Modular Expansion Connector for Long-Span Conductor Rail Joints
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Solution Overview
Problem
Existing expansion connectors for conductor rails struggle with assembly complexity, require additional cable connections, and fail to provide secure, uninterrupted electrical connections while accommodating significant longitudinal expansion due to temperature fluctuations.
Innovation Solution
An expansion connector with intermediate parts and stop connections that allow for secure, compact assembly, enabling continuous electrical contact and accommodating large expansion gaps by dividing them into shorter segments, using plug connections and stop elements to maintain guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a conventional expansion connector with single socket and plug parts is used, then the assembly is simple, but it can only bridge relatively short distances between conductor rail ends and requires additional cable connections for longer distances
Solution Approach 1:
The expansion connector is divided into multiple modular components: a socket part with connecting opening, a plug part with connecting plug, and one or more intermediate parts that can be inserted between them. This segmentation allows the connector to bridge longer distances by adding intermediate parts without significantly increasing overall complexity, as each module follows the same design pattern.
Solution Approach 2:
The intermediate parts serve multiple functions: they extend the bridging distance, provide additional electrical connections through their own connecting openings and plugs, and maintain the structural integrity of the expansion joint. This multi-functionality allows a single component design to address multiple requirements.
2Adaptability or versatility
If larger expansion gaps are accommodated, then temperature fluctuation compensation is improved, but the contact area between conductor rail contact and busbar becomes too short
Solution Approach 1:
By dividing the expansion gap into multiple smaller segments separated by intermediate parts, each segment maintains adequate contact area between the conductor rail contact and busbar. The intermediate parts act as intermediate contact points, ensuring that no single contact area becomes too small even when accommodating large total expansion gaps.
Solution Approach 2:
The intermediate parts serve as intermediary elements between the socket part and plug part, providing additional contact surfaces and electrical connection points. These intermediaries ensure continuous electrical connection while allowing the overall expansion gap to be larger than what a single connector could accommodate.
3Length of stationary object
If additional intermediate parts are added to bridge larger expansion gaps, then the distance bridging capability is improved, but the device complexity increases
Solution Approach 1:
The use of standardized intermediate parts that can be added in series allows the expansion gap span to be increased in modular increments. While the number of components increases, the modular design keeps assembly and maintenance relatively simple, as each intermediate part follows the same connection interface.
Solution Approach 2:
The intermediate parts are designed to be integrated into the same connector assembly, merging multiple functional elements (electrical connections, mechanical support, expansion accommodation) into a unified structure that reduces overall system complexity compared to using separate components.
Data Source
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AI summary
The invention relates to an expansion connector (4; 29) for connecting a first conductor rail profile (2) of a conductor rail (1) to a second conductor rail profile of the conductor rail (1) adjoining it in a longitudinal direction (L) of the conductor rail (1), with a first connecting part (5) for connecting to the first conductor rail profile (2) and a second connecting part (7) for connecting to the second conductor rail profile.The invention solves the problem of providing an expansion joint that is easy and quick to assemble, as compact as possible, and provides a secure electrical connection between two successive busbars, in particular without additional cable or conductor connections, and allows for the greatest possible longitudinal compensation of the busbars with largely uninterrupted guidance of the conductor rail contact of a current collector moving along the busbar, by means of an expansion joint in which at least one intermediate part (6; 30) is provided in the longitudinal direction (L) between the first connection part (5) and the second connection part (7) and connects the connection parts (5, 7) electrically and/or mechanically in such a way that a first maximum expansion gap (D1) and a second maximum expansion gap (D2) can be set between the intermediate part (6; 30) and the first connection part (5) and between the intermediate part (6; 30) and the second connection part (7).