Lever-Based Electrical Connector for Power Busbar
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connector systems for power distribution systems are cumbersome and time-consuming to install, and limited to specific locations on the power busbar, making them inflexible for easy and reliable low-resistance connections.
Innovation Solution
A lever-based electrical connector design with a base, conductors, and a biasing member that allows for pivotable engagement and disengagement with a power busbar, enabling flexible and reliable low-resistance connections at any location along the busbar, using a hinge and biasing mechanism to ensure consistent contact force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolting methods are used to fasten connectors to the power busbar, then high contact force and low resistance interface are achieved, but installation becomes cumbersome and time-consuming
Solution Approach 1:
The connector employs a lever arm that can rotate between engaged and disengaged positions, transforming the static bolted connection into a dynamic mechanism. The lever arm rotates about a pivot axis to engage with the busbar, providing high contact force during operation while allowing quick engagement and disengagement without tools.
Solution Approach 2:
The biasing member automatically applies force to maintain the lever arm in the engaged position, ensuring consistent contact force without requiring external fastening devices. The mechanism self-regulates to maintain optimal electrical contact through the biased lever arm pressing against the busbar.
2Reliability
If bolting methods are used to fasten connectors to the power busbar, then high contact force is achieved, but installation time increases
Solution Approach 1:
The lever arm rotation mechanism enables rapid engagement by simply rotating the lever arm into position, eliminating the time-consuming process of aligning and fastening bolts. The disengagement is equally rapid, allowing for quick maintenance and reconfiguration.
Solution Approach 2:
The biasing member automatically maintains engagement force, eliminating the need for operators to manually adjust or tighten connections during installation. The self-biasing mechanism ensures consistent contact force is achieved immediately upon engagement without additional time for adjustment.
3Reliability
If bolting methods are used to fasten connectors to the power busbar, then high contact force is achieved, but connection locations are limited to predetermined positions
Solution Approach 1:
The lever arm connector is designed to engage with the busbar at any position along its length, making the connection device universal. The opening in the lever arm can accommodate the busbar regardless of location, and the arcuate contact portions can establish electrical contact at various positions, providing versatility that bolted connections with fixed hole patterns cannot achieve.
Solution Approach 2:
The rotatable lever arm can be positioned and engaged at different locations along the busbar, allowing the connector to adapt to various installation positions. The pivot axis rotation enables the connector to accommodate different busbar positions and orientations, providing flexibility in installation locations.
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 solution provides easy, flexible, and reliable low-resistance electrical connections to power busbars, reducing installation time and increasing connectivity options while maintaining low resistance and high contact force, thus improving the efficiency of power distribution systems.
Implementation Method 1
A biasing member is operatively connected between the base and the lever arm, the biasing member being configured for biasing the lever arm in an engagement direction towards the engaged position
Implementation Method 2
A hinge pivotally attaches between the base and the lever arm at a pivot axis for rotation of the lever arm about the pivot axis between an engaged position for electrical coupling of the at least two conductors with the power busbar and a disengaged position for electrical decoupling of the at least two conductors from the power busbar
Data Source
AI summary
An electrical connector includes a base disposed along a central axis having a base terminal end and a base contact end. A lever arm is disposed along the central axis and has a biasing end and a lever arm contact end. At least two conductors are interposed between the base and the lever arm, and include contact ends opposite each other separated by an opening configured to receive a power busbar. The conductors have terminal ends opposite each other and separated by a slot configured to receive an electrical component. A hinge pivotally attaches between the base and the lever arm at a pivot axis for rotation of the lever arm about the pivot axis between an engaged position for electrical coupling of the at least two conductors with the power busbar and a disengaged position for electrical decoupling of the at least two conductors from the power busbar.