Description:TECHNICAL FIELD
[001] The embodiments herein generally relate to an electrical busduct system and more particularly, to a busduct connector assembly which facilitates electrical connection between two busbars of the busduct system.
BACKGROUND
[002] A busduct system, also referred to as a busway, is an enclosed electrical power distribution arrangement comprising conductive busbars, joint assemblies, and a housing. The conductive busbars, typically manufactured from copper or aluminum, serve as the primary current-carrying elements. Joint assemblies interconnect the busbars of adjacent sections, ensuring both mechanical retention and electrical continuity. The housing, generally fabricated from metallic material, encloses and protects the busbars while also serving as a grounding medium. In a typical installation, multiple busduct sections are interconnected to form a continuous power distribution path between the supply source and load points. Each section consists of a defined length of enclosed busbars, terminated at both ends with joint interfaces for connection to adjoining sections. Other functional elements, such as tap-off units, offsets, elbows, expansion joints, and support systems, may be incorporated in the overall installation.
[003] The operational reliability of a busduct system depends critically on the integrity of its joint assemblies. These joints form the conductive interface between busbars of adjacent sections and are susceptible to degradation from mechanical stress, electrical overloading, thermal expansion, or environmental ingress. Joint failure may manifest as excessive heating, arcing, or surface damage, leading to loss of electrical continuity and consequent outage of the connected power distribution path.
[004] When a busduct system fails, the damage is often localized to a single joint or section. Restoration of service requires replacing the damaged element with a compatible, site-specific component. As busduct systems are frequently custom-fabricated to the installation’s exact routing and electrical specifications, replacement parts must be specially manufactured. This process, including fabrication, delivery, and installation, generally takes a minimum of three to five days, during which the affected busduct run remains out of service. In critical environments such as multi-storey buildings, data centers, and industrial plants, such prolonged downtime can result in significant operational and financial impact.
[005] Existing emergency restoration methods for busduct systems are inadequate for the rapid reinstatement of power. Conventional temporary connections, such as improvised conductive links or external cabling, are often mechanically unstable, difficult to install, and incapable of sustaining the rated load over extended periods. They may also compromise insulation integrity, require invasive modification of the busduct housing, and fail to comply with safety regulations, thereby introducing further operational risk. These methods can require invasive modification of the housing, may not conform to safety standards, and are unsuitable for sustained use under full load conditions, thereby introducing further risks.
[006] Further, the installation environment imposes additional constraints. In many facilities, the clearance between parallel busduct runs is minimal, restricting the available space for any temporary connector assembly. This limited space poses challenges in meeting insulation requirements, maintaining mechanical robustness, and enabling safe installation without dismantling adjacent infrastructure.
[007] Therefore, there exists a need for a busduct connector assembly which obviates the aforementioned drawbacks.
OBJECTS
[008] The principal object of embodiments herein is to provide a busduct connector assembly for a busduct system that enables quick restoration of electrical power between at least two busbars of the busduct system, thereby minimizing downtime during maintenance or fault conditions.
[009] Another object of embodiments herein is to provide the busduct connector assembly that can be implemented in a wide variety of installation sites, including industrial, commercial, and utility applications, without significant alterations to existing busduct layouts.
[0010] Another object of embodiments herein is to provide the busduct connector assembly that is adaptable for use with busduct systems of different manufacturers by facilitating modification of a connection interface with a main busduct run of the busduct system, thereby enhancing cross-compatibility and flexibility in deployment.
[0011] Another object of embodiments herein is to provide the busduct connector assembly that is suitable for installation in congested spaces, including configurations where spacing between individual busbar runs is less than 150 mm, without compromising electrical clearances or operational reliability.
[0012] Another object of embodiments herein is to provide the busduct connector assembly having connecting arms and connecting members arranged to facilitate reliable mechanical engagement and optimal electrical contact, thereby reducing connection resistance and improving current-carrying capacity.
[0013] Another object of embodiments herein is to provide the busduct connector assembly that reduces the need for extensive downtime, specialized tools, or complex installation procedures, thereby improving serviceability and reducing operational costs.
[0014] Another object of embodiments herein is to provide the busduct connector assembly that maintains safe electrical clearances and phase separation even in compact configurations, thereby ensuring compliance with electrical safety standards.
