Pivotable Insulator with Ratchet Busbar Retention
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Solution Overview
Problem
Existing insulators for pivotable electrical connections between busbars and cables are prone to disconnection, restrict cable movement, are complex to install, and have a high risk of foreign object damage (FOD), as they often require multiple parts and can be difficult to secure properly.
Innovation Solution
A simplified insulator design with a rotatable structure that includes a bottom and wall with an opening for the busbar, engagement portions, and a ratchet system with a clip to secure the busbar, allowing for adjustable orientation and reduced parts, thereby preventing separation and FOD.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulator has a structure that prevents cable movement, then connection stability is improved, but the cable cannot move to find its natural position, causing tension and potential damage
Solution Approach 1:
The insulator incorporates a pivotable connection mechanism that allows dynamic movement. The busbar can rotate or pivot within the insulator structure around a fixed axis, enabling the cable to find its natural position while maintaining secure electrical connection. This dynamic capability prevents cable tension and damage.
2Adaptability or versatility
If the insulator is comprised of many parts, then functionality is improved, but installation time increases and difficulty increases
Solution Approach 1:
Multiple functions are merged into a single integrated insulator structure. The insulator combines protection, busbar retention, pivotability, and cable guidance functions in one component, eliminating the need for multiple separate parts and reducing installation time.
Solution Approach 2:
The insulator is designed as a multi-functional component that simultaneously provides electrical insulation, mechanical retention of the busbar, pivotable connection capability, and cable positioning guidance, replacing what would traditionally require multiple separate components.
3Adaptability or versatility
If the insulator has a complex structure with many parts, then functionality is improved, but the risk of foreign object damage (FOD) increases due to loose screws and multiple components
Solution Approach 1:
The insulator integrates multiple functions into one solid structure, eliminating separate screws, clips, and retention elements that could loosen and cause FOD. The unified structure has fewer potential failure points and loose components.
Solution Approach 2:
The design removes unnecessary separate components and fastening elements (screws, clips) from the structure, retaining only the essential functional elements integrated into the insulator body, thereby reducing FOD risk from loose parts.
Data Source
AI summary
The application relates to an insulator (30) for an electrical connection (110) pivotable between a busbar (12) and at least one lug of a cable (25), the insulator (30) being suitable for being secured so as to be rotatably movable relative to the busbar (12). The insulator (30) includes a bottom (31), a wall (32) and an opening (33) near to said bottom for receiving a portion of the busbar (12). It is suitable for enabling the insertion of one side of said portion, and comprises the insertion portions suitable for preventing the insulator (30) from being separated from the busbar (12), and comprises a pivot structure suitable for being aligned with a pivot structure of the busbar (12) when the insulator (30) and the busbar (12) are inserted together. The insulator (30) is also suitable for connections where two cables (25) are connected to the busbar (12).