Floating Power Bus Bar Alignment for Connector Tolerance
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Solution Overview
Problem
Power supplies with increased power capacity face challenges in mating with electronic systems due to dimensional tolerance issues between power bus bars and fixed connectors, leading to difficulties in alignment and increased complexity and cost with floating connectors.
Innovation Solution
A system featuring a backplane with auxiliary and power connectors that allow the power bus bar to float along axes, enabling alignment with the electronic system while maintaining electrical contact through discrete components, thereby mitigating tolerance differences and reducing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed connectors are used on the power supply, then the connector position is stable and precise, but the power supply cannot mate with electronic systems that have power bus bars due to dimensional tolerance issues
Solution Approach 1:
The connector is designed to float along the Z-axis (vertical direction) relative to the backplane, transitioning from a fixed position to a dynamic, adjustable position. This allows the connector to automatically align with the power bus bar during mating, accommodating dimensional tolerances while maintaining precise electrical contact
2Adaptability or versatility
If floating connectors are used to enable mating over tolerance ranges, then adaptability improves, but the connector size and complexity increase
Solution Approach 1:
The connector assembly is segmented into distinct functional components: the floating mechanism (allowing Z-axis movement), the connector body, and the electrical contacts. This segmentation enables the floating function to be achieved through simple vertical translation rather than complex multi-degree-of-freedom mechanisms, reducing overall complexity
3Adaptability or versatility
If floating connectors are used to accommodate tolerance differences, then mating capability improves, but cost increases due to greater number of components
Solution Approach 1:
The floating function is extracted as a separate, dedicated mechanism (vertical translation capability) rather than being integrated into a complex multi-functional connector design. This allows the floating mechanism to be implemented using simpler, fewer components focused solely on the Z-axis movement requirement, reducing component count and manufacturing cost
Data Source
AI summary
A system includes a backplane and an auxiliary connector mounted to the backplane. The auxiliary connector is configured to mate with a corresponding mating auxiliary connector of an electrical power supply. A power connector is mounted directly to the backplane. The power connector is configured to mate with a corresponding mating power connector of the electrical power supply. A power bus bar is mounted to the backplane. The power bus bar is engaged in electrical contact with the power connector.