Switchgear Busbar Joint Insert for Low-Resistance Connections
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Solution Overview
Problem
Current busbar systems in switchgears face challenges in achieving low resistance connections without the need for silver-coated ends, which increases costs and complexity.
Innovation Solution
A busbar system comprising a first and second bar with an electrically conductive insert, such as a thin silver-coated copper plate, placed between the connection ends of the bars to provide a low resistance connection, eliminating the need for silver-coated bars and reducing supply chain complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silver coating is applied to busbar ends to reduce connection resistance, then connection resistance decreases, but manufacturing cost and device complexity increase
Solution Approach 1:
The busbar system is segmented into three distinct components: a first bar, a second bar, and an insert. The insert is a separate component that can be independently manufactured and supplied, allowing each component to be optimized separately. This segmentation eliminates the need for complex silver-coated busbars while maintaining low connection resistance through the dedicated insert component.
2Reliability
If silver coating is applied to busbar ends to reduce connection resistance, then connection resistance decreases, but manufacturing cost increases
Solution Approach 1:
By segmenting the system into separate bars and an insert, the expensive silver material is concentrated only in the insert where it is most needed for low resistance connection. The bars themselves can be manufactured from standard copper or aluminum without expensive silver coating, significantly reducing overall manufacturing cost while maintaining connection performance.
Solution Approach 2:
The insert acts as an intermediary component between the two bars, providing the necessary low resistance connection property. This mediator approach allows the bars to remain simple and inexpensive while the insert, containing the precious metal, performs the critical function of reducing connection resistance at the joint interface.
3Reliability
If silver coated bars are used to ensure good current carrying ability, then current carrying capability improves, but supply chain complexity and ordering errors increase
Solution Approach 1:
The system is divided into standard bars and a specialized insert. The bars can be ordered from standard inventory without special silver coating specifications, while the insert is a separate item that can be stocked and supplied independently. This segmentation simplifies supply chain management by eliminating the need for complex silver-coated bar specifications and reducing ordering errors.
Solution Approach 2:
The bars are designed to be universal components that can be used in various applications without requiring silver coating. The silver-coated insert serves as a universal solution for low resistance connections that can be applied to different bar configurations, simplifying inventory management and reducing supply chain complexity across multiple applications.
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 reduces connection resistance, lowers costs, and enhances current carrying capability while simplifying the supply chain and reducing the risk of hot spots, making the system more efficient and cost-effective.
Implementation Method 1
The insert comprises an electrically conductive material... provides for a low resistance connection... reduction in contact resistance
Implementation Method 2
A silver sheet or plate conforms very well to the two bars because of its softness, in effect deforming slightly and adjusting its position
Data Source
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AI summary
The present invention relates to a busbar system for a switchgear, the busbar system comprising: - a first bar; - a second bar; and - an insert; wherein the first bar comprises a connection end; wherein the second bar comprises a connection end; wherein the insert comprises an electrically conductive material; wherein the connection end of the first bar is connected to the connection end of the second bar, wherein the insert is between the connection end of the first bar and the connection end of the second bar.