembly and a floating connector thereof. The bus bar assembly includes a linking bus bar and a floating connector. The floating connector is configured to transmit electric power received by the linking bus bar to a rack bus bar. The linking bus bar includes an output terminal. The rack bus bar includes a connection terminal. The floating connector includes a connection module. The connection module includes a bus bar adapter and a rack adapter. The output terminal of the linking bus bar is slidably and blindly plugged into the bus bar adapter of the connection module. The rack adapter is configured for allowing the connection terminal of the rack bus bar to be slidably and blindly plugged therein.