[0015] These and other objects of embodiments herein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0016] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0017] Fig. 1 depicts a side view of a busduct connector assembly for a busduct system, according to embodiments as disclosed herein;
[0018] Fig. 2 depicts a top view of the busduct connector assembly, according to embodiments as disclosed herein;
[0019] Figs. 3A and 3B depict isometric views of a connector of the busduct connector assembly, according to embodiments as disclosed herein;
[0020] Fig. 4A depicts a side view of the connector, according to embodiments as disclosed herein;
[0021] Fig. 4B depicts a top view of the connector, according to embodiments as disclosed herein;
[0022] Fig. 5A depicts a front view of a connecting terminal of a connecting member of the busduct connector assembly, according to embodiments as disclosed herein; and
[0023] Fig. 5B depicts a side view of the connecting terminal of the connecting member of the busduct connector assembly, according to embodiments as disclosed herein.
DETAILED DESCRIPTION
[0024] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0025] The embodiments herein achieve a busduct connector assembly for a busduct system that enables quick restoration of electrical power between at least two busbars of the busduct system. Referring now to the drawings Figs. 1 through 5B, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0026] Figs. 1 and 2 depict a side view and a top view of a busduct connector assembly (100) for a busduct system, respectively, according to embodiments as disclosed herein. The busduct system (not shown) includes at least one busduct run having a plurality of conductive busbars (10, 20) connected in series through respective joint assemblies (not shown), wherein the plurality of conductive busbars (10, 20) and the joint assemblies are enclosed within a housing (not shown). The busduct connector assembly (100) includes at least two connectors (102, 104) configured to be electrically connected with corresponding busbars (10, 20) of the busduct system, and a plurality of connecting members (106). For the purpose of this description and ease of understanding, the busduct connector assembly (100) is explained herein with below reference to establishing an electrical connection between two nearest consecutive busbars of the busduct system. However, it is also within the scope of the invention to use/practice the components of the busduct connector assembly (100) for establishing an electrical connection between at least any two busbars of the busduct system without otherwise deterring the intended function of the busduct connector assembly (100) as can be deduced from the description and corresponding drawings.
[0027] Figs. 3A and 3B depict isometric views of the connector (102, 104) of the busduct connector assembly (100) according to embodiments as disclosed herein. Each connector (102, 104) includes a body (102A, 104A) having a first end (102AF, 104AF) and a second end (102AS, 104AS) positioned opposite to the first end (102AF, 104AF), a plurality of first connecting arms (102B, 104B) extending from the first end (102AF, 104AF) of the body (102A, 104A), and a plurality of second connecting arms (102C, 104C) extending from the second end (102AS, 104AS) of the body (102A, 104A). The plurality of first connecting arms (102B, 104B) of each connector (102, 104) are configured to mechanically and electrically engage with a corresponding busbar of at least two busbars (10, 20) of the busduct system. Further, each connecting member (106) is electrically coupled to a corresponding second connecting arm (102C, 104C) of each connector (102, 104) to provide an electrical connection between the at least two busbars (10, 20) of the busduct system.
[0028] In an embodiment, the plurality of first connecting arms (102B, 104B) are arranged in a branched configuration corresponding to an arrangement of busbar arms (10A, 20A) of the respective busbar (10, 20). Further, two adjacent first connecting arms (102B, 104B) are spaced apart by a predetermined gap (G), and the predetermined gap (G) between two adjacent first connecting arms (102B, 104B) is adjustable to facilitate alignment of each first connecting arm (102B, 104B) with its corresponding busbar arm (10A, 20A). In an embodiment, the plurality of first connecting arms (102B, 104B) include four first connecting arms, each first connecting arm being a plate member made of sheet metal, wherein the predetermined gap (G) between two adjacent first connecting arms (102B, 104B) is adjustable with a spacing tool. This adjustability improves on-site adaptability and reduces downtime during replacement or maintenance of busduct runs.
