Mounting Rail Busbar Layout for Flexible Luminaire Connections
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Solution Overview
Problem
Existing mounting rails for lights and electrical units lack flexibility in connection options and have complex structures, limiting the ability to easily connect various components and maintain a simple design.
Innovation Solution
A mounting rail with a U-shaped profile featuring two side busbars and an additional busbar on the connecting wall, where the lines of the additional busbar are accessible from outside, allowing for increased flexibility in component connection and simplified access through a common insulating line holder profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two busbars are arranged on the side walls of the support rail, then power supply is achieved, but connection flexibility is limited
Solution Approach 1:
The support rail is segmented into multiple functional zones: side wall busbars for power supply and a connecting wall busbar for signal/control connections. This segmentation allows different types of electrical units to be connected at different locations according to their specific needs, enhancing connection flexibility without requiring a complete redesign of the entire rail structure.
Solution Approach 2:
The patent transitions from a two-dimensional arrangement (busbars only on side walls) to a three-dimensional configuration by adding a busbar on the connecting wall. This spatial expansion provides multiple access directions (from below and from the top/side), enabling electrical units to connect from different orientations and positions, thereby significantly improving connection versatility.
2Ease of manufacture
If cable support profiles with separate receptacles are used, then cable organization is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the cable support function and the insulating structure into a single integrated cable support profile. The profile includes built-in grooves and receptacles that simultaneously provide mechanical support, cable routing guidance, and electrical insulation. This consolidation eliminates the need for separate cable management components, simplifying manufacturing while maintaining organized cable arrangement.
Solution Approach 2:
The cable support profile is designed as a multi-functional component that performs multiple tasks: it supports the busbar mechanically, provides grooves for cable routing, offers receptacles for connector insertion, and ensures electrical insulation between conductive parts. This universal design reduces the total number of components needed and simplifies the manufacturing process.
Data Source
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AI summary
The invention relates to a mounting rail (1) for luminaires (100, 150) or electric units, having a mounting rail profile (2) with two lateral walls (4) and a connecting wall (5) which connects the lateral walls (4) to each other, said walls together enclosing an elongated receiving chamber (3), and having at least one busbar (10, 20) which is arranged on one of the two inner faces of the lateral walls (4) of the mounting rail profile (2) and which comprises contactable lines (15, 25). According to the invention, an additional busbar (30) with contactable lines (35) is arranged on the connecting wall (5) of the mounting rail profile (2).