Molded Busway Connector Assembly With Fewer Electrical Interfaces
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Solution Overview
Problem
Existing electrical busway connector assemblies are complex to manufacture and install, and they pose a higher risk of electrical faults due to multiple interfaces and the need for customized insulation materials.
Innovation Solution
The electrical busway system features a connector assembly composed of molded connector subassemblies with conducting and insulating portions, which are simpler to produce and install, and reduce the risk of electrical faults by minimizing interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple conductor plates and insulation plates are compressed by a central bolt, then electrical connection is achieved, but the number of electrical interfaces increases and the risk of insulation failure increases
Solution Approach 1:
The patent combines multiple separate conductor plates and insulation plates into a single molded connector assembly. The connector is formed as one integrated piece with conducting portions and insulating portions molded together, eliminating the need for multiple separate components and their associated interfaces. This merging reduces the number of electrical interfaces from multiple plate-to-plate contacts to a single integrated connector-busbar interface, thereby improving insulation reliability.
2Ease of operation
If connector assemblies are manually installed and bolted, then connection is achieved, but installation time and labor increase
Solution Approach 1:
The connector assembly is pre-assembled and molded as a complete unit before installation. The conducting portions, insulating portions, and clamp assembly are all prepared and integrated in advance during manufacturing. During installation, the entire pre-assembled connector is simply positioned between the busbars and secured, eliminating the need for on-site assembly of multiple components and manual tightening of multiple bolts. This preliminary action significantly reduces installation time and labor requirements.
3Adaptability or versatility
If customized insulation materials are used for different environments, then environmental adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The molded connector assembly is designed with universal applicability across different environments. The insulating portions are molded with properties that provide adequate insulation for various operating conditions without requiring customization. The same basic connector design and molding process can be used for different environments, eliminating the need to create and manufacture different insulation materials for different applications. This universality maintains environmental adaptability while greatly simplifying manufacturing.
Data Source
AI summary
An electrical busway system including one or more busbar assemblies and one or more connector assemblies. Each busbar assembly includes a plurality of busbars. Each connector assembly includes a plurality of connector subassemblies fitted together within a clamp assembly. Each connector subassembly includes a conducting portion, an insulating portion surrounding an exterior of the conducting portion, and a channel proximate an interior of the conducting portion, the channel being configured to receive one of the plurality of busbars.