UPS Electrode Connector Rotation Prevention via Asymmetric Head and Slot
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing uninterruptible power supply (UPS) systems face challenges in maintaining stable electrical connections and preventing rotation or separation of electrode connectors, which can lead to power interruptions and increased manufacturing costs.
Innovation Solution
The UPS module unit incorporates a conductive terminal with a head part and body part, where the head part has a larger cross-sectional area and an angled shape to prevent rotation, and is positioned within the unit case, while the body part is inserted into the conductive terminal, with a slot to secure the connector, and a connecting member like a bolt with a washer to fix a bus bar for stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode connector is inserted into the conductive terminal without a slot, then the assembly is simple, but the electrode connector can rotate and separate leading to unstable electrical connections
Solution Approach 1:
The slot acts as an intermediary element between the electrode connector and the unit case. It provides a guiding and constraining function that prevents rotation and separation of the connector, thereby ensuring stable electrical connections without requiring complex additional components.
Solution Approach 2:
The slot introduces a dimensional constraint by providing a guided path for the electrode connector insertion. This dimensional guidance prevents rotational movement and separation, transforming an unstable connection into a stable one through spatial constraint.
2Reliability
If a complex fixing mechanism is used to prevent rotation and separation, then connection stability is improved, but manufacturing costs increase
Solution Approach 1:
The slot structure provides self-service functionality by automatically guiding and constraining the electrode connector during insertion. The geometry of the slot itself performs the fixation function without requiring additional active components or complex assembly steps, thereby reducing manufacturing costs while ensuring connection stability.
3Reliability
If the head part of the electrode connector has a larger cross-sectional area, then rotation is prevented, but the space required in the unit case increases
Solution Approach 1:
The head part of the electrode connector features an asymmetric geometry with a larger cross-sectional area in the direction that prevents rotation. This asymmetric design efficiently prevents rotational movement while minimizing the overall space required within the unit case by concentrating the dimensional increase only where needed for rotation prevention.
Data Source
AI summary
An uninterruptible power supply (UPS) module unit including a storage battery; a unit case to contain the storage battery; a conductive terminal electrically connected to the storage battery, and disposed in the unit case; and an electrode connector partly inserted from the unit case into a hole formed in the conductive terminal, and electrically connecting the conductive terminal to an external device, wherein a slot is formed in the unit case so as to correspond to the conductive terminal and the electrode connector, wherein rotation of the electrode connector is prevented and the electrode connector is not separated from the unit case.