Threaded Cable Terminal Assembly for Faster Busbar Connection
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Solution Overview
Problem
Conventional terminal assemblies for connecting cables to busbars are time-consuming, require significant human effort, and are dependent on the expertise of assembly personnel, especially when dealing with thick cables that are difficult to manipulate and route.
Innovation Solution
A terminal assembly comprising a tubular body with a recess for receiving the cable end and a fastener with external threads for secure attachment to a busbar, allowing for easy rotation and orientation of the cable without specialized tools, thereby simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional terminal assembly with multiple mating parts is used to connect thick cables, then electrical connection is established, but assembly time increases and human effort is required
Solution Approach 1:
The patent combines multiple separate components (tubular body, fastener, coupling member) into an integrated terminal assembly that connects to the busbar as a single unit. The tubular body receives the cable, the fastener threads through the busbar, and the coupling member secures both together, eliminating the need for multiple separate assembly steps and reducing overall assembly time while maintaining reliable electrical connection.
Solution Approach 2:
The terminal assembly is divided into distinct functional segments: the tubular body for cable reception and electrical contact, the fastener for mechanical attachment to the busbar, and the coupling member for securing the assembly. This segmentation allows each component to be optimized for its specific function while simplifying the overall assembly process compared to conventional multi-part systems.
2Reliability
If thick cables are manipulated to connect with conventional terminal blocks, then connection is established, but difficulty in manipulation increases
Solution Approach 1:
The tubular body is designed with a curved or angled orientation relative to the busbar connection point, creating a natural cable routing path. This curvature allows thick cables to be easily fed into the tubular body without requiring sharp bends or complex manipulation, as the curved geometry guides the cable naturally into position while maintaining reliable electrical connection.
3Manufacturing precision
If specialized tools are used for cable assembly, then assembly precision is improved, but device complexity increases
Solution Approach 1:
The terminal assembly is designed with self-aligning features where the tubular body, fastener, and coupling member automatically position themselves during installation. The threaded fastener and coupling member create natural alignment points that guide the assembly process without requiring specialized alignment tools, while still achieving precise electrical and mechanical connections through the inherent geometry of the components.
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
The terminal assembly significantly reduces assembly time, eliminates the need for specialized tools, and provides a reliable, high-performance electrical connection with fewer electrical interfaces, making it cost-effective and easy to handle.
Implementation Method 1
The coupling member defining a plurality of internal threads that engage with the plurality of external threads on the second portion of the fastener to releasably secure the tubular body and the fastener with the busbar
Data Source
AI summary
A terminal assembly for connecting a cable to a busbar includes a tubular body having a tubular portion disposed about a central axis and an annular end-wall. The tubular body defines an elongate recess configured to receive a free end of the cable therein. The terminal assembly also includes a fastener protruding outwardly from the annular end-wall. The fastener includes a first portion configured to be received within the tubular body and a second portion having a plurality of external threads thereon. The terminal assembly further includes a coupling member configured to couple the fastener with the busbar upon receipt of the second portion of the fastener within an opening in the busbar. The coupling member defining a plurality of internal threads that engage with the plurality of external threads on the second portion of the fastener to releasably secure the tubular body and the fastener with the busbar.