[0029] Figs. 4A and 4B depict side view and a top view of the connector (102, 104), respectively, according to embodiments as disclosed herein. In an embodiment, the plurality of second connecting arms (102C, 104C) are arranged in an offset configuration such that adjacent second connecting arms (102C, 104C) are spaced apart by a corresponding predefined pitch distance (D1, D2) (shown in Fig. 4B), and each second connecting arm (102C, 104C) is oriented at a corresponding predetermined angular offset relative to a longitudinal axis (L) (shown in Fig. 4B) of the body (102A, 104A). This arrangement of the plurality of second connecting arms (102C, 104C) with the predetermined pitch distances (D1, D2) and the orientation at the corresponding predetermined angular offset, facilitates maintaining consistent electrical clearance between adjacent second connecting arms (102C, 104C), and enables installation of the corresponding connector (102, 104) in a restricted installation space. Furthermore, in an embodiment, the plurality of second connecting arms (102C, 104C) includes four second connecting arms (102CA, 102CB, 104CA, 104CB). The four second connecting arms include two outer second connecting arms (102CA, 104CA), and two inner second connecting arms (102CB, 104CB) positioned between the two outer second connecting arms (102CA, 104CA). Each outer second connecting arm (102CA, 104CA) and each inner second connecting arm (102CB, 104CB) is formed as a plate which includes a first planar portion (102CAF, 104CAF, 102CBF, 104CBF), an angular portion (102CAA, 104CAA, 102CBA, 104CBA), and a second planar portion (102CAS, 104CAS, 102CBS, 104CBS). The first planar portion (102CAF, 104CAF, 102CBF, 104CBF) extends orthogonally from the second end (102AS, 104AS) of the body (102A, 104A) of the connector (102, 104). The angular portion (102CAA, 104CAA, 102CBA, 104CBA) extends at a corresponding predefined angle (A1, A2) from the first planar portion (102CAF, 104CAF, 102CBF, 104CBF) (shown in Fig. 4B). The second planar portion (102CAS, 104CAS, 102CBS, 104CBS) extends from the angular portion (102CAA, 104CAA, 102CBA, 104CBA) in a plane parallel to a plane of the first planar portion (102CAF, 104CAF, 102CBF, 104CBF). Moreover, each second planar portion (102CAS, 104CAS, 102CBS, 104CBS) is configured to facilitate connection of at least three connecting members (106) to enable transmission of three-phase current in the busduct system, while maintaining balanced phase spacing to minimize electromagnetic interference. As an illustrative example, the second planar portion (102CAS, 104CAS, 102CBS, 104CBS) of each second connecting arm (102C, 104C) includes a plurality of apertures (P), wherein each aperture (P) is configured to receive a fastening element (F) (shown in Fig. 1) to secure the corresponding connecting member (106) to the second connecting arm (102C, 104C). As a non-limiting example, the predefined angle (A1) between the angular portion (102CAA, 104CAA) of each outer second connecting arm (102CA, 104CA) and the first planar portion (102CAF, 104CAF) ranges from 200° to 250°, the predefined angle (A2) between the angular portion (102CBA, 104CBA) of each inner second connecting arm (102CB, 104CB) and the first planar portion (102CBF, 104CBF) ranges from 120° to 150°. Further, the predefined pitch distance (D1) between each outer second connecting arm (102CA, 104CA) and its corresponding adjacent inner second connecting arm (102CB, 104CB) ranges from 32 mm to 40 mm, and the predefined pitch distance (D2) between the two adjacent inner second connecting arms (102CB, 104CB) ranges from 90 mm to 120 mm, thereby achieving both spatial compactness and compliance with insulation clearance requirements.
[0030] In an embodiment, the plurality of first connecting arms (102B, 104B) and the plurality of second connecting arms (102C, 104C) are positioned in two spaced-apart sets (S1, S2) (shown in Fig. 4A), each set corresponding to a defined current-carrying capacity range. As an illustrative example, each set is configured to carry a current of 2000 amperes, and a voltage of 1000 V, thereby ensuring compatibility with standard industrial power distribution requirements while maintaining thermal limits within safe operating ranges.
