EP1451906A1

EP1451906A1 - Conductor rail system

Info

Publication number: EP1451906A1
Application number: EP02792889A
Authority: EP
Inventors: Wolfgang Reiser; Stefan Huwer
Original assignee: Vision Electric GmbH
Current assignee: Vision Electric GmbH
Priority date: 2001-12-04
Filing date: 2002-12-04
Publication date: 2004-09-01
Also published as: WO2003049238A1; AU2002358604A1; DE10159401A1

Abstract

The invention relates to a conductor rail system comprising a conductor rail in the form of a profile having one or more open profiles, e.g. in the form of U-shaped profiles. One or more conductor rail profiles are held by one or more insulating spacers inside said profile, the above-mentioned spacers extending over the entire length of the profiles. Due to the fact that the spacers hold the current conductor at given support spacings in certain points and that they extend uninterruptedly over the entire length of the conductor rail, the ready-to-use conductor rail having current conductors and insulator can be sectioned at any given point, e.g. using a saw, without having to perform complicated treatment of the resulting front face, e.g. by placing or gluing an insulating piece optionally serving as a supporting piece. Said sectionability provides greater flexibility for the installer of the conductor rails, who can easily jump over unforeseeable obstacles during assembly or can compensate for wrong measurements made during planning.

Description

Busbar system

The present invention relates to a busbar system and a method for installing the same.

Busbar systems are used to feed and distribute electrical energy. Known busbar systems are built on a modular principle, so that complex electrical installations can be efficiently implemented with them. The consumers are connected to the power rails at the appropriate point. Busbar systems are used in particular in building installation as a main power line in transformer switchgear connections, in the supply of individual floors and in floor distribution, but also in DataComCenters and in the industrial area for further distribution of electrical energy, such as in painting lines, conveyor systems, transport systems, Assembly lines, printing and paper machines, production machines.

Advantages of busbar systems compared to cables result from the reduction in project planning time by using a modular system, less space required by the compact design, predefined, type-tested technical data that is independent of installation conditions, shorter commissioning times by less wiring, high service and ease of maintenance, in comparison, short cable routes for less space requirements, as well as high reuse value for renovation measures.

Busbar systems for the above-mentioned purposes are designed for currents from approx. 100 to 8000 A and alternating operating voltages up to approx. 1 kV and direct operating voltages of approx. 1.5 kV. A typical conflict of objectives in the design of busbar systems for such high currents is to ensure a safe and low-loss power line at the contact point between two busbar elements with a housing that is relatively small, light and solid in relation to the conductor cross-section of the busbar and with one At the same time, good accessibility to the current conductor, as is known, for example, from conductor rails for lighting purposes or for smaller outputs. The functionality of these systems is based on the fact that only moderate forces applied by spring elements are required for the conductors, which are usually designed for only 16-32 amperes, in order to connect the conductors of two adjacent busbars to one another in an electrically conductive manner. These comparatively low spring forces only slightly expand the housing, so that the spring elements necessary for the electrical contact are still pressed on without a large loss of spring force. Manufacturing tolerances can be compensated for by the flexibility of the overall construction. However, these design standards are applicable to systems with the above mentioned higher ones

Amperages and the associated larger conductor cross-sections, so-called high-current rail systems, are not transferable. The wall thicknesses of the housings of such busbar systems for lighting purposes correspond approximately to the thicknesses of the actual current conductors. These housings are essentially subjected to bending due to the direction of attack of the contact forces of the rail connector or pantograph. The non-operational current-conducting profile of a busbar, which has a current conductor held in its interior by insulators, must be open, for example in a C, V or U shape or in the form of a slotted "O", in order to make the electrical connection to the current conductor on each However, the high contact forces between the current pick-up or the rail connector on one side and the busbar on the other side bend the open profile, as a result of which the contact forces decrease and the electrical contact is adversely affected.

Since at the same time there is a demand for a housing that is relatively small and light in relation to the conductor cross section, the solution does not lie in making the conductor rail profile more solid and thus more expensive and heavier. Therefore, the features that are typical for the busbars for lighting purposes or for the low-current range are not readily transferable to the high-current range.

Typical high-current rail systems have a mechanically stable housing that is not intended for the power line, in the interior of which electrical conductors with a sufficient cross section are guided. So that the conductor does not touch the housing or neighboring conductors and a certain mechanical stability for the has usable scrapers, it is held on the inside by a sufficient number of support points of insulators, for example made of plastic or ceramic. It is understood that in the high-current rail described, an insulator must be provided at both ends for mechanical support of the conductors at the contact points, so that two adjacent high-current rails can be contacted. Since the position of the insulators mounted at certain support intervals must be taken into account with this high-current rail, it is not possible to shorten a 4 m long conductor rail to 3.60 m by sawing. Therefore, before installing such a system, it is necessary to carry out detailed geometric planning, that is, to precisely define the required busbar elements and their length before starting the installation and to provide them accordingly on the construction site. Tolerances or obstacles that were overlooked during planning cannot therefore be compensated for or skipped during installation, since rails with the required dimensions have not been provided and cannot be produced on site without any special effort. This results in delays and additional costs during installation.

Because the high-current rail described above is pre-assembled in fixed sizes, the electrical installer, for example, has to keep the rails in different lengths ready, which ties up his capital, stresses the warehouse and therefore makes the product more expensive for the buyer.

It is therefore an object of the present invention to provide a device and a method which are simpler in construction and handling and cheaper.

This object is achieved by a device and a method with the features of the independent claims. Advantageous refinements result from the subclaims.

