U-Shaped Electrical Connector Lateral Tolerance Compensation
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Solution Overview
Problem
Existing connection devices for electrical devices and distribution bars face alignment issues due to manufacturing variations, making it difficult to connect the devices securely.
Innovation Solution
The connection device features U-shaped connectors with lateral travel capabilities, allowing for compensation of manufacturing tolerances and alignment discrepancies, while maintaining simplicity and avoiding significant size or complexity increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid connectors are used in the connection device, then manufacturing precision can be maintained, but alignment difficulties occur due to manufacturing variations
Solution Approach 1:
The connector is designed with a flexible intermediate portion that allows dynamic adjustment during connection. This flexible section enables the connector to adapt its position laterally, compensating for manufacturing variations and alignment discrepancies between the electrical device and distribution bar, while rigid portions maintain manufacturing precision where needed.
2Reliability
If alignment tolerance compensation is added to the connection device, then connection reliability improves, but device complexity increases
Solution Approach 1:
The connector structure incorporates a flexible intermediate portion that changes its physical state from rigid to flexible in the critical alignment zone. This allows the connector to absorb misalignment through elastic deformation, improving connection reliability without adding complex adjustment mechanisms or multiple components.
3Ease of manufacture
If the connector structure is simplified to reduce manufacturing complexity, then manufacturing cost decreases, but alignment compensation capability is reduced
Solution Approach 1:
The connector is segmented into distinct rigid and flexible portions. The rigid portions can be manufactured with standard precision using conventional processes, while the flexible intermediate portion is designed with specific geometric features that provide the necessary compliance. This segmentation allows each part to be optimized independently for its function.
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
Facilitates easy insertion and secure connection of electrical devices to distribution bars, even with poorly aligned connectors, ensuring reliable electrical and mechanical connections without increasing manufacturing complexity or costs.
Implementation Method 1
each electrical connector has, at a first end, a first connection lug configured to cooperate with a connection terminal of the electrical device and, at a second end, a second connection lug configured to cooperate with connection terminals of the distribution busbar, each electrical connector further comprising an intermediate portion which connects the first connection lug to the second connection lug, The second connecting leg of the first electrical connector is disposed on the side of a first lateral edge of the rear face of the connection device, and in that the second connecting leg of the second electrical connector is disposed on the side of a second lateral edge of the rear face of the connection device
Data Source
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AI summary
This connection device (4) for connecting an electrical device (2) to an electrical distribution busbar (6), comprising at least one electrical connector (32) and a housing (30) configured to be mechanically attached to a mounting point of a distribution busbar and to the electrical device, in which each electrical connector (32) has a first connection tab configured to cooperate with a connection terminal (12) of the device, and a second connection tab (50) configured to cooperate with a connection terminal (26) of the distribution busbar, each electrical connector (32) further comprising an intermediate portion which has an elastically deformable U-shaped bent portion open towards the second connection tab.