Insulating Busbar Mounting Structure for Low-Leakage Assembly
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Solution Overview
Problem
Existing busbar systems face challenges such as high manufacturing and logistics costs due to use of multiple materials, promotion of leakage currents, complex assembly processes, and limited adaptability in installation configurations, which affect operational safety and efficiency.
Innovation Solution
A busbar system featuring a fastening system with electrically insulating materials, including a first fastening device with a base and cover elements, and a second fastening device with a guide web and receiving space, allowing lateral insertion and secure fixation of the busbar, ensuring mechanical stability, easy assembly, and compliance with electrical requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple materials (metals, glass fiber reinforced plastic) are used in busbar system components, then functional performance is achieved, but manufacturing and logistics costs increase
Solution Approach 1:
The patent combines multiple functional components (fastening device, support device, insulator) into a single integrated fastening system made of electrically insulating material. The support device with base and support arm is manufactured as one piece, eliminating the need for separate metal fasteners and reducing the number of different materials required.
Solution Approach 2:
The fastening system is made entirely of electrically insulating material (such as glass fiber reinforced plastic), creating a homogeneous material composition. This eliminates the need for different materials (metal fasteners, glass fiber reinforced plastic insulators) and simplifies manufacturing while maintaining electrical insulation performance.
2Strength
If metal fastening components are used, then mechanical strength is achieved, but leakage currents are promoted
Solution Approach 1:
The patent converts the potential harm of metal components (leakage currents) into a benefit by using electrically insulating material for the entire fastening system. The glass fiber reinforced plastic provides both mechanical strength and electrical insulation, eliminating leakage currents while maintaining structural integrity.
3Reliability
If complex fastening systems with multiple components are used, then electrical insulation is improved, but assembly effort increases
Solution Approach 1:
The patent merges the support device and fastening elements into a single integrated component made of electrically insulating material. The one-piece construction with base and support arm eliminates the need for assembling multiple separate insulator components, reducing assembly effort while maintaining electrical insulation.
4Ease of manufacture
If fixed installation configurations are used, then manufacturing simplicity is maintained, but adaptability to different installation situations is limited
Solution Approach 1:
The patent enables adjustable installation configurations by allowing the busbar to be positioned at different locations along the support arm. The modular design with receiving grooves and positioning elements provides flexibility for vertical and horizontal adjustment while maintaining manufacturing simplicity.
Data Source
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AI summary
The invention relates to a busbar system comprising at least one busbar, at least one mounting system with a first mounting device and a second mounting device, and at least one support device, wherein the mounting system can be fixed to the support device, which receives at least one busbar, wherein the mounting device of the mounting system is made of an electrically insulating material, wherein the first mounting device has a base with two cover elements arranged opposite each other on it, which at least partially cover the support device, which is characterized in that the first mounting device has at least one positioning element projecting away from the base, that at least one guide element is arranged on the positioning element, and that the second mounting device has at least one receiving space.which is bounded on at least one longitudinal side by at least one guide rib, such that the recording space has at least one recording opening.