[0031] In an embodiment, each connecting member (106) includes a conductive cable (106A), and a connecting terminal (106B) connected at each end of the conductive cable (106A) (shown in Figs. 5A and 5B). The length (L1) of the conductive cable (106A) is variable based on a distance between two busbars (10, 20) of the busduct system to accommodate different spacings between busbars (10, 20), thereby enabling the busduct connector assembly (100) to be adapted to site-specific layouts without requiring redesign. Each connecting terminal (106B) is configured to connect to the second planar portion (102CAS, 104CAS, 102CBS, 104CBS) of the corresponding second connecting arm (102C, 104C). Each connecting terminal (106B) has a hole (106H) which is configured to receive the fastening element (F) to facilitate the connection of the connecting member (106) with the corresponding second connecting arm (102C, 104C), ensuring low-resistance contact and mechanical stability during service life. In an embodiment, each connecting terminal (106B) includes a mounting portion (106BA) and a cable connecting portion (106BB) extending from the mounting portion (106BA). The mounting portion (106BA) has a flat surface with the hole (106H) defined centrally on the flat surface, wherein the flat surface of the mounting portion (106BA) provides reliable contact between the connecting terminal (106) and the corresponding second connecting arm (102C, 104C), thereby ensuring a stable electrical and mechanical connection. The cable connecting portion (106B) has a tubular profile and is configured to receive the cable to facilitate secure connection of the cable (106A) with the connecting terminal (106B). As an illustrative example, the connecting terminal (106B) is made of copper, and the cable (106A) is a non-armored cable with a thickness ranging from 25 mm to 40 mm.
[0032] Further, in an embodiment, the busduct connector assembly (100) includes at least one mounting member (108) connected to the body (102A, 104A) of each connector (102, 104). The at least one mounting member (108) is a bracket configured to enable mechanical fixation of the corresponding connector (102, 104) on a mounting surface of the busduct system. As an illustrative example, the busduct connector assembly (100) includes two mounting members (108) connected at lateral ends of the body (102A, 104A) of each connector (102, 104).
[0033] The technical advantages of the busduct connector assembly (100) for the busduct system are as follows. The busduct connector assembly (100) facilitates immediate restoration of electrical power by enabling a quick and secure connection between busbars (10, 20) thereby minimizing downtime and improving system availability. The arrangement of the plurality of first connecting arms (102B, 104B) and the plurality of second connecting arms (102C, 104C) allows installation in a wide range of site conditions, including congested layouts with inter-busduct run gaps of less than 150 mm, thus expanding applicability without requiring major structural modifications. The configuration of the connecting members (106) and connectors (102, 104) provides adaptability to busduct systems from different manufacturers through minor alterations at the connection interface of the busbars, thereby enhancing interoperability. The offset configuration of the second connecting arms (102C, 104C) ensures optimum electrical clearance and alignment, which reduces the risk of phase-to-phase faults, improves current-carrying stability, and enhances the operational reliability of the busduct system.
[0034] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein.
, Claims:We claim:
1. A busduct connector assembly (100) for a busduct system, the busduct connector assembly (100) comprising:
at least two connectors (102, 104), wherein each connector (102, 104) comprises:
a body (102A, 104A) having a first end (102AF, 104AF) and a second end (102AS, 104AS) positioned opposite to the first end (102AF, 104AF);
a plurality of first connecting arms (102B, 104B) extending from the first end (102AF, 104AF) of the body (102A, 104A); and
a plurality of second connecting arms (102C, 104C) extending from the second end (102AS, 104AS) of the body (102A, 104A); and
a plurality of connecting members (106);
wherein the plurality of first connecting arms (102B, 104B) of each connector (102, 104) are configured to mechanically and electrically engage with a corresponding busbar of at least two busbars (10, 20) of the busduct system; and
wherein each connecting member (106) is electrically coupled to a corresponding second connecting arm (102C, 104C) of each connector (102, 104) to provide an electrical connection between the at least two busbars (10, 20) of the busduct system.
2. The busduct connector assembly (100) as claimed in claim 1, wherein the plurality of second connecting arms (102C, 104C) are arranged in an offset configuration such that adjacent second connecting arms (102C, 104C) are spaced apart by a corresponding predefined pitch distance (D1, D2), and each second connecting arm (102C, 104C) is oriented at a corresponding predetermined angular offset relative to a longitudinal axis (L) of the body (102A, 104A),
wherein the arrangement of the plurality of second connecting arms (102C, 104C) facilitates maintaining consistent electrical clearance between adjacent second connecting arms (102C, 104C), and enables installation of the corresponding connector (102, 104) in a restricted installation space.
