Kit for the automatic assembly or disassembly of laminated circuits

Abstract

This invention discloses a kit for automatically assembling or disassembling a laminated circuit (100). The laminated circuit (100) consists of an insulating sheet (100.i), line conductors (80) disposed between the insulating layers, and optionally includes insulating pads for structural straightening. Special electrical components (200) are connected to the structure via kit components. The kit includes: a jumper (90), a mounting nut (10), a stepped bushing (20), a bushing (30), a threaded head screw (40), a cylindrical head screw (50) for another embodiment, a plug (60), a connecting screw (70), and a slot (400) for integrating third-party components into the circuit (100), ensuring good electrical and mechanical contact with them. This invention enables the automated assembly or disassembly of the laminated circuit (100) by an industrial robot.

Description

Technical Field

[0001] This invention relates to a kit for automatically assembling or disassembling laminated circuits. The main technical field of this invention is the installation of busbars and their electrical components. More specifically, the invention relates to laminated busbars, wherein a conductive material, i.e., a kit component according to the invention, is applied to a layered insulating support to form a desired conductive pattern within the multilayer circuit conductors, sandwiched within the insulating support. Background Technology

[0002] Technical issues

[0003] The distribution panels used in electrical cabinets are well known in the art. These distribution panels, with appropriate wiring, are installed in various locations for power distribution and circuit protection, and are mainly equipped with circuit breakers, fault current circuit breakers, and similar electrical components known in the art.

[0004] The main technical challenge in manufacturing such distribution panels lies in the fact that the assembly process still requires a significant amount of manpower and is difficult to automate. In practice, distribution panels typically include top-up profile mounting rails on the back of the enclosure, onto which switchgear is secured. The switchgear is connected phase-by-phase via suitable electrical conductors (i.e., busbars), with one busbar for each single-phase device. A device called a "busbar box" is used for multi-phase applications. Therefore, the enclosure of the cabinet includes multiple cable conduits and numerous conductors inserted into these conduits, with connecting tabs positioned on the conductors. The conductors are inserted into and securely clamped to the connection terminals on the switchgear. The numerous conductors and corresponding contacts create a complex network that can be tracked, assembled, and disassembled with sufficient manpower and the attention of wiring personnel.

[0005] This invention solves the aforementioned standardization problems by using kit components, along with pre-fabricated insulating sheets and plate-shaped line conductors, to form a laminated circuit, to which electrical components are fixed. This kit component allows different layers to be electrically connected in the desired manner, and enables electrical components to be connected to them. The kit components are designed to use a minimal set of components suitable for automated assembly or disassembly. Thus, the complex conductor mesh is replaced by wiring similar to known multilayer printed circuits, provided that all mechanical contacts are interconnected via kit components and / or further connected to the line connectors and electrical components used. This solution provides a wiring mesh with virtually no connecting tabs, where the electrical components are specifically designed to mate with the kit. Furthermore, the contacts of this wiring type exhibit low contact resistance and excellent temperature resistance.

[0006] Those skilled in the art will immediately recognize the necessity of connecting third-party electrical components to the aforementioned (closed) component system in a certain manner. This invention addresses this technical problem by using a specific slot designed to receive third-party electrical components and provide a connection interface for engaging the laminated circuit. The slot is designed to enable automatic assembly to or removal from the laminated circuit. Furthermore, the slot allows the corresponding third-party electrical components to be automatically inserted into / ejected from the slot.

[0007] The term "automatic assembly or disassembly process" as used in these regulations refers to a process achieved using industrial robots without human intervention. A semi-automated process is one that requires only human intervention to perform a limited number of operations.

[0008] Existing technology

[0009] Some existing technical documents partially address the subject matter addressed by this invention.

[0010] In the invention "Busline Equipment for Use with Circuit Breakers or Other Devices" by Labinal LLC [US], published in European Patent Publication No. EP2724596B1, the formation of laminated circuits, the formation and interconnection of insulating layers and plate-shaped line conductors, and the connection of circuit breakers and other electrical components are taught. The system described in the '596 document is not universal, and virtually no modifications are possible. The cited '596 solution does not appear to mention the use of non-standard components (i.e., third-party components used with it).