The busbar system according to the invention comprises a busbar in the form of a profile which has one or more open profiles, for example U-shaped profiles, in the interior of which one or more conductor profiles are held by one or more insulating spacers which extend over the entire length of the profile , The fact that the spacer not only keeps the conductor at certain support intervals, but also without interruption over the entire length extends the busbar, it is achieved that the operational busbar with current conductor and insulator, for example by means of a saw, can be cut to length at any point without it being necessary that the resulting end face is expensive, for example by inserting or gluing one, possibly also supporting insulating piece to have to treat. In some known busbars, a leakage current path is formed on the cut surface between the current conductor and the housing or other current conductors. It is therefore often necessary to take further measures such as: B. the separate sheathing of the conductor or the provision of grooves in the end face of the spacer in the region of the cut surface forming the end face. Post-treatment measures of this type can be avoided if the spacers provide for a minimum leakage current path dimensioned according to the relevant standards. B. max. 1 kV AC voltage of at least 5.6 mm long enough. The ability to cut to length results in a greater flexibility for the installer of the busbars, who can, for example, easily jump over unpredictable obstacles during assembly or compensate for the incorrect dimensions used in the planning. It also enables the installer to compensate for existing construction tolerances directly on site and without further planning steps. Furthermore, the work of the planner is made easier, since the determination of the main geometric dimensions is sufficient for the installation. Geometric detailed planning can therefore be dispensed with, so that the

The main focus of planning is on the electrical design, for example current, mechanical load and load profile. The omission of the detailed planning phase not only reduces the overall project effort, but also financially. There are no unforeseen delays due to deviations from the planning.

If the components of the busbar system are made in one piece, they can be manufactured more cheaply and easily. It is in particular possible to produce the connecting profile together with the busbar housings made of metal or else the busbar housing together with the spacer made of plastic.

The busbar system also includes, for example, a connection profile to be fastened to a wall or ceiling, to which the busbar profiles can be clicked and fixed. On the one hand, this connection profile enables easy assembly of the conductor rail system, since the comparatively light connection profile, which has no heavy parts, such as the solid conductor, is first attached to the ceiling or wall using conventional means, e.g. screws, bolts, dowels, and then the heavier conductor rails via a clamping mechanism along the connection profile be clicked. The locking lugs of the connection professional, which snap into place, can then be fixed, for example by means of a screw, in such a way that the busbars are secured against unintentional removal / falling out, that is to say are firmly connected to one another.

Due to the fact that in one configuration the connection profile has connections for receiving two conductor rails on both sides, the system can be used particularly flexibly, that is to say the phases and current strengths can be varied by combining conductor rails, which can also be configured differently in terms of performance.

Different current tapping situations and applications arise if fastening means for connecting to the connection profile 1 are provided on at least two sides, preferably three sides, of the conductor rail profile.

Seals that connect the face of two contacting busbars protect the inside of the busbar system from dirt, dust and moisture, i.e. the so-called industrial atmosphere. As a result, leakage currents can be more difficult and the distances necessary to avoid leakage currents (e.g. the spacer) can be shorter, which makes the system more compact, lighter and cheaper. The seals are therefore not measures to extend the leakage current paths, such as the separate sheathing of the current conductor described above or the provision of grooves in the end face of the spacer in the region of the cut surface forming the end face.

Due to the closed design of the busbar system according to the invention with, for example, a connecting profile, busbars attached to the right and left and a cover which connect the two busbar profiles at their free end, the overall construction cannot be bent open. This ensures that the individual elements for assembly purposes (e.g. when clicking) Although they can be bent up elastically, the cover results in a closed design after assembly, so that the mechanical contact forces introduced, for example by the current pickups or busbar connectors, do not lead to a disadvantageously acting deformation of the busbars. As a result, the system tolerances required for electrical contact are adhered to. The closed form thus makes contacting safer, enables a more compact design and less material consumption, enables a favorable ratio of housing to current conductor, ensures a small external dimension and more mechanical stability. It is important that the cover not only has a touch and privacy function, but that together with the busbar system it forms a closed unit in the mechanical sense. The cover therefore fulfills a dual function according to the invention.

The closed system according to the invention therefore has the effect, in particular, that the contact forces, which are in any case reduced in any case by spring elements in comparison to direct contacting, partially cancel one another and the load on the housing material due to the all-round closed design of the housing, essentially as in the case of a pipe subjected to internal pressure, essentially limited to uncritical mechanical tensile stresses instead of critical bending stresses. An open, for example C-shaped profile, would be opened by the contact forces. According to the invention, the wall thicknesses of the housing can therefore be significantly smaller than the thickness of the current conductors and the essential requirement for economy can be met.

The cover to achieve a closed design can be interrupted in sections or have openings for making connections in such a way that the mechanical stability of the still closed busbar system described above is not impaired. This enables the busbars to be contacted at any point, for example by means of taps. The opening for the passage of cables is closed by a seal so that the inside of the busbar is protected against dirt and insects.

Maintenance is facilitated in that the covers can be removed in sections. The closed design also enables the fastening of Loads, for example junction boxes, on the busbar system. At least 10 kg per meter length can be attached.

The continuous, i.e. in the housing over the length of uninterruptible spacers, which are also insulators, prevent the current conductor from coming into contact with the outer wall of the busbar or another current conductor, for example as a result of current forces or a mechanical load exerted by a connecting or tapping element , This means that the system is short-circuit proof and can withstand high mechanical loads. Short-circuit-related forces on the current conductors, like the contact forces described, act in such a way that essentially uncritical tensile stresses occur instead of critical bending stresses in the housing material, so that large housing material cross sections can also be dispensed with in this case. Even when cutting to length, for example sawing off, it is ensured that the current conductor does not suffer any mechanical deformation, such as bending, and therefore remains true to size.

The spacers are preferably designed in the form of a hollow chamber profile. This leads to material savings and weight savings compared to, for example, full profiles. The individual hollow chambers serve as an air insulator and also reduce the thermal conductivity of the insulator. If the profile cross section of the

Spacer has a profile made of struts that form the cavities, the spacer fitted into the conductor rail profile, which must have a certain thickness in particular to avoid leakage currents, is nevertheless mechanically sufficiently stable. Therefore, it is possible to use the conductor rails with the conductor held therein as a whole by means of, for. B. to a saw. Also, the current forces that occur during operation cannot deform the current conductor, which is why the electrical contact to connectors or taps, for example, is not reduced, and contact with other phase conductors with the housing of the busbar (short circuit) is avoided.

The mechanical compressive stresses in the spacer / insulator profile caused by the contact forces of the resilient contact elements are to be designed together with the plastic used so that there is no significant flow of the plastic in the region of the webs of the spacer even during the period of use of the busbar system. The resilient contact elements are also in this sense interpret that a slight setting or flow of the plastic can be compensated for without a negative impact on the intended current carrying capacity. This ensures the functionality of the busbar system and pantographs for the intended period of use of several years. The person skilled in the art can determine the necessary design by systematic tests while changing the parameters, in particular spring force, number of springs, spring material, conductivity of the spring surface and choice of material for the spacer.

