Claims:We Claim:
1. A system (100) for wrapping a busbar (110) comprising of:
a wrapping bed (20);
a plurality of trolleys (40) configured on the wrapping bed (20) while leaving a transferrable gap (130) corresponding to width of atleast one trolley (40) at an edge (20b) of the wrapping bed (20); and
an insulation roller (60) having an insulation roll (55) mounted thereon, the insulation roll (55) having a continuous sheet of an insulation paper (55a) rolled thereon for wrapping the busbar (110), the insulation roller (60) mounted on insulation roller supports (70) and operably connected to the wrapping bed (20) through a cavity (80) formed therebetween for facilitating sealing of a first offset bend (110a) of the busbar (110) with the insulation paper (55a) therein,
wherein the insulation paper (55a) is dragged from the insulation roll (55), aligned with an initial edge (20a) of the wrapping bed (20) and dragged further depending upon length of the busbar (110) to be wrapped to cause outward pushing movement of the plurality of trolleys (40) subsequent to the insulation paper (55a) and creating a trolley gap (120) therebetween, and thereinafter the insulation paper (55a) is slit to have length equal to length of the busbar (110) to be wrapped and the busbar (110) is placed on the insulation paper (55a) in a way that the first offset bend (110a) of the busbar (110) lies within the cavity (80) and a second offset bend (110b) of the busbar (110) lies within the trolley gap (120) such that rolling of the busbar (110) with the insulation paper (55a) and sealing of the first offset bend (110a) of the busbar (110) within the cavity (80) results in wrapping thereof.

2. The system (100) as claimed in claim 1, wherein the plurality of trolleys (40) is disposed on the wrapping bed (20) such that edges (20a, 20b) of the wrapping bed (20) constrain movement of the plurality of trolleys (40) in X-axis direction.
3. A method (200) for wrapping a busbar (110) comprising the steps of:
dragging a continuous sheet of insulation paper (55a) from an insulation roll (55) and aligning with an initial edge (20a) of a wrapping bed (20), the insulation roll (55) mounted on an insulation roller (60), the insulation roller (60) mounted on insulation roller supports (70) and operably connected to the wrapping bed (20) through a cavity (80) formed therebetween;
dragging forward the insulation paper (55a) at a distance further onto plurality of trolleys (40) configured on the wrapping bed (20), the distance depending upon the length of the busbar (110) to be wrapped such that the plurality of trolleys (40) subsequent to the insulation paper (55a) gets pushed outwards thereby creating a trolley gap (120) therebetween;
sliting the insulation paper (55a) such that length of the insulation paper (55a) is compatible with length of the busbar (110) to be wrapped onto the wrapping bed (20);
placing the busbar (110) to be wrapped on the insulation paper (55a) such that a first offset bend (110a) of the busbar (110) lies within the cavity (80) and a second offset bend (110b) of the busbar (110) lies within the trolley gap (120);
rolling and wrapping the busbar (110) with the insulation paper (55a) so as to close tightly around the busbar (110) thereby making longitudinal edges of the insulation paper (55a) to overlap; and
sealing the overlapping edges of the insulation paper (55a) lengthwise followed by sealing the first offset bend (110a) of the busbar (110) with the insulation paper (55a) within the cavity (80) and sealing the second offset bend (110b) of the busbar (110) with the insulation paper (55a) within the trolley gap (120) so as to tightly wrap the insulation paper (55a) around the busbar (110),
wherein the sealing is effected by anyone of welding and gluing.
Dated this 20th day of March 2017
Prafulla Wange
(Agent for Applicant) IN-PA/2058 , Description:SYSTEM FOR WRAPPING BUSBAR AND METHOD THEREOF

Field of the invention
The present invention relates to wrapping busbars with insulation in form of a thin film or paper, and more particularly provides a system and an improved method for wrapping the busbar.
Background of the invention
Busbars of relatively flat configuration are widely employed as a means of transmitting electrical power, and often a plurality of such busbars are stacked one upon another in close thermal contact and enclosed within an enclosure or housing that provides protection and support for the busbars.
Busbars of a busway system are insulated so as to minimize or eliminate air gaps between the busbars. The busbars are commonly insulated by wrapping/covering them with either single or plural layers of insulating tape. Further, paper insulation is commonly used in busways owing to the minimal thickness of such insulation which yields low reactance in the busways.
Prior art patent WO 2003105301 A1 discloses a method of wrapping the busbar by molding the insulating sheath to match cross-section and length of the busbar to be covered and then sealing the insulating sheath using either a glue or ultra-sonic welding. However, it is apparent from the mosaics of this invention that the busbar is bent after being covered by the insulating sheath.