[0011] In the invention "Busline Assembly" by ABB Patent GmbH [DE], European patent application publication number EP 1296431 A2, the connection of external elements (e.g., input lines) to a pre-prepared laminated circuit (busline) is taught. This cited patent application discloses a general method for achieving desired contacts at any depth of the laminated busline using a conductor equipped with a resilient member that adapts to the required hole around the contact. Furthermore, a plug for connecting the two conductive layers of the laminated busline is disclosed. The advantage of the '643 solution over the prior art lies in the simplification of the entire wiring process, enabling access to any laminated line conductor within the laminated structure. The cited solution has shortcomings in terms of the quality of the established contacts, and the flexibility of the solution remains questionable.

[0012] In the invention "Power Conversion Device" filed by Mitsubishi Electric Corporation [JP] and Toshiba MitsubishiElec.Inc. [JP], Japanese Patent Application Publication No. JP 2012095472 A, a screw connection for electrically connecting the electrical components of a power converter to a laminated circuit is disclosed.

[0013] Similarly, in the Japanese Patent Publication No. JP 3550970 B2, entitled "Power Converter, Multilayer Conductor and Electrical Component Connector," filed by Hitachi Ltd. [JP], a screw connection for electrically connecting electrical components of a power converter to a laminated circuit is again disclosed. Both solutions, '472 and '970, disclose permanent screw connections between components and laminates, which are known in the art, and do not address the interconnection issues between laminated circuit layers or the problem of automated assembly / disassembly.

[0014] In the invention “Circuit Breaker Distribution Panel”, filed by Power Distribution Products Inc. [US], U.S. Patent Publication No. 6,002,580, a detachable connection is taught between a circuit breaker or similar element and a laminated circuit located within the distribution panel. The solution cited in '580 provides a quick and reliable connection, but does not address the interconnection issues between laminated circuit layers or the issues of automated assembly / disassembly.

[0015] In the invention “Wiring Structure and Junction Box Including the Thereof”, with the applicant Mitsubishi Cable Industry Ltd. [JP] and U.S. Patent Publication No. 8,366,457, specific pin geometries for establishing electrical connections with desired conductive components and for establishing electrical connections within a laminated structure forming a circuit board are taught.

[0016] In the invention "Laminated Power Busbar for Suspension Chopper of Maglev Train" by Southwest Jiaotong University [CN], Chinese patent application publication number CN101237102A, a high-current laminated busbar is taught, which has contacts formed by the addition of conductive layers. The disclosed '102 system lacks flexibility.

[0017] In the invention “Method for manufacturing a multiphase busbar and apparatus for carrying out the method”, which is applied for by ABB Schweiz AG [CH] and has European patent application publication number EP3555980A1, a method of forming a laminated busbar structure is taught, which, like all the prior art mentioned above, is permanent and is additionally filled with resin, making the solution difficult to disassemble.

[0018] The cited prior art documents do not solve the technical problem, for example, by providing a method of forming a laminated circuit using kit components that facilitates the automated assembly or disassembly of the formed laminated structure (e.g., a distribution panel and components attached thereto). Summary of the Invention

[0019] This invention discloses a kit for automatically assembling or disassembling laminated circuits and their corresponding electrical components. The laminated circuit is based on two or more insulating sheets and multiple line conductors sandwiched between each of two adjacent insulating sheets. Optionally, a set of insulating pads with a thickness close to that of the line conductors are provided on the same layer to reinforce the structure. The entire laminated circuit is mechanically secured once formed.

[0020] Each line conductor from the same layer has at least one line terminating at a line connector equipped with a central hole for forming electrical contact with other kit components. One or more electrical components, or optionally third-party electrical components pre-inserted into slots, are connected to the laminated circuit via electrical and mechanical connections. This is implemented such that the electrical contacts of the electrical components are connected via kit components to desired line conductors located within the aforementioned laminated circuit.

[0021] The disclosed kit includes the following components:

[0022] (i) A jumper, each jumper having a jumper wire of arbitrary width and equipped with two or more jumper wire connectors, wherein each jumper wire connector is equipped with a center hole for forming electrical contact with other kit components distributed on the same layer.

[0023] (ii) Insert nuts for receiving screws from compatible kits, wherein the contact surface of each insert nut is sized to receive a line connector or jumper connector.

[0024] (iii) Stepped bushings, wherein each stepped bushing is sized to receive a line connector or jumper connector through its contact surface and is equipped with a hole through which a screw can pass freely.

[0025] (iv) Bushings, wherein each bushing has a hole through which a screw can pass freely.

[0026] When used in the same layer, the embedded nut, stepped bushing, and bushing are at the same height. One or more anti-rotation parts are formed on the outer surface of the kit element, which are nested in the corresponding insulating layer to prevent the kit element from rotating.