The hollow chamber profile also makes it possible to manufacture the spacers shaped by a profile-shaping process, such as extrusion, more precisely, in particular by means of a calibration path or subsequent processing, such as grinding, for example, to bring the profiles to the desired dimension. This ensures that its external dimensions are of the order of a few hundredths of a millimeter true to size. This is important for the electrical contact between the current conductor and the wiper / connector. For example, in the vacuum calibration section, when the profile cools down, the hollow chambers are pressurized and / or a vacuum is applied outside the cooling section, so that the profile to be calibrated is pressed against the mold when it cools, resulting in particularly precise dimensions and compensating for shrinkage.

The spacers have contact surfaces on their outer wall and the conductor rail profiles have a plurality of contact surfaces on their inner wall. The spacers are fixed in the interior of the conductor rail profile via these contact surfaces. The correct positioning of the current conductors held by the spacers also depends on the dimensional accuracy of the contact surfaces of the busbar. If those

Contact surface in the inside of the conductor rail profile is not flat but runs serrated, then the profile can be manufactured with an even smaller tolerance. Because the serration has two advantages over a flat surface:

1) An extrusion die to produce the substantially U-shaped

Stromschienenpro file or profiles in general is subject to ongoing wear when pressing the aluminum material through the extrusion die. The wall thickness therefore increases with each kilometer of profile produced. To the small tolerances of a total of less necessary for a safe electrical contact To be able to adhere to 0.2 mm, it would normally be necessary to identify the finished profiles by lot, for example, to be able to assign them to suitably manufactured spacers. The serrated profile, on the other hand, enables simple recalibration in such a way that the tips of the serrated contact surface can be compressed to size using a roller / tube.

2) It is also known that during extrusion, the pressing tool in the corners is less stressed because of the lower pressing pressure there, that is, the wear on the pressing tool is lower there. The serrated shape of the contact surfaces ensures that the point of the point, which can also be flat in the form of a web, and which forms the support for the spacer, is shaped in such a lightly loaded corner of the pressing tool. This corner is therefore subject to less wear and tear, as a result of which the contact surface, which is intended for receiving the spacer and is defined by the tip of the prong, is less impaired in its dimensional accuracy than other parts of the profile due to the wear of the pressing tool. This ensures that a comparatively large amount, e.g. 50,000 m of the profile can be manufactured with the same pressing tool, without there being any wear-related deviations at the points of the conductor rail profile that are relevant for the dimensional accuracy.

The tapping elements have connecting elements designed as spring elements

Contact elements that establish a safe electrical contact to the conductors without screwing. It is important that the contact elements act on the current conductor selectively and therefore with a large surface pressure. This enables a high current carrying capacity with very low spring forces acting on the current conductors. This in turn comes from the stability and dimensional accuracy of the

Track system benefits. As part of the spring travel, the springs make it possible to compensate for certain tolerances in the distance between, for example, the connector and the current conductor. The common screwing of two current conductors, on the other hand, shows poorer long-term behavior, since force must be applied over a much larger area in order to achieve a comparable and necessary for a reliable current transfer

Generate surface pressure. The lower contact forces, which are sufficient for the current transfer and which act on the current conductor, exert a comparatively small force on the spacers. These can therefore advantageously be made lighter and as hollow profiles. Also, the taps / connectors are over Spring contacts create the current flow, easier and more flexible to insert without tools at any point of the busbar system. The spring elements also have the advantage that the contact pressure is defined in the range of the defined spring travel. However, the spring travel is limited by the current carrying capacity on the one hand, i.e. the area where the spring force becomes too low or goes to zero and on the other hand by the plastic deformation in the event of excessive compression of the spring. The spring travel desired for the application with an approximately constant spring force must therefore be greater than the tolerance of the busbar system.

In an advantageous embodiment, two similar, advantageously identical, contact elements are provided which are arranged one above the other in such a way that the springs of one element are located in the gap between two adjacent springs of the other element, hereinafter referred to as a double contact element. This ensures that the amount of current that can be conducted by the double contact element is doubled for the same area used. As a result, the busbar system is generally more short-circuit proof, since the contact elements are not immediately overheated in the event of a short circuit and therefore do not have to be replaced.

These double contact elements are particularly inexpensive because they can be manufactured uniformly if they consist of two identical contact elements which are offset from one another. It should be noted that the contact elements have springs that protrude slightly asymmetrically above and below a central plane. With a suitable design, the springs of the two contact elements placed one on top of the other end in one plane and ensure a uniform current carrying capacity of both contact elements.

Another advantage of the movable connection instead of the screw connection of the current conductors is that the system can expand thermally without any stresses that lead to deformation being built up. Depending on the load, there may be temperature differences of up to 100 ° C between zero and full load during operation for the power conductor. Since the current conductor is movably mounted in the longitudinal direction in the spacer and this in turn in the housing, they can extend differently and stress-free in the longitudinal direction. The spring fins of the connectors slide over the surface of the current conductors when they move against each other as a result of thermal expansion. This scraping tears open the oxide skin that forms in the contact area between the connector and the current conductor, and improves the current carrying capacity in the long term.

The flexible spring lamellae also make it possible to contact the conductor with the connector by pushing it in the longitudinal direction of the conductor rail. This means that any thin oxide layer that may be present is scraped off during initial assembly and good electrical contact is made. In addition, this additional mounting option significantly simplifies the mounting of the busbars in narrow installation situations, such as in floor connecting shafts.

Current conductors contacted by screwing may be subject to creeping and wandering processes, which is why they may have to be tightened after assembly and also require regular maintenance afterwards, which causes costs. Screwed connections are therefore more susceptible to faults and therefore require maintenance.

The invention also includes current conductors which are held parallel to one another along the two U-legs of the current rail in the interior of the spacer. The current conductors can have different cross-sections and thereby make the system suitable for different currents. The opposing current conductors can, for example, have a different phase, so that four-phase systems with lower demands on the current strength can be realized with a single double-U busbar profile. In the case of larger current loads, on the other hand, it is conceivable that the cross section of the two current conductors is combined and thereby further increased, that they are connected to one another by a further leg and thereby form a U-shaped conductor profile.