3. The busduct connector assembly (100) as claimed in claim 2, wherein the plurality of second connecting arms (102C, 104C) includes four second connecting arms (102CA, 102CB, 104CA, 104CB), the four second connecting arms comprising:
two outer second connecting arms (102CA, 104CA); and
two inner second connecting arms (102CB, 104CB) positioned between the two outer second connecting arms (102CA, 104CA);
wherein each outer second connecting arm (102CA, 104CA) and each inner second connecting arm (102CB, 104CB) is formed as a plate including:
a first planar portion (102CAF, 104CAF, 102CBF, 104CBF) extending orthogonally from the second end (102AS, 104AS) of the body (102A, 104A);
an angular portion (102CAA, 104CAA, 102CBA, 104CBA) extending at a corresponding predefined angle (A1, A2) from the first planar portion (102CAF, 104CAF, 102CBF, 104CBF); and
a second planar portion (102CAS, 104CAS, 102CBS, 104CBS) extending from the angular portion (102CAA, 104CAA, 102CBA, 104CBA) in a plane parallel to a plane of the first planar portion (102CAF, 104CAF, 102CBF, 104CBF);
wherein each second planar portion (102CAS, 104CAS, 102CBS, 104CBS) is configured to facilitate connection of at least three connecting members (106) to enable transmission of three-phase current in the busduct system.
4. The busduct connector assembly (100) as claimed in claim 3, wherein the predefined angle (A1) between the angular portion (102CAA, 104CAA) of each outer second connecting arm (102CA, 104CA) and the first planar portion (102CAF, 104CAF) ranges from 200° to 250°, the predefined angle (A2) between the angular portion (102CBA, 104CBA) of each inner second connecting arm (102CB, 104CB) and the first planar portion (102CBF, 104CBF) ranges from 120° to 150°, and
wherein the predefined pitch distance (D1) between each outer second connecting arm (102CA, 104CA) and its corresponding adjacent inner second connecting arm (102CB, 104CB) ranges from 32 mm to 40 mm, and the predefined pitch distance (D2) between the two adjacent inner second connecting arms (102CB, 104CB) ranges from 90 mm to 120 mm.
5. The busduct connector assembly (100) as claimed in claim 1, wherein the plurality of first connecting arms (102B, 104B) are arranged in a branched configuration corresponding to an arrangement of busbar arms (10A, 20A) of the respective busbar (10, 20),
wherein two adjacent first connecting arms (102B, 104B) are spaced apart by a predetermined gap (G), and the predetermined gap (G) between two adjacent first connecting arms (102B, 104B) is adjustable to facilitate alignment of each first connecting arm (102B, 104B) with its corresponding busbar arm (10A, 20A).
6. The busduct connector assembly (100) as claimed in claim 1, wherein the busduct connector assembly (100) includes at least one mounting member (108) connected to the body (102A, 104A) of each connector (102, 104),
wherein the at least one mounting member (108) is a bracket configured to enable mechanical fixation of the corresponding connector (102, 104) on a mounting surface of the busduct system.
7. The busduct connector assembly (100) as claimed in claim 1, wherein the plurality of first connecting arms (102B, 104B) and the plurality of second connecting arms (102C, 104C) are positioned in two spaced-apart sets (S1, S2), each set corresponding to a defined current-carrying capacity range.
8. The busduct connector assembly (100) as claimed in claim 3, wherein each connecting member (106) comprises:
a conductive cable (106A); and
a connecting terminal (106B) connected at each end of the conductive cable (106A),
wherein
a length (L1) of the conductive cable (106A) is variable based on a distance between two busbars (10, 20) of the busduct system; and
each connecting terminal (106B) is configured to connect to the second planar portion (102CAS, 104CAS, 102CBS, 104CBS) of the corresponding second connecting arm (102C, 104C).
9. The busduct connector assembly (100) as claimed in claim 8, wherein the second planar portion (102CAS, 104CAS, 102CBS, 104CBS) of each second connecting arm (102C, 104C) includes a plurality of apertures (P), wherein each aperture (P) is configured to receive a fastening element (F) to secure the connecting terminal (106B) of the corresponding connecting member (106) to the second connecting arm (102C, 104C).
10. The busduct connector assembly (100) as claimed in claim 5, wherein the plurality of first connecting arms (102B, 104B) include four first connecting arms, each first connecting arm (102B, 104B) being a plate member made of sheet metal,
wherein the predetermined gap (G) between two adjacent first connecting arms (102B, 104B) is adjustable with a spacing tool.