[0027] (v) Threaded head screws, wherein each threaded head screw has threads formed on its head to receive a connecting screw, to which an electrical component or slot is fastened.

[0028] (vi) A cylindrical head screw, wherein each cylindrical head screw has a cylindrical head with a fastening groove for receiving a snap fastener for a desired electrical component.

[0029] Each threaded head screw or cylindrical head screw has a shank with threads for fastening the screw into the insert nut, and the length of the shank is designed to accommodate n (n≥1) bushings or stepped bushings between the nut and the head stop.

[0030] (vii) Plugs, wherein each plug has at least a partially threaded rod for fastening the plug into an insert nut. The corresponding rod is sized to accommodate n (n≥1) bushings or stepped bushings between the nut and the flat end of the plug.

[0031] (viii) Connecting screws, wherein each connecting screw has at least a partially threaded shank for screwing the connecting screw into a threaded head screw.

[0032] (ix) Optionally, the kit includes one or more slots formed in the same or different manner. Each slot is equipped with an electromechanical mechanism designed for easy insertion and ejection of third-party electrical components. Furthermore, each slot enables the inserted third-party electrical component to have a locked mechanical position and good electrical contact with the laminated circuitry by means of threaded head screws designed to secure the slot and the electrical component.

[0033] The insert nut is designed to form electrical contact with a line connector or jumper connector, the geometry of its contact hole matching the external geometry of the threaded cylinder formed within the insert nut, and the distance from the contact surface to the top of the nut determined by the thickness of the line connector or jumper connector. Similarly, the stepped bushing is designed to form electrical contact with a line connector or jumper connector, the geometry of its contact hole matching the external geometry of the cylinder formed within the stepped bushing, and the distance from the contact surface to the top of the stepped bushing determined by the thickness of the line connector or jumper connector. In a variation of the invention, the stepped bushings and ordinary bushings (e.g., non-contact bushings) of all kits are of equal height, and the geometry of the corresponding contact hole or jumper hole is chosen to be the simplest geometry—a circle.

[0034] Each threaded head screw is equipped with a drive portion formed on the top of the head, which has machined threads formed in the head. The drive portion enables the threaded head screw to be screwed into and out of a fitted nut. Each cylindrical head screw is equipped with a drive portion formed on the top of the head, wherein the drive portion enables the cylindrical head screw to be screwed into and out of a fitted nut. Similarly, each plug is equipped with a drive portion formed in the flat head, wherein the drive portion enables the plug to be screwed into and loosened in a selected fitted nut.

[0035] In a preferred embodiment, the slot profile is sized to accommodate a dedicated third-party electrical component. The profile has a set of paired holes. Screw holes allow the slot to be fastened to a corresponding threaded head screw emerging from the laminate by inserting a pair of connecting screws through the screw holes. Assembly holes enable top-tooling operations during component assembly / removal within the slot using a component insertion rod. Contact ejection holes are the holes through which the component insertion rod ejects or retracts. Trigger pin holes are the holes through which the trigger pin protrudes during mechanical contact with the electrical component.

[0036] The electromechanical mechanism consists of a trigger pin, component insertion rods, pins, contacts, and springs. Inserting an electrical component into the slot engages with the trigger pin, which pushes the spring to the bottom of the slot and causes a pair of component insertion rods to rotate and be secured to their corresponding pins via their pin receiving portions. This action causes the component insertion rods to extend from the ejector hole into the electrical component contact hole and be secured with a component screw. Through the resilient contacts, the component insertion rods and their corresponding contacts are in permanent electrical contact. The contacts are electrically connected to the threaded screw and therefore also electrically connected to the laminated circuitry.

[0037] In a preferred embodiment, kit elements (i) to (ix) are used for automatically or semi-automatically assembling or disassembling the laminated circuit. In another variation, the automatic assembly or disassembly of the laminated circuit is carried out by an industrial robot in a manner known in the art. Attached Figure Description

[0038] Figure 1 An electrical component (i.e., a circuit breaker) connected to a laminated circuit is shown.

[0039] Figure 2 It shows Figure 1 A side view of the situation shown.

[0040] Figure 3 The internal structure of the laminated circuit and the corresponding circuit breaker connected to it are shown.

[0041] Figure 4 It shows Figure 3 The situation described, but without a circuit breaker.

[0042] Figure 5 The layer-by-layer peeling of the laminated circuit is shown to reveal the kit components used and how the in-layer contacts are formed.