In a further embodiment, the cover can only be removed with a tool or special tool. Such a device can be, for example, a screwdriver or a lever that acts on the nose of the cover, comparable to a bottle opener. In a further embodiment, two current conductors are provided in each cavity of the busbars, which are applied to different phases. For a 4-phase track system, a double U-track profile is sufficient, with each U-profile holding two conductors with different phases, i.e. two phases. This reduces the stray field magnetic area of the conductors and thus the stray field magnetic effect. Fewer eddy currents are therefore induced in the metallic housing of the busbar, which is why the power loss and heating of the system are reduced. Therefore, more current can be transported in the busbar that is switched off in this way with the same losses. It should be noted, however, that the connector or gripper must be designed with two poles, ie two pieces with a connecting insulation. This makes contacting particularly easy.

A further embodiment enables a multiplication of the current strengths to be transported by a multiplication of those integrated in the busbar system

Busbars. This is achieved either by a connection profile, which is designed to accommodate one or more busbars, or the repeated connection of alternating connection profile to the busbar.

The current intensity conveyed by the busbar system can also be influenced by a changed cross section of the current conductors. It is important to ensure that the current conductor with a reduced cross-section also has external dimensions such that contact with the taps / connectors is ensured and the current conductor can be securely fixed in the spacer. This avoids oversizing the cross sections in systems for small

Amperages, thus saving material and weight. Compared to a solid current conductor, material for reducing the cross-section has been removed at points that are not absolutely necessary for securely fixing the conductor in the rail. The easiest way to create a corresponding profile is by rolling or extrusion. It is also possible to make the conductor hollow, but this would be more complex.

In the following the invention will be explained in detail with reference to drawings, namely Fig. 1 shows a section through the busbar with built-in connectors on the

Joint of two busbar elements, Fig. 2 Examples of possible combinations based on the busbars

Realization of different currents, Fig. 3 different ways to change the line cross section of a

4, a section through a spring lamella of a contact element, as in the case of the

5 and a connector is used in a similar manner for the consumers, FIG. 5 shows a consumer for tapping the current from a power rail with a consumer element equipped with connecting conductors and an unpopulated consumer element,

6 shows a connecting element with a contact element for contacting two pairs of busbars abutting one another, FIG. 7 shows a detailed view of the jagged contact surface of the busbar, and FIG. 8 shows various options for executing the components in one piece.

Fig. 1 shows a section through the busbar with built-in connectors at the joint of two busbars. It can be seen that the connection profile 1 forms a closed system together with the two busbars 2 and the cover 4, as a result of which a high mechanical stability of the busbar system is achieved with less use of material. The cover 4 also protects the current-carrying components, such as the current conductor 40 and the connector 30, against environmental influences and unintentional contact.

The connection profile 1, which is designed here as a triangular connector, is attached to a ceiling or wall. Fastening means for connecting to the busbars 2 are provided on the two side legs of the triangular connector 1. The attachment is carried out in the exemplary embodiment by double-sided clamp-like profile lugs 8 for snapping into the double-sided profile grooves 9 of the busbars 2. Clamping fastening is effected, for example, by the profile lugs 8 of the triangular connector opening and then closing when the busbar 2 penetrates, the profile lugs then 8 then snap into the profile groove 9 and thereby hold the busbar. The profile lugs 8 are provided at the end of an upper or lower tongue 50 and 51, the lower tongue 51 being elastically bendable to the side as long as the clamping rail 5 for fixing the tongue 51 has not yet been installed. The lower tongue 51 also forms a stop 10 against which the busbar 2 abuts with a stop surface 11 in the installed state. A particularly dimensionally stable connection between triangular profile 1 and busbar 2 is thereby achieved. As soon as the screw 7 has been screwed so far into a threaded rail 6 that the clamping rail 5 holds the lower tongue 51 of the connecting profile, the profile lugs 8 and also the rails 2 are fixed on one of their sides, that is to say secured against unintentional pulling out of the connecting profile. In particular, it must not be possible for the busbars to be torn out of the connecting profile by the attachment of loads, for example junction boxes. The cover 4 fixes the rail on one of its other sides, so that the rail is thus fixed on two of its long sides or edges.

The space between the upper and lower tongues 50 and 51 is easily accessible before the busbars 2 are clamped in and therefore forms a tube space 13, which is used, for example, as a cable duct for control, measurement and data lines, bus systems, fiber optic cables or for carrying technical gases, such as B. compressed air, oxygen, etc. can be used, openings in the connection profile can be provided in an advantageous manner to lead these lines out of the pipe space serving as a cable duct. This is advantageous if, along the busbar system, there are provided distribution boxes attached to the busbar system, which can be controlled and monitored via a bus, or are equipped, for example, with a compressed air line. The busbar system then fulfills several tasks at the same time: 1) It feeds the current to the distribution box via the current conductors 40 in conjunction with taps not shown in FIG. 1. 2) It carries the distribution box because of its high mechanical stability. 3) Finally, it carries the data lines or technical gases intended for the control / monitoring of the distribution box.

The exemplary embodiment shown in FIG. 1 shows that the busbars 2 have an opening 12 for tapping current inwards, that is to say in the direction of the cover 4. As a result of the symmetrical design of the profile lugs 8 or profile grooves 9, the busbars can also be latched the other way around in the connection profile, as a result of which power can also be tapped from the outside. The busbars 2, like the connecting profile 1, are made of a high-strength material, for example an aluminum-magnesium alloy, such as AlMgSi0.5, by a profile-shaping process, such as edges, extrusion or extrusion. Each busbar 2 consists in principle of two U-profiles, each with a profile opening 12 for receiving the spacer 20 and the current conductors 40 held therein. The spacer 20 does not support the two current conductors 40 in sections at certain support intervals, but continuously over the entire length of the busbars , This ensures a short-circuit protection to a particular extent and the conductor rail can be cut to length at any point, for example by sawing. The spacer is also produced particularly inexpensively as an endless profile, it not being of solid construction, but rather having a cross-section of cavities 27 formed from webs, which leads to a saving in material and as a result of which the insulating effect of the air is used. Any insulating, extrudable and mechanically sufficiently stable material is suitable as material, in particular plastics such as PC, PC-ABS, PPS, PPOetc.

