Movable Spacer Frame for Busbar Thermal Expansion Compensation
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Solution Overview
Problem
Existing busbar systems face issues due to differing coefficients of expansion between the housing and busbars, leading to potential tension and misalignment, which can affect electrical connectivity and thermal expansion.
Innovation Solution
A spacer frame with a U-shaped cross-sectional contour, featuring through-openings and support elements that can move within the housing to accommodate thermal expansion, is designed to maintain busbar spacing and stability while allowing for cooling airflow, with ends of tensioning elements fastened to the frame and support elements on the outer contour capable of moving to compensate for expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid spacers are used to hold busbars in housing, then busbar positioning is stable, but thermal expansion differences cause tension and misalignment
Solution Approach 1:
The spacer design incorporates movable support elements that can shift position along the busbar length. This dynamic capability allows the spacer to accommodate thermal expansion and contraction of the busbars without creating tension or misalignment, while maintaining stable positioning during normal operation
Solution Approach 2:
The spacer utilizes changes in the positional parameter of its support elements to adapt to thermal expansion. The support elements are designed to move within specific ranges, changing their position along the busbar to compensate for dimensional changes caused by temperature variations
2Reliability
If fixed spacers are used to maintain busbar distance from housing, then insulation is ensured, but thermal expansion causes tension in the busbars
Solution Approach 1:
The support elements are designed with movable connections to the busbars, allowing them to shift position as the busbars expand or contract thermally. This dynamic adjustment maintains the required insulation distance while preventing tension buildup in the busbars
Solution Approach 2:
The movable support elements act as intermediaries between the fixed housing and the expanding busbars. They transmit the insulation function while absorbing the thermal expansion through their own movement, preventing direct transmission of expansion forces to the busbar structure
3Device complexity
If simple insulation elements are used for spacing, then device complexity is reduced, but thermal expansion compensation is insufficient
Solution Approach 1:
The spacer is segmented into a frame structure with multiple independent support elements. Each support element can move independently to compensate for thermal expansion, providing enhanced reliability without requiring a completely complex overall structure
Solution Approach 2:
The support elements incorporate movable joints or sliding mechanisms that enable thermal expansion compensation. This dynamic feature is integrated into an otherwise simple frame structure, achieving reliable thermal compensation with minimal added complexity
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
This solution ensures that the busbars are held securely without tension, allowing for efficient electrical connectivity and improved cooling through airflow, while accommodating thermal expansion without misalignment, thus enhancing the stability and performance of the busbar system.
Implementation Method 1
the different coefficients of expansion of the housing and busbars do not lead to any tension
Data Source
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AI summary
The invention relates to a spacer means (6a) for busbars (3) which are arranged in a housing (2) of a module (1) of a busbar system, which busbars each run parallel in relation to one another, are spaced apart with the aid of electrically insulating spacer elements (10), are held together with the aid of clamping elements (5b) which run transversely through the busbars (3) and the spacer elements (10), and the busbar ends (3a, 3b) of which busbars project, at the end, out of the housing (2), wherein a plurality of modules (1) of the busbar system are each arranged one behind the other in the longitudinal direction and are electrically connected to one another. The technically simple spacer means proposed is a frame (6) which is arranged transversely in relation to the longitudinal extent in the housing (2) and in which a passage opening (9) is formed, the busbars (3) running through said passage opening and leaving a space (A, B, C), wherein the ends of the clamping element (5b) are fastened to the frame (6) on both sides of the passage opening (9), and having a supporting element (22) which is arranged on the outer contour of the frame (6) and, when it makes contact with the immediately opposite inner face of the housing (2), can be moved in the direction of the longitudinal extent in the housing (2). The invention further relates to a corresponding module (1) and to a corresponding busbar system.