[0043] Figure 6 Two wire connections are shown, each originating from a different laminated circuit layer and connected by a stepped bushing, a screw plug, and a fitted nut. Figure 6A The exploded view shows all the components used for the same connection.

[0044] Figure 7Two wire connections are shown, where both wires come from the same laminate layer and are connected by corresponding jumpers. Figure 7A The exploded view shows all the components used for the same connection.

[0045] Figure 8 This illustrates how external electrical components can be connected to the required wire connections located on a laminated circuit layer, wherein the connections are performed using threaded head screws and multiple bushings. Figure 8A The exploded view shows all the components used for the same connection.

[0046] Figure 9 This demonstrates how to connect an external electrical component to two wire conductors, each located on a different laminated circuit layer, wherein the connection is implemented by the use of threaded head screws and multiple bushings. Figure 9A The exploded view shows all the components used for the same connection.

[0047] Figure 10 This illustrates how external electrical components can be connected to some of the necessary wire connections located at the bottom of the laminated circuit, i.e., near the insert nut. The connections are implemented using threaded head screws and multiple bushings on each laminate layer. Figure 10A The exploded view shows all the components used for the same connection.

[0048] Figure 11A , 11B Figures 11C and 11C respectively show the fitted nut, the stepped bushing, and the standard bushing.

[0049] Figure 12A , 12B 12C and 12D show threaded head screws, cylindrical head screws, plug screws, and connecting screws, respectively. All screws can also be made in different heights (h) and widths.

[0050] Figure 13A and 13B Line conductors of various widths (w) and corresponding line connectors compatible with the aforementioned kit components are depicted.

[0051] Figure 14 A jumper with different lengths (D) and widths (w) is shown, which is compatible with the kit elements described above.

[0052] Figure 15 A mounting junction box (i.e., electrical component) suitable for fastening to a cylindrical head screw is shown. Figure 16 A 3D view of the junction box in its secured state. Figure 17 This is a side view under the same conditions.

[0053] Figure 18A third-party electrical component is shown, namely a circuit breaker and a corresponding slot in the form of receiving the component. Figure 19 A 3D view of a third-party electrical component being inserted into a slot. Figure 20 The slot and its mechanism are shown in their form after a third-party electrical component is inserted.

[0054] Figure 21 Side view of a third-party electrical component being inserted into a slot. Figure 22 A perspective view of the slot is shown when a third-party electrical component pops out. Figure 23 As shown Figure 21 A side view of the slot mechanism when a third-party electrical component is inserted. Figure 24 As shown Figure 22 The side view of the slot mechanism when there are no third-party electrical components inside the slot.

[0055] Figure label:

[0056] 10 Embedded Nuts

[0057] 11 Anti-rotation part 12 Threaded cylinder 13 Contact surface 14 Stop step

[0058] 15 outer surface, 16 holes, 17 threads

[0059] 20 stepped bushings

[0060] 21 Anti-rotation part 22 Cylinder 23 Contact surface 25 Outer surface 26 Hole

[0061] 30 bushing

[0062] 31 Anti-rotation part; 32 Cylindrical body; 35 Outer surface; 36 Hole

[0063] 40 threaded head screw

[0064] 41. Rod 42. Head stop 43. Neck 44. Head

[0065] 45 drive section 47 thread 48 starter thread

[0066] 50 cylindrical head screw

[0067] 51. Bar; 52. Head stop; 53. Neck

[0068] 54 Cylindrical head 55 Drive section 57 Thread 59 Fastening groove

[0069] 60 screw plug

[0070] 61 rod, 63 neck, 64 flat head, 65 drive section, 67 thread.

[0071] 70 connecting screws

[0072] 71 rod, 74 head, 75 drive section, 77 thread

[0073] 80 line conductor

[0074] 81 Line 82 Connection Part 86 Contact Hole

[0075] 90 jumper

[0076] 91 Jumper wire; 92 Connector; 96 Contact hole

[0077] 100-layer laminated structure

[0078] 101.i insulating sheet; i = 1, 2, 3, ...

[0079] 200 electrical components

[0080] 202 Screw hole; 207 Electrical contact; 209 Snap fastener; 210 Spring

[0081] 300 third-party electrical components

[0082] 302 screw hole 320 contact hole

[0083] 400 slots

[0084] 401 Trigger pin hole; 402 Assembly hole; 404 Contact ejection hole; 407 Screw hole

[0085] 410 Trigger pin; 420 Component insertion rod; 423 Pin receiving part

[0086] 430 pin, 440 contact part, 444 elastic contact, 450 spring Detailed Implementation

[0087] This invention relates to a kit for automatically assembling or disassembling laminated circuits. Those skilled in the art will recognize the necessity of component standardization if they wish to automate the assembly or disassembly of circuits, particularly laminated circuits.