The spacer 20 is mirror-symmetrical about its longitudinal axis, that is to say it partially clasps with its two side walls in each case a current conductor 40 which is designed, for example, as an essentially rectangular, band-like profile. The rectangular profile of the current conductor 40 tapers at its two ends to form a wedge-shaped tongue 42, which is held in a corresponding groove 24 in the spacer 20. This protects the current conductor 40 from the spacer and insulator 20 on all sides against accidental short-circuiting, with the exception of the free side 41 looking in the direction of the opposite conductor 40. This free side 41 is used for contact with the taps or connectors 30 which are in the 2 to 6 are explained in more detail.

In order to ensure good electrical contact, it is necessary for the free side 41 of the current conductor 40 to be aligned very precisely with respect to the longitudinal axis of the busbar 2, that is to say with a tolerance of less than 0.2 mm. It should be noted that the tolerances of the busbar, spacer and current conductor components add up, the spacer and busbar profile components being particularly critical in the production by extrusion processes. The hollow chamber profile of the spacers 20 is deformed during extrusion during cooling. In that runs through a vacuum calibration section after the pressing process, its external dimensions can be manufactured with a tolerance of a few hundredths of a millimeter. However, it is more difficult to continuously manufacture the walls of the conductor rail profile with a comparable tolerance. The more the extrusion mold wears out, the thicker the walls become and thus the contact surface 21 on the inside of the profile, which positions the spacer 20, changes its position.

It can be seen that the spacer 20 is not only held in the profile opening 12, but is also largely held in shape by it. Known busbar systems, for example light bars, carry a spacer element with current conductors which serves as an isolator, the strength and shape retention of which alone determine the position of the current conductors. The spacer is only attached to the housing. According to the invention, however, the housing itself contributes to the positioning and fixing of the current conductors without being directly connected to them.

FIG. 7 explains the serrated contact surface 21 of the housing 3 of the busbar, consisting of grooves 101 and serrations 102 produced by the extrusion tool. As long as the pressing tool is still new, the profile shown in FIG. 7 is generated. In the area of the grooves 101, however, the pressing tool is particularly stressed and is therefore subject to greater wear than in the recesses in the pressing tool, which form the contact teeth 102. Therefore, the wear on the pressing tool is particularly noticeable by a flattening of the grooves 101, as indicated by the broken line 101 'in FIG. 7B. However, since the outer side of the spacer 20 bears against the prongs 102, which changes less as a result of the wear of the extrusion tool, the wear for the positioning of the spacer 20 is not noticeably less noticeable.

Another advantage of the contact surface of the busbar profile 2 formed by serrations is that such a profile can easily be recalibrated by rolling or rolling, i.e. the tips of the prongs 102 become comparatively light since only a little

Material is to be shaped to size by compression, as shown in Fig. 7A, by the dashed line.

In particular by combining the two aforementioned measures, namely 1) Vacuum calibration of the spacers 20 and

2) Providing a jagged profile of the contact surface 21 of the busbar profile with

3) if necessary, recalibration of the teeth, the tolerances required for the use of the contact springs explained in more detail in FIG. 4 are made possible.

The busbar configuration shown in Fig. 1 is designed so that each chamber of the busbars can each hold two current conductors 40 which carry the same current phase. For this purpose, one would essentially need a solid block consisting of highly conductive material as the connector 30, which electrically connects the ends of two busbars which meet at their end faces.

If, on the other hand, the two current conductors 40 held by a spacer 20 carry a different current phase, then the two-pole connectors shown in Fig. 1 with two poles 34, 35, i.e. Connector with an insulation layer 11 between its two sides (poles), necessary, as also shown in more detail in Fig. 6.

The two-pole connector 30 shown here consists of the two highly conductive solid poles 34, 35, which are conductively connected to the conductors 40. The poles are held by an insulator frame 11, which forms a mechanical unit 30 with them. The insulator 11 forms a handle 33 at its free end, which facilitates the insertion or removal of the connector 30 into the opening 12 of the profile 2. The mounting direction can run both in the drawing plane and perpendicular to it. In the assembled state, the handle 33 protrudes slightly beyond the profile opening 12 for this purpose. An unintentional electrical contact between the connector 30 and the environment after its assembly is prevented by the insulator rail 11. The connector is therefore manageable in operation. 6 shows a cover clip 10, preferably made of spring steel, which finally closes the profile opening 12 and fixes the connector in the conductor rail profile. It also protects the connector against accidental contact and the contacts against the ingress of dirt or unintentional additional mechanical loads. The connector 30 is thus completely fixed all around, also on the other side through the head region of the spacer 20.

In order to protect two busbar elements connected to one another at their joint against dirt and moisture, the Cross sections of the profile strips, and optionally the spacers 20, are provided with a seal, for example in the form of cellular rubber provided with a one-sided or two-sided adhesive coating. A sufficiently elastic material also enables the sealing of interconnected busbars that are not exactly aligned in their longitudinal axes. An elastic seal can therefore absorb certain “kinks” without the sealing ability being adversely affected.

Fig. 2A illustrates that for the construction of a busbar system, even a single busbar profile with two U-shaped openings for receiving the spacers and current conductors is sufficient to implement a three-phase + zero busbar system. Each of the current conductors P1, P2, P3 and N is connected to a phase or zero. Because the conductors lie close together, their stray field magnetic area is reduced, which results in lower power loss and heating of the busbar housing. Another use of the conductors, for example a 2- or 6-phase or to convey direct current, is also conceivable. The cover 4 closes the opening of the busbar 2 and at the same time fixes its free leg against undesired bending.

The system shown in Fig. 2B includes a total of four bus bars 2, so that in

Compared to Fig. 2A approximately four times the current can be transported. It is also clear that the connection profile 1 is not designed here as a triangular profile, but as a double triangular profile. This is a one-piece, compact connection of two triangular profiles known from FIG. 1. The busbars 2 and the cover 4 can be adopted unmodified from the embodiment in FIG. 1.

