Rounded Busbar Clamping Connection Without Screws or Flattening
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Solution Overview
Problem
Existing busbar connection methods require a large number of screws and additional electric field shielding components, and involve the time-consuming process of flattening cylindrical busbars, leading to inhomogeneity in the electric field.
Innovation Solution
A connection device with a plug-in mechanism featuring claws and a locking mechanism that reduces the number of components needed, eliminates the need for screws and electric field shielding, and simplifies the connection process by using a threaded part and a hollow frustoconical clamping mechanism to securely connect busbars with rounded end cross-sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw connection method is used to connect busbars, then the connection is reliable, but the number of components increases and the connection process becomes complex
Solution Approach 1:
The patent combines multiple functions into the connection device: the clamping structure integrates both the connection and fixation functions, while the locking mechanism combines locking and retention functions. This merging eliminates the need for separate screws and electric field shielding components, reducing component count while maintaining connection reliability through the integrated design that secures busbars directly.
Solution Approach 2:
The connection device is designed with multi-functionality: the clamping structure not only connects busbars but also provides fixation and positioning. The locking mechanism serves both to secure the connection and to maintain electric field homogeneity. This universal design allows a single device to perform multiple functions that previously required separate components.
2Reliability
If traditional screw connection method is used, then the busbars can be connected securely, but the connection process requires flattening the busbar ends which adds time
Solution Approach 1:
The busbar ends are pre-formed with rounded cross-sections during the busbar manufacturing process itself, rather than requiring flattening operations at the connection stage. This preliminary action during manufacturing eliminates the time-consuming flattening step while ensuring the busbars are ready for direct insertion into the clamping structure, maintaining secure connection without additional processing time.
3Reliability
If screws are used to connect busbars, then the connection is stable, but electric field inhomogeneity occurs near the busbar ends
Solution Approach 1:
The locking mechanism incorporates structures that maintain electric field homogeneity by providing uniform electrical contact and symmetry around the busbar ends. The design ensures that the electric field distribution remains consistent near the connection points, eliminating the inhomogeneity caused by traditional screw connections while maintaining connection stability through the locking mechanism.
Data Source
Figure 1a~1b
Figure 1c~2
Figure 3a~3b
AI summary
The present disclosure relates to a connection device for connecting a plurality of busbars with rounded end cross-sections, the connection device comprising: a plug-in mechanism with at least two cylindrical ends, wherein each end has a claw and the corresponding busbar is adapt to plug into the end; and a locking mechanism adapted to cooperate with the claw to lock the claw and the corresponding busbar. Through the connection device for connecting a plurality of busbars with rounded end cross-sections according to the present disclosure, the number of components used to connect the busbars can be significantly reduced. A large number of screws and electric field shielding parts are not required. The process of flattening the two ends of the busbars is omitted. The connection of the busbars is simplified, fast and reliable, and the work efficiency is improved.