Tap-off Element for Encased Busbar Systems
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Solution Overview
Problem
Existing busbar designs face challenges in maintaining a compact, mechanically stable, and efficient heat dissipation structure while allowing easy connection of tap-off plugs, as they require spacing between conductors for plug contacts, which compromises structural rigidity and increases manufacturing complexity.
Innovation Solution
A busbar design with conductors arranged in parallel within a metal casing, where tap-off elements are welded to the conductors, allowing for close conductor spacing and stable contact without the need for conductor spacing, using clamping members and tap-off elements with varying thicknesses to facilitate plug connection without increasing overall size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conductors are spaced apart to allow plug contact introduction, then tap-off connection is enabled, but heat dissipation efficiency deteriorates and structural rigidity is compromised
Solution Approach 1:
The tap-off element extends in the transverse direction (perpendicular to conductor length) rather than requiring longitudinal spacing between conductors. This dimensional change allows plug contacts to engage with the tap-off element without compromising conductor proximity, thus maintaining heat dissipation efficiency while enabling easy tap-off connections.
Solution Approach 2:
The tap-off element acts as an intermediary component that provides a dedicated contact point for plug connections. It is electrically connected to the conductor but physically extends outward, serving as a mediator that enables plug engagement without requiring direct access to the conductor surface, thereby maintaining structural rigidity and heat dissipation.
2Ease of operation
If conductor spacing is increased for plug engagement, then tap-off connection is enabled, but structural rigidity under short-circuit forces deteriorates
Solution Approach 1:
The tap-off element projects in the transverse direction from the conductor, allowing plug contacts to engage perpendicular to the conductor axis. This eliminates the need for longitudinal spacing between conductors, maintaining close conductor spacing for structural rigidity while enabling easy plug engagement through the transverse extension.
Solution Approach 2:
The tap-off element is a distinct segmented component that separates the connection function from the conductor structure. It can be independently designed with appropriate thickness and geometry to provide mechanical strength for plug engagement while the conductor maintains its integrity and rigidity for withstanding short-circuit forces.
3Ease of operation
If conductor folding is implemented for tap-off spacing, then plug engagement is enabled, but manufacturing complexity increases
Solution Approach 1:
The tap-off element is extracted as a separate component from the conductor body. It is welded to the conductor surface and extends outward, eliminating the need for complex folding operations on the conductors themselves. This simplifies manufacturing by using standard welding processes rather than specialized folding equipment and operations.
Solution Approach 2:
The tap-off element's thickness is designed to vary along its length, with greater thickness at the base for strong welding and mechanical support, and reduced thickness toward the end for easier plug contact engagement. This gradual parameter change optimizes both manufacturing ease and functional performance without requiring complex folding.
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 design enables efficient heat dissipation and structural robustness while maintaining a compact form, allowing for easy tap-off plug connections without the need for complex folding operations, enhancing both electrical and mechanical stability.
Implementation Method 1
The tap-off element is welded to its respective busbar conductor in a stable manner
Data Source
Figure 1~2
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AI summary
The present invention relates to a busbar (1) which comprises a casing (2), a tap-off opening (8), a plurality of busbar conductors (10, 11, 12, 13, 14) and a plurality of tap- off elements (30, 31, 32, 33, 34). Each tap-off element is stably fixed to a respective busbar conductor (10, 11, 12, 13, 14). In each busbar conductor (10), the thicknesses of the central portion (10a) and of an edge portion (10b, 10c), have values s1 and s2 respectively, s2 being less than s1, and each tap-off element (30) is stably fixed to a respective busbar conductor (10) at a contact surface (16) of the edge portion (10b, 10c) having a thickness s2.