[0088] kit components

[0089] Figure 11A An insert nut (10) is depicted. In a preferred embodiment, the insert nut (10) is formed as a rotating body, and an anti-rotation portion (11) is formed at a portion near the outer cylindrical surface (15) formed at the bottom of the nut (10). In a preferred embodiment, Figure 11A The anti-rotation portion (11) is formed as a rectangular surface perpendicular to the bottom of the insert nut (10). In other variations, two or more surfaces may be machined on the cylindrical surface, for example, by machining it into a hexagonal nut.

[0090] The nut (10) also has a contact surface (13) and a stop step (14). The stop step (14) allows the nut (10) to be nested in the desired insulating sheet (100.i) after being covered, for example, with Figure 3 As shown, the diameter of the hole formed in the insulating sheet corresponds to the diameter of the covering insulating sheet (100.i), which is smaller than the stop step (14), and the hole has the diameter of the contact surface (13). Therefore, once the corresponding screws (40, 50, 60) are screwed into the nut (10), the stop step (14) prevents the nut (10) from passing through the covering insulating sheet (100.i).

[0091] In one variation, the nut (10) is machined without the stop step (14), and the contact surface (13) extends to the outer surface (15). In this variation, the diameter of the hole formed in the corresponding covering insulating sheet (100.i) is equal to the diameter of the outer surface (15), and is machined to match one or more anti-rotation portions (11). In this variation, the nut (10) cannot secure different layers as in the variation described above, but the insulating sheet (100.i) can be machined more easily without forming a step in the hole formed in the insulating sheet (100.i).

[0092] Once the insert nut (10) is covered by the insulating sheet (100.i) during assembly, it will be locked in place by the stop step (14) or other elements connected to the nut (10), just as in the variant without the stop step (14).

[0093] One or more anti-rotation portions (11) prevent the nut (10) from rotating during the tightening of the screws (40, 50, 60). The contact surface (13) is designed to make contact with connectors (82, 92) formed at the ends of the lines (81, 91), i.e., the line conductors (80) or the jumpers (90). The contact surface (13) is Figure 13A The connectors (82, 92) depicted in 13B and 14 have simple, stepped placement. Contact holes (86, 96) are designed to easily accommodate threaded cylinders (12) with internal threads (17), into which compatible screws (40, 50, 60) are screwed by inserting their threads into holes (16). It will be readily apparent to those skilled in the art that the screws (40, 50, 60) used may have different heights and diameters that match the inner diameter of the nut (10) used.

[0094] Those skilled in the art will immediately recognize that all outer nut surfaces can also be machined into polygons. In this sense, even the connectors (82, 93) and their corresponding contact surfaces (13) can be machined into polygons that match each other. However, the simplest geometry for machining and assembly is a circular geometry.

[0095] Figure 11B A stepped bushing (20) is depicted. The stepped bushing (20) is primarily formed as a rotating body, having one or more anti-rotation portions (21) formed on portions of the outer cylindrical surface (25). The one or more anti-rotation portions (21) function the same as those in the previously described insert nut (10) and can be machined in the same manner. The stepped bushing (20) is also equipped with a contact surface (23). The contact surface (23) functions the same as the contact surface (13) formed on the nut (10). Contact holes (86, 96) are designed to easily accommodate a hollow cylinder (22) equipped with a hole (26) through which various screws (40, 50, 60) can pass without obstruction. As previously described, those skilled in the art will readily recognize that all outer stepped bushing surfaces can also be machined into polygons, as can the corresponding connectors (82, 92).

[0096] Figure 11C The bushing (30) is depicted. The bushing (30) is mainly formed as a rotating body (32) and has one or more anti-rotation portions (31) formed on the cylindrical surface (35), which have the aforementioned technical functions. The hole (36) formed through the bushing (30) is designed to allow various screws (40, 50, 60) to pass through it without obstruction.

[0097] Figure 12A A threaded head screw (40) with a shank (41) is depicted, the shank (41) having a thread (47) compatible with a nut (10), wherein the shank (41) has an arbitrary height (h). In a variation of the invention, the screw (40) has a stepped neck (43) connecting the shank (41) and a head stop (42). The head (44) is formed as a cylinder above the head stop (42). The head (44) is equipped with an internal thread (48) capable of receiving a corresponding connecting screw (70) and is equipped with a drive portion (45) for screwing the screw (40) into the nut (10).