FIG. 2C shows an exemplary embodiment for six times the current strength compared to FIG. 2A. A triangular connection profile 1, as is known from FIG. 1, is mounted here alternately with a busbar 2, so that there is an overall zigzag cross section. Every second connecting profile is attached to the ceiling. The fact that these connection profiles are permanently mounted at regular intervals, the system is mechanically sufficiently stable even without cover 4. Nevertheless, the use of the cover 4, not shown, is recommended at least on the underside in order to Protect electrical contacts against contamination or contact. The examples shown in FIGS. 2A to C are intended to show that the busbars can be combined in order to implement busbar systems for different current intensities. 2A-2C have a closed design in the sense of the invention, since the busbars 2 are each fixed on two sides.

3A to 3C, on the other hand, show that in the case of busbar systems for lower currents, it is also possible to use current conductors which are matched thereto, which saves material and weight. It is important that each current conductor, regardless of its cross section, has essentially identical external dimensions in order to be fixed in the recess of the spacers 20. It is important that the free side 41 provided for the electrical contact is fixed in the same place regardless of the design of the current conductor, that is, it occupies the same position.

4A and 4B show the configuration of a contact element 60 which forms the surface of the tapper or connector 30 in the region of the electrical contact to be produced. Free-standing lamellae 61 run between two parallel webs 62 and are twisted out of the web plane. The twist in the central section of the lamella 61 is greater than at the two ends on the web side. The upper and lower ends of the central region of the twisted slats form a contact zone 63 which the

Establish a current between the conductor 40 and connector 30 or poles 34, 35, provided the contact element 60 is clamped between the connector and the conductor. A high surface pressure is particularly necessary for good contact closure, that is to say the current carrying capacity. With a small contact area, such as is provided by the contact elements 60 with their contact zones 63, this can be achieved with comparatively small forces. In the case of large contact areas, the contact forces increase with the contact area in order to achieve the same surface pressure. These forces must then be absorbed by the housing of the busbar system (1, 2, 4), with the result of a more expensive and higher use of materials and a higher weight. The use of such contact elements made of slats in the field of

Electrical contacts are known and their known advantages and effects are therefore not further explained here. The double contact element already mentioned is suitable for increasing the current conveyed by the contact elements. It is clear that this is advantageous in terms of manufacturing and handling technology from two identical, but each has contact elements 60 provided asymmetrically above or below the web 62 springs 61 or contact zones 63. Thus, after assembly, all contact zones 63 lie below or above the web in one plane and ensure uniform contact. FIG. 4A in connection with FIG. 1 explains, by way of example, a possibility of fastening a contact element 60 to the connector 30, which is also analogously applicable to the tapper. The two webs 62 are pressed against the ends of the insulator frame 11, which also holds the poles 34, 35 together. 5 that the free ends of the insulator frame have grooves 38 for receiving the side edges of the webs 32. This particularly prevents the contact element 60 from moving out of the image plane if, for example, during the installation of the connector 30 in a direction perpendicular to the sheet plane between the current conductors 40, which exert a clamping pressure on the contact elements.

Fig. 5 shows a pickup for tapping the current from a busbar. The pickup 70 comprises two similar tapping elements 71, which, like the connector 30, is designed with two poles with two poles 34, 35 connected by an insulator frame 11. Each of the poles 34, 35 has a free-standing connection contact surface 74, which is conductively connected, for example by welding, to a connection conductor 73. The connection conductor has an opening for connection to the current conductor by means of connecting parts that are common in electrical installations. The two poles 34, 35 of the tapping element 71, like the connector 30, are provided with contact elements 60, with a smaller number of contact lamellae 61 than with the connector 30 being sufficient, since the tapper generally only part of the one

Current rail system taps current. Of course, larger quantities of electricity can also be dissipated by a plurality of consumers 71 connected in parallel without having to change the construction of the consumer 70. The tapping element 71 shown at the top in FIG. 5 is not connected to the two associated connecting conductors 73 for the purpose of illustration. The pickup 71 can be, because he two over one

Rail 72 interconnected tapping elements 71 has particularly easy to insert into the two openings 12 of a double-U busbar, so that by plugging in a particularly simple connection of the three phases and neutral conductors to a consumer, distribution box or the like can be realized. The busbar system is particularly flexible if, in addition to the straight connectors already described, 30 flexible angle connectors, not shown, are provided. These can be formed, for example, from two taps connected by a cable, such as, for example, a spiral cable or, preferably, a cable consisting of highly flexible strands (see also FIG. 5). It is particularly expedient if the two end faces of two busbars running at an angle to one another are connected by a bellows-like sleeve, in the interior of which the connecting cables run. The cuff is advantageously both flexible in terms of length and angle, ie it can be used for all conceivable connection problems, even with two angular planes. The flexible connecting piece also serves as an expansion joint, for example when using the busbar system in technical systems that are subject to high thermal or mechanical expansion or in which individual system parts vibrate. The connection cable lying inside the sleeve with a lot of play is able to absorb the change in length without any force acting on the rest of the conductor rail. The flexible angle connector according to the invention can therefore be used for all angles from 0 to 180 °, preferably 0 to 135 °, and moreover solves all connection problems which can occur due to an offset or a relative movement of two busbars to one another.

A common cavity can be provided in the interior of the bellows for receiving all connecting cables. A common cavity makes it possible, for example, to accommodate the cable running, compressing or compressing inside a bend, while the cable running in the outer region of the curve is almost taut. The bellows should be tightly connected at the connection point to the end faces of the busbars for safety and contamination reasons, for example by gluing or mechanical fastening.

The bellows can also be designed so that two rails 2 can be connected to each other, or that an entire busbar system profile (several busbars 2 simultaneously) are connected to each other.

In the case of the bellows, it is advantageously also taken into account that the cable pipe can be guided around bends, for example for data lines or glass fibers. Just like a cable, the flexible angle connector allows an unrestricted change of direction in the route of the conductor rail. As an independent component that can be integrated at any point, it is the solution to the practical problems described above. Unpredictable obstacles can also be easily skipped during assembly. A handicap caused by other trades, e.g. piping due to air conditioning and ventilation, can also be reacted to promptly. Together with the simple deflectability of the busbars, the planner can also achieve a planning goal by simply defining the main routes, even in the case of demanding architectural structures. Determining the exact

Angle dimensions are done by the installer during assembly on site. Dates and costs are therefore not negatively affected by unforeseeable events and the planning effort is reduced.