Prior art patent US 3382118 discloses a method of using strips of insulation packed closely to achieve minimal distance between two parallel busbars.
Prior art patent US 3427396 discloses a wrapping technique in which a ribbon on insulation is wound around the busbar.
However, the existing techniques for wrapping the busbars make use of either insulation strips or ribbons wrapped around the busbar and require busbar bending after wrapping. Further, the existing techniques require great workmanship and damage the insulation during the bending process.
Therefore, there exists a need for an improved system and method which overcomes the above mentioned drawbacks of the existing method of wrapping the busbars with a protective and insulation sheath.
Objects of the invention
The primary object of present invention is insulation of busbars of a busway system for eliminating air gaps between the busbars.
Another object of the present invention is wrapping of busbars having variable sizes and lengths without any need of bending the busbars after wrapping with an insulation sheath.
Yet another object of the present invention is increasing productivity and reducing need for labor during insulation of busbars of a busway system.
Summary of the invention
The present invention, in one aspect, provides a system for wrapping busbar. The system can be modified to accommodate a variety of busbar lengths for wrapping purposes thereof. The system comprises of: a wrapping bed, a plurality of trolleys and an insulation roller. The wrapping bed is a flat wrapping station allowing easy wrapping of the busbars thereon. The plurality of trolleys are mounted on the wrapping bed in a way that a transferrable gap corresponding to width of atleast one trolley is left at one edge of the wrapping bed which lies opposite to the edge facing the insulation roller. The insulation roller consists of an insulation roll. The insulation roll includes a continuous sheet of an insulation paper rolled thereon for wrapping the busbar. The insulation roller is mounted on insulation roller supports. Further, the insulation roller is operably connected to the wrapping bed through a cavity formed therebetween for facilitating sealing of an offset bend of the busbar with the insulation paper therein.
In another aspect, the present invention provides a method for wrapping the busbar. The method includes dragging the insulation paper from the insulation roll and aligning the insulation paper with respect to initial edge of the wrapping bed. Thereinafter, the continuous sheet of insulation paper is placed on the plurality of trolleys up to a distance which depends upon the length of the busbar to be wrapped, and is then slit thereto. Upon placement of the insulation paper (55a) therein, the plurality of trolleys (40) subsequent to the insulation paper (55a) gets pushed outwards thereby creating a trolley gap (120) therebetween. Further, the method includes placing the busbar to be wrapped on the insulation paper such that first offset bend of the busbar lies within the cavity and second offset bend of the busbar lies within the trolley gap. Thereafter, the busbar is rolled within the insulation paper and the first offset bend of the busbar is sealed with the insulation paper within the cavity for tight wrapping thereof. The sealing is achieved by anyone of welding and gluing.
Brief description of the drawings
Figure 1 shows a perspective view of the system for wrapping busbar, in accordance with the present invention;
Figure 2 is a perspective view of the system for wrapping busbar, in accordance with the present invention, showing the slit insulation paper;
Figure 3 is a perspective view of the system for wrapping busbar, in accordance with the present invention, showing a trolley gap created according to the length or size of the insulation paper depending upon length of the busbar to be wrapped;
Figure 4 is a perspective view of the system for wrapping busbar, in accordance with the present invention, showing the busbar placement before wrapping;
Figure 5 is a perspective view of the system for wrapping busbar, in accordance with the present invention, showing a longer busbar being wrapped;
Figure 6 shows a perspective view of the trolley;
Figure 7 shows a perspective view of the busbar;
Figure 8 shows a top view of the system for wrapping busbar, in accordance with the present invention; and
Figure 9 shows a flow chart of a method for wrapping busbar, in accordance with the present invention.
Detailed description of the invention
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with the prior art techniques and approaches are overcome by the present invention as described below in the preferred embodiment.
The present invention provides a system for wrapping busbar and method thereof. The system can be modified to accommodate a variety of busbar lengths and sizes for wrapping purposes thereof. The system and the method are adapted to provide a flat surface whose length can be varied to match the desired length of the busbar to be wrapped.
This present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description.
Accordingly, in one aspect, the present invention provides a system (100) (hereinafter referred to as “the system (100)) for wrapping a busbar (110). The system (100) is adapted to effectively wrap the busbar (110) having varied lengths and sizes. In an embodiment, the system (100) is a wrapping station used for wrapping of the busbar (110).
Referring to figures 1 to 8, the system (100) comprises of: a wrapping bed (20), a plurality of trolleys (40) and an insulation roller (60).
The wrapping bed (20) is a flat wrapping station allowing easy wrapping of the busbar (110) thereon. In an embodiment, the wrapping bed (20) is a flat table top.
The plurality of trolleys (40) are mounted on the wrapping bed (20) in a way that a transferrable gap (130) corresponding to width of atleast one trolley (40) is left at an edge (20b) of the wrapping bed (20). In an embodiment, the plurality of trolleys (40) are placed over the wrapping bed (20) such that edges (20a, 20b) of the wrapping bed (20) constrain movement of the plurality of trolleys (40) in the X-axis direction. Particularly, the plurality of trolleys (40) is mounted on the wrapping bed (20) such that the total length of the wrapping bed (20) is longer by width of atleast one trolley (40) placed on thereon. In an embodiment, length of the wrapping bed (20) is longer than the widths of the plurality of trolleys (40) being mounted thereon. In another embodiment, length of the wrapping bed (20) can be varied as per need by employing the plurality of trolleys (40) mounted on the wrapping bed (20) and capable of longitudinal sliding movement thereon.
The insulation roller (60) consists of an insulation roll (55). The insulation roll (55) includes a continuous sheet of an insulation paper (55a) rolled thereon for wrapping the busbar (110). The insulation roller (60) is mounted on insulation roller supports (70). Further, the insulation roller (60) is operably connected to the wrapping bed (20) through a cavity (80) formed therebetween for facilitating sealing of a first offset bend (110a) of the busbar (110) with the insulation paper (55a) therein.
Referring to figure 9, in another aspect, the present invention provides a method (200), hereinafter referred to as “the method (200)”, for wrapping the busbar (110). The method (200) is explained in conjunction with the system (100). The method (200) starts at step (10).
At step (20), the method (200) includes dragging the continuous sheet of the insulation paper (55a) from the insulation roll (55) and aligning with the edge (20a) of the wrapping bed (20).
At step (30), the method (200) includes dragging forward the insulation paper (55a) and placing on the plurality of trolleys (40) at a distance which corresponds to the length of the busbar (110) to be wrapped. Upon placement of the insulation paper (55a) on the plurality of trolleys (40), the plurality of trolleys (40) subsequent to the insulation paper (55a) gets pushed outwards in X-axis direction thereby creating a trolley gap (120) therebetween. Thereinafter, the insulation paper (55a) is slit to have length of the insulation paper (55a) equal with the length of the busbar (110) to be wrapped. (Step (40)).
At step (50), the method (200) further includes placing the busbar (110) to be wrapped on the insulation paper (55a) such that the first offset bend (110a) of the busbar (110) lies within the cavity (80) and a second offset bend (110b) of the busbar (110) lies within the trolley gap (120).
At step (60), the method (200) includes rolling and wrapping the busbar (110) with the insulation paper (55a) so as to close tightly around the busbar (110) thereby making longitudinal edges of the insulation paper (55a) to overlap. The busbar (110) is rolled and wrapped with the insulation paper (55a) till the insulation paper (55a) covers entire periphery of straight section of the busbar (110).
Thereafter, at step (70), the method (200) includes sealing the overlapping edges of the insulation paper (55a) lengthwise followed by sealing of the first offset bend (110a) of the busbar (110) with the insulation paper (55a) within the cavity (80), and sealing the second offset bend (110b) within the trolley gap (120) for tight wrapping of the insulation paper (55a) around the busbar (110). The insulation paper (55a) is sealed to the busbar (110) for wrapping thereof using anyone of welding and gluing. In an embodiment, the insulation paper (55a) is taped or glued to the busbar (110) for wrapping thereof. In another embodiment, the insulation paper (55a) is sealed using adhesive backed insulating tapes. The method (200) ends at step (80).
Thereinafter, after wrapping and sealing, the busbar (110) is removed from the system (100) by manual lifting, to make space for wrapping another busbar (110).
In an alternative embodiment, the method (200) is repeated for wrapping the busbar (110) having varied length and sizes. In another embodiment, placement of the transferrable gap (130) is chosen based on length and size of the busbar (110) to be wrapped.
The system (100) is adapted to slit the insulation paper (55a) to the desired size depending upon the length of the busbar (110) to be wrapped. The method (200) is adapted in wrapping the busbar (110) that is bent before wrapping with layers of the insulation paper (55a) such that all of these layers are part of a singular sheet.

Advantages of the present invention
1. The system (100) can be modified to accommodate varied lengths of the busbar (110) for wrapping thereof.
2. The system (100) provides flat surface having varied lengths depending on the length of the busbar (110) by employing the plurality of trolleys (40) that are capable of sliding movement.
3. The present invention creates a tightly wound insulation over the busbar (110) without air gaps.
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiment. Detailed descriptions of the preferred embodiment are provided herein; however, it is to be understood that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure, or matter. The embodiments of the invention as described above and the methods disclosed herein will suggest further modification and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the spirit and scope of the invention.