High Current Clamping Connector for Tool-Free Power Supply Replacement
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Solution Overview
Problem
Existing power distribution systems in complex electronic equipment, such as network test units and mainframe computers, face challenges with high current electrical connectors that are bulky, require high insertion force, and cause significant voltage drops, making them unsuitable for easy tool-free replacement of power supplies.
Innovation Solution
The implementation of a power distribution system using high current clamping connectors and bus bars with toggle clamps and spring plungers that allow for secure, low-resistance electrical connections without the need for tools, enabling easy removal and replacement of power supplies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high current electrical connectors are used to conduct hundreds of Amperes between power supply and power distribution system, then current conduction capability is improved, but the connectors become bulky, have high insertion force, and cause significant voltage drop
Solution Approach 1:
The electrical connection is segmented into multiple parallel bus bar contacts instead of a single connector. Each bus bar provides a separate current path, distributing the hundreds of Amperes across multiple lower-current pathways. This reduces the size and insertion force requirements of individual connection points while maintaining overall high current conduction capability.
Solution Approach 2:
Bus bars serve as intermediary conductive elements between the power supply and power distribution system. These rigid, low-resistance bus bars with clamping connectors provide a stable electrical pathway that reduces voltage drop compared to flexible cables, while the clamping mechanism enables tool-free connection without requiring bolted joints.
2Reliability
If bolted joints with bus bars or heavy electrical cables are used to make electrical connections, then current conduction capability is improved, but tools and easy access to connections are required for maintenance
Solution Approach 1:
The clamping connectors incorporate a self-latching toggle mechanism that enables tool-free attachment and detachment. The toggle clamp design allows technicians to securely connect or disconnect power supplies by simple manual operation, eliminating the need for wrenches or other tools required by traditional bolted joints. This self-service capability significantly improves maintenance accessibility.
3Reliability
If traditional electrical connectors are used for power supply connections, then electrical connection is established, but replacement of power supply requires tools and causes downtime
Solution Approach 1:
The connection system transitions from static bolted joints to dynamic toggle clamps that can be rapidly opened and closed. The toggle mechanism provides mechanical advantage, allowing a single hand motion to securely engage or disengage the electrical connection. This dynamic connection method reduces power supply replacement time from minutes (with tools) to seconds (tool-free), minimizing system downtime while maintaining connection stability.
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 ensures reliable, low-voltage drop power delivery to blades within the chassis, facilitating tool-free replacement of power supplies and reducing the complexity of electrical connections, thereby improving the efficiency and maintainability of complex electronic systems.
Implementation Method 1
a spring plunger urging the clamped bus bar against the backplane bus bar
Implementation Method 2
The first clamp may include a toggle clamp
Data Source
AI summary
There is disclosed an apparatus including a chassis configured to accept a plurality of blades. The chassis may contain a backplane assembly may include a backplane bus bar configured to provide electrical power to the plurality of blades and a power supply configured to deliver electrical power through a power delivery bus bar. A clamp may be disposed to force the power delivery bus bar into electrical contact with the backplane bus bar.