Slotted Bus Bar for Flexible Electrical Distribution
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Solution Overview
Problem
Traditional bus bars for electrical power distribution are inflexible, requiring specific hole layouts and non-uniform current carrying capacity, leading to inefficient manufacturing and labor-intensive installation processes, as well as cumbersome attachment features that are difficult to configure for different amperage levels and enclosure arrangements.
Innovation Solution
A copper or aluminum bus bar with adjustable T-shaped slots and lugs allows for flexible positioning and attachment at any location, using insulative support members and recessed bolts for secure mounting, enabling uniform current capacity and versatile configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If holes are punched at specific predetermined positions in bus bars, then the bus bars can be mounted on supports and connected to each other, but the current carrying capacity is not uniform and metal is wasted at imperforate portions
Solution Approach 1:
The invention changes the geometric parameters of the bus bar by introducing slots instead of holes, and by varying the thickness distribution along the bus bar length. This allows the conducting cross-section to be optimized at each location, maintaining uniform current density while eliminating metal waste at imperforate portions.
Solution Approach 2:
The bus bar is designed with non-uniform thickness distribution, where the thickness varies along the length to compensate for the areas occupied by slots. This local quality adjustment ensures that each cross-section has sufficient conducting material to handle the required current, eliminating the waste of metal at portions without holes.
2Adaptability or versatility
If holes are punched at predetermined positions, then connections can be made at specific arrangements, but the position of bus bars relative to each other and supporting structure is limited to specific arrangements
Solution Approach 1:
The bus bar design with slots and adjustable thickness makes it universally adaptable to different installation configurations. The slots can accommodate connectors at various positions, and the non-uniform thickness allows for flexible mounting arrangements without requiring custom hole layouts for each application.
Solution Approach 2:
The invention introduces adjustability and flexibility to the bus bar system, allowing the position of connectors and supporting structures to be varied dynamically according to installation requirements, rather than being fixed to predetermined hole positions.
3Ease of operation
If traditional bus bars with punched holes are used, then connections can be made at specific locations, but considerable layout time and expense is involved in positioning and punching selected holes
Solution Approach 1:
The bus bar is pre-manufactured with slots and non-uniform thickness distribution, so that no field punching or custom hole layout is required during installation. The preliminary preparation of the bus bar geometry eliminates time-consuming layout and punching operations at the installation site.
4Ease of manufacture
If uniform thickness bus bars with holes are used, then manufacturing is simplified, but excess conducting cross section exists at imperforate portions resulting in inefficient metal use
Solution Approach 1:
The invention changes the thickness parameter along the bus bar length, creating a non-uniform thickness profile that compensates for the areas occupied by slots. This allows the conducting cross-section to be optimized at each location, maintaining uniform current density while eliminating metal waste.
5Adaptability or versatility
If traditional bus work is manufactured to specific length with punched holes, then electrical transmission can be provided, but the attachment features are complex, expensive, nonadjustable and difficult to configure for different amperage levels
Solution Approach 1:
The bus bar with slots and variable thickness serves multiple functions: it provides electrical conduction, mechanical support, and flexible mounting capabilities. The standardized slot design can accommodate different connector types and positions, making the bus bar universally adaptable to various amperage levels and enclosure arrangements without requiring complex custom attachment features.
Data Source
AI summary
A bus bar for electrical power distribution may be an elongated extruded metal bar having slots extending the entire length thereof. The slots may be of T-shape cross section, each with the channel opening through a face of the bar. Bolts are arranged with their heads captured in, and slidable along the length of the slots to any desired position. The bolts may have threaded stems which extend from the head through the channel of the T-slot in which its head is disposed and beyond that face of the bar through which the associated T-slot opens. Each stem is adapted to threadably receive a nut for clamping, supporting or connecting lugs to the bar. The bus bars can be mounted on insulating support members.