[0098] Figure 12B A cylindrical head screw (50) with a shank (51) having a thread (57) compatible with a nut (10) is depicted, wherein the shank (51) has an arbitrary height (h). In a variation of the invention, the screw (50) has a stepped neck (53) connecting the shank (51) and a head stop (52). The head (54) is formed as a cylinder above the head stop (52). The head (54) is equipped with a fastening groove (59) capable of interacting with a snap fastener (209) of a desired electrical component (200) and is equipped with a drive portion (55) for screwing the screw (50) into the nut (10).

[0099] Figure 12CA plug screw (60) is depicted having a threaded shank (61) of arbitrary height (h) and threads (67) for screwing into a fitted nut (10), wherein the shank (61) is of arbitrary height (h). In a variation of the invention, the screw (60) has a stepped neck (63) connecting the shank (61) and a flat head (64) equipped with a drive portion (65).

[0100] When the aforementioned screws (40, 50, 60) are machined with stepped necks (43, 53, 63), the stepped necks have the same technical function as the stop step (14). Machined on the nut (10), they have the following function: once the screw is screwed into the corresponding nut (10), the stepped necks (43, 53, 63) allow the screws (40, 50, 60) to fasten the corresponding insulating sheet (100.i) and this stepped component together, as shown in the image. Figure 3 and Figure 4 As shown. If the screws (40, 50, 60) are machined without the stepped neck (43, 53, 63), the diameter of the hole formed in the corresponding covering insulating sheet (100.i) is equal to the diameter of the head stop (42, 52) or flat head (64) used. In this variation, the screws (40, 50, 60) cannot secure different layers as in the variation above, but the insulating sheet (100.i) used can be machined more easily.

[0101] Figure 12D A threaded (77) connecting screw (70) is depicted, the thread (77) being formed on the rod (71), which engages with the head thread (48) in a threaded head screw (40). The connecting screw (70) has a head (74) and a corresponding drive portion (74) formed thereon.

[0102] Those skilled in the art will immediately recognize that the only size requirement imposed on the screws (40, 50, 60) lies in the internal thread (17) formed in the insert nut (10). Other sizes are arbitrary and can be selected according to the needs of different insulating sheets.

[0103] Figure 14 A jumper (90) is depicted with two holes (96) formed at its connector (92), wherein the connector (92) is connected to a jumper wire (91) of arbitrary length (D). Those skilled in the art will readily deduce the design regarding the length (D), width (W), and number of connectors (92) here. The jumper (90) may be equipped with three or more connectors (92) distributed along the same line, or in any other convenient geometry, such as a zigzag. The thickness of the jumper (90) depends on the kit components used and other technical requirements.

[0104] Figure 13A and13B Various line conductors (80), i.e., lines of various widths (w), and end connectors (82) formed at the ends of the corresponding lines (81) are depicted. Such ends, i.e., connectors (82), form the input / output of a complex mesh made of conductors (80) arranged in various topologies and schemes within each laminate. Each connector (82) is equipped with a contact hole (86) that matches a hollow cylinder (12, 22), which is formed on a nut (10) and a stepped bushing (20), respectively. The line conductors (80) and the corresponding elements (81, 82) do not constitute compatible kit elements (10, 20, 30, 40, 50, 50, 70).

[0105] All of the aforementioned kit elements (10, 20, 30, 40, 50, 60, 70, 90) and the corresponding line conductors (80) are preferably formed of a metal with good electrical and thermal properties, for example, aluminum, copper, and their alloys. In another variation, if desired, the nut (10) may be formed of an insulating material; it should be remembered that this choice will certainly improve the insulation performance of the entire insulating sheet using the nut (10).

[0106] Formation of laminated circuits

[0107] Figures 1 to 5 A good example of a laminated circuit is described. A laminated circuit (100) used in an electrical cabinet typically consists of two or more insulating sheets (101.i), where i = 1, 2, ... n. Typically, the thickness of the insulating sheets can be the same or different. The number of insulating sheets (101.i) depends on the complexity of the circuit, the number of phases used, etc. Generally, the material of the insulating sheets (101.i) is a common material used in the manufacture of printed circuit boards (PCBs) and has good insulation properties. Those skilled in the art will select a suitