Plug Insert Busbar Coupling for Vibration-Tolerant Power Feedthrough
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coupling systems for electric connections in motor vehicles fail to withstand long-term loads and vibrations due to high power transmission, leading to unreliable and costly assembly.
Innovation Solution
A coupling system with a plug insert comprising an insulator part, a sleeve, and a washer nut, allowing for flexible assembly and compensation of manufacturing tolerances through elastic materials and anti-rotation features, ensuring reliable and cost-effective current feedthrough.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid connection parts are used to ensure stable electrical contact, then electrical connection reliability is improved, but the ability to compensate for manufacturing tolerances and vibrations deteriorates
Solution Approach 1:
The patent employs flexible connection parts including a flexible printed circuit board (FPC) and elastic contact elements that can deform to accommodate manufacturing tolerances and vibrations while maintaining reliable electrical contact. The FPC acts as a flexible shell that absorbs dimensional variations, and elastic contacts provide continuous pressure compensation for vibration resistance.
Solution Approach 2:
The patent utilizes parameter changes through elastic materials with specific hardness values (Shore A 40-70) and controlled deformation characteristics. The elastic contact elements are designed with specific elasticity parameters to compensate for tolerance fluctuations dynamically, changing their physical state under different operational conditions to maintain stable electrical connection.
2Reliability
If complex coupling systems are used to withstand high power transmission and vibrations, then long-term reliability is improved, but assembly complexity and cost increase
Solution Approach 1:
The patent merges multiple functions into integrated components: the FPC combines electrical connection, mechanical flexibility, and vibration damping; the housing integrates mounting structures and sealing; the elastic contacts combine electrical conduction with mechanical tolerance compensation. This functional integration reduces the number of separate components and simplifies assembly while maintaining reliability under high power and vibration conditions.
3Manufacturing precision
If precise manufacturing tolerances are enforced to ensure connection accuracy, then connection precision is improved, but manufacturing cost and difficulty increase
Solution Approach 1:
The patent incorporates beforehand cushioning through elastic contact elements and flexible circuit boards that are pre-designed to compensate for expected manufacturing tolerances. These components are manufactured with controlled elasticity parameters that automatically absorb dimensional variations, eliminating the need for tight tolerance enforcement while ensuring accurate electrical connections.
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
Enables reliable and cost-effective assembly of electric connections, compensating for manufacturing tolerances and vibrations, ensuring consistent current transmission.
Implementation Method 1
the insulator part is made of an elastic material and can have sealing lips and a collar. The insulator part must be flexible so that the plug insert can change its position in space so that tolerance fluctuations of the rigid busbar can be compensated.
Implementation Method 2
the busbar, the current connection and the sleeve each have a bore through which a screw can be inserted, so that the current connection, the sleeve and the busbar can be fixed to relative to one another between the screw and the washer nut.
Data Source
AI summary
A coupling system establishes an electric connection between two electric components. The first component is positioned in a housing and includes at least one busbar, and the second component is disposed outside the housing and includes at least one current connection. An electrically conductive connection can be established between the busbar and the current connection by the coupling system. The coupling system includes a plug insert which can be plugged into the housing. The plug insert includes an insulator part, in which a sleeve and a washer nut are fixed. The insulator part has a recess which is formed in such a way that the busbar can be moved between the sleeve and the disc nut through the recess. A plug insert for a coupling system is also provided.