The embodiment of Fig. 8A shows one piece manufactured together

Busbars 2 with connecting profile 1. In addition, the shafts 13 are closed instead of being open laterally, as in FIG. 1. The shafts can serve as cable ducts or compressed air or cooling water pipes. The heat generated in the system by the current resistance can be dissipated via the cooling water. In plastic housings and connecting profiles can be in one of the open or closed shafts, for. B. 13A a grounding conductor (PE).

FIG. 8B essentially corresponds to FIG. 8 A, but the busbar and connecting profile are connected to one another in two pieces. However, the shafts 13 cannot be opened laterally either. However, unlike the embodiment from FIG. 1, the connection here is not made by clicking, but rather by pushing it in in the longitudinal direction.

Due to the modular structure, the busbar system according to the invention is superior in conceptual clarity to the known busbar systems. It consists of essentially six components. This includes the connection profile 1, the busbar 2, the straight connector 30, the angle connector, the feed element and the universal current collector. The small number of individual components ensures maximum clarity on the Construction site reached. The site preparation time is reduced and the actual start of assembly takes place shortly after delivery of the components. Due to the small number of components, the creation of the material lists is extremely easy during the planning phase. The administrative effort for tendering, ordering and tracking deadlines is reduced to a minimum. The clear concept makes efficient cost compliance and warehousing easier.

In contrast to known energy distribution systems in the high-current range, the current tapping in the busbars according to the invention is not subject to any system-related grid dimensions. Power can be tapped at any point, the current being tapped via special spring contacts 60 which, together with the tapper, are inserted at any point on the busbar between the current conductors 40. In particular, no fixed rail contact point is necessary. If necessary, the tap can even be pulled under voltage during operation and reinserted at another location. This makes it easier to make changes to the electrical installation within the term of a building or an industrial system. Thanks to the flexible tappers that can be used at any point, the busbar system can be easily adapted to any change in use. For the operator, there is a high degree of flexibility in use, or flexibility in the use of space with DataComCenters.

Another advantage of the invention lies in its fastening technology. The click system described above between the connection profile and the individual busbars or the cover ensures simple, fast, problem-free and harmless, even overhead installation at any location. The heavy loads (busbar) simply have to be clicked in overhead, after which they are already being held temporarily. The final fixation by the screw 7 and the clamping rail 5 can then take place without physical strain on the fitter. Installation and maintenance are carried out using simple standard tools, e.g. screwdrivers, dowel drills, etc.

The track system is also visually appealing because of its clear and simple elements. 1, only the material, for example aluminum in the shape of a triangle, can be seen. By the The system can therefore be installed in public areas with attractive design, even in the visible area, where it is even perceived as a design element. The costs for hiding the busbar behind the coverings and the installation of expensive inspection flaps in the ceiling construction are therefore eliminated. The free access also makes maintenance and modification of the system easier, as the facings do not have to be removed beforehand. The system can be fully integrated, for example, in suspended ceiling constructions thanks to easy-to-install additional connection profiles.

The individual components of the busbar system are made of sorted materials (no paint or insulating material-coated metals), which enable later separation and recycling without problems.

The materials are particularly environmentally friendly when halogen-free, non-toxic plastics are processed in the spacers 20. A particular advantage arises when additional materials are used that minimize the fire load in the event of a fire, which is positive for operational safety. In the event of a fire, there is in particular no additional damage to buildings or operating equipment caused by toxic substances and the risk of endangering people is minimized.

The characteristics of each system component, e.g. Busbars, housings, connectors, consumers, contact lamellae, spacers, current conductors, etc. also develop their effect according to the invention independently of a busbar system and are not bound to it. The invention is therefore not limited to a busbar system as a whole. Rather, the components mentioned can also be the subject of a further application.

Claims

claims

1. conductor rail system with longitudinal rails (2), with

- A housing (3) designed as a profile,

- At least one current conductor (40) running in the longitudinal direction of the busbar along its length

- Spacers (20) for fastening the current conductors to the housing.

2. System according to claim 1, characterized in that the housing is integrally formed, preferably made of plastic, together with the spacer.

3. System according to claim 1 or 2, characterized in that the busbars can be cut to length at any point in such a way that the current conductors can be electrically contacted by two busbars lying one behind the other in the longitudinal direction without further spacers being mounted on the end face of the busbars which has been cut to length have to.

4. System according to any one of the preceding claims, characterized in that the busbar can be cut to length by means of a saw, cutting disc or the like.

5. System according to any one of the preceding claims, characterized in that an elastic seal on the end face of the housing (3) of the busbar and / or the spacer (20), in particular by means of an adhesive layer, is attached.

6. System according to any one of the preceding claims, characterized in that the spacer (20) extends over the entire length of the conductor rail and with the housing of the conductor rail and with the conductor over the entire length of the conductor rail in one direction, in particular all directions , perpendicular to the longitudinal axis of the busbar, is connected.

7. System according to any one of the preceding claims, characterized in that the spacer is designed such that a leakage current path of at least 5, 6 mm is provided between the current conductor held by him and the housing or a current conductor running in parallel.

8. System according to any one of the preceding claims, characterized in that the spacer is movable in the longitudinal direction against the housing and / or the current conductor.

9. System according to any one of the preceding claims, characterized in that the spacer is designed as a profile.

1 O.System according to any one of the preceding claims, characterized in that the spacer is designed as a profile open in one direction, in particular as a V-shaped or U-shaped or cut O-shaped profile.

1 1. System according to one of the preceding claims, characterized in that the spacer can be produced or produced by a profile-shaping method, such as, for example, edging, extrusion or extrusion.

12. System according to one of the preceding claims, characterized in that the spacer is calibrated, preferably after the profile-forming method is vacuum calibrated.

13. System according to any one of the preceding claims, characterized in that the wall of the spacer is designed as a full or preferably with a plurality of longitudinally extending cavities (27) provided hollow profile.

14. System according to any one of the preceding claims, characterized in that the spacer consists of a solid electrically insulating material, in particular of plastics, such as PC, PC-ABS or the like.

15. System according to any one of the preceding claims, characterized in that spacers and current conductors have fastening means, in particular grooves (24) and springs (42), for fastening current conductors to the spacer.

16. System according to any one of the preceding claims, characterized in that the housing (3) is designed as an open in one direction (12) profile, in particular as a V-shaped or U-shaped or cut O-shaped profile with a profile space encompassed by the profile ,

17. System according to any one of the preceding claims, characterized in that the housing comprises several, in particular two, laterally connected, in particular integrally connected, open profiles.

18. System according to any one of the preceding claims, characterized in that the housing is made by a profile-shaping method, such as edges, extrusion or extrusion, preferably made of a high-strength material, such as an aluminum alloy, in particular AlMgSi0.5 and the like.

19. System according to any one of the preceding claims, characterized in that the housing on its inner wall (21) has prongs (102) which extend in the longitudinal direction of the housing.

20. System according to one of the preceding claims, characterized in that the outer wall of the spacer rests on the prongs (102), in particular exclusively on the prongs, on the housing.

21. System according to one of the preceding claims, characterized in that two current conductors, in particular current conductors which can be connected to a different electrical phase, are each fastened in a profile space.

22. System according to any one of the preceding claims, characterized in that the current conductor and / or spacer is provided in the profile space.

23. System according to any one of the preceding claims, characterized in that two current conductors which are in electrical contact and adjacent in the longitudinal direction are arranged to be movable with respect to one another.

24. System according to one of the preceding claims, characterized in that the current conductor has a contactable long side (41) over its entire length.

25. System according to any one of the preceding claims, characterized in that a connecting profile (1) is provided for laterally fastening one or more busbars on the longitudinal sides or edges of its housing.

26. System according to one of the preceding claims, characterized in that the connecting profile (1) is fastened over the entire length of the busbar on the longitudinal sides or edges of the housing.

27. System according to any one of the preceding claims, characterized in that the connecting profile is integrally connected to one or more busbars.

28. System according to any one of the preceding claims, characterized in that the connecting profile can be fastened to a wall or ceiling.

29. System according to one of the preceding claims, characterized in that the connecting profile has a continuous shaft (13) over its entire length

30. System according to any one of the preceding claims, characterized in that the shaft (13) is open to the side, wherein a longitudinal side of the busbar connected to the connecting profile closes the open side.

3 1. System according to one of the preceding claims, characterized in that the connecting profile is positively connected to the busbar via elastically deformable locking means (8).

32. System according to one of the preceding claims, characterized in that the elastically deformable locking means (8) in particular by a screw (6,7,8) can be fixed.

33. System according to one of the preceding claims, characterized in that consumers (70) are provided for tapping the current from the busbar system, the busbar and pick-up being designed such that contact of the customer with the current conductor at each location of the busbar is possible.

34. System according to one of the preceding claims, characterized in that connectors (30) are provided for the electrical connection of two longitudinally adjacent current conductors (40).

35. System according to one of the preceding claims, characterized in that the connector (30) are designed angled such that they can be used for the electrical connection of two current conductors (40) abutting at an angle.

36. System according to one of the preceding claims, characterized in that the customer (70) or connector (30) by vertical movement

/

Longitudinal direction of the busbar can be contacted with the conductor.

37. System according to one of the preceding claims, characterized in that the connector (30) can be contacted with the conductor by movement in the longitudinal direction of the conductor rail.

38. System according to one of the preceding claims, characterized in that the consumer (70) or connector (30) is formed with one or more poles, in particular with two poles.

39. System according to one of the preceding claims, characterized in that the customer (70) or connector (30) has a plurality of electrically insulated blocks (35) connected to one another by means of an insulator (1 1) and made of conductive material.

System according to one of the preceding claims, characterized in that two consumers or connectors are connected to one another by one or more flexible conductors.

41. System according to one of the preceding claims, characterized in that the flexible conductor is guided in a flexible sleeve, the sleeve being designed such that it can rest against the end faces of the busbars.

42. System according to one of the preceding claims, characterized in that a contact element (60) are provided on the customer (70) or connector (30).

43. System according to one of the preceding claims, characterized in that the contact element is clamped between the consumer or connector and the conductor.

44. System according to one of the preceding claims, characterized in that the contact elements are provided with springs (61).

45. System according to one of the preceding claims, characterized in that the contact elements have webs (62) on their longitudinal edges and the springs (61) connect the webs.

46. System according to one of the preceding claims, characterized in that the springs are twisted out of the web plane.

47. System according to one of the preceding claims, characterized in that two contact elements are arranged offset from one another and lying one above the other.

48. System according to one of the preceding claims, characterized in that the two contact elements are of identical construction, the springs being twisted asymmetrically out of the web plane in such a way that they project differently above and below the web.

49. System according to one of the preceding claims, characterized in that the current conductor is designed for currents of at least 100 A with an AC voltage of a maximum of 1,000 V.

50. System according to one of the preceding claims, characterized in that the system is designed such that loads, in particular distribution boxes, of at least 100 N per meter length can be attached to the system.

51. System according to one of the preceding claims, characterized in that the conductor rail system has a closed profile in cross section.

52. System according to one of the preceding claims, characterized in that a cover (4) is provided which is connected to the one or more busbars (2) in such a way that the current conductors (40) guided therein against environmental influences, in particular accidental contact, insects , Dust and dirt are protected.

53. System according to one of the preceding claims, characterized in that the cover can only be detached from the busbars by means of a tool, in particular a special tool.

54. System according to one of the preceding claims, characterized in that the connector (1), busbars (2) and cover (4) form a closed profile in cross section.

55. System according to one of the preceding claims, characterized in that the busbar is fixed on two longitudinal sides or edges.

Driving for installing busbars with busbars running in the longitudinal direction (2),

- Which is formed as a profile housing (3) with

- At least one current conductor (40) running in the longitudinal direction of the busbar along its length, and

- have spacers (20) for fastening the current conductors to the housing,

with the following steps:

- Cutting the busbar to length, in particular by means of a saw, thereby creating an end face on the busbar (2),

- Attach the busbar, and

- electrical contact of the current conductor (40) with further current-conducting parts (40),

without taking measures to extend the leakage current between the conductor and the housing, such as. B. installing additional spacers or acting on the spacer on the end face of the busbar or spacer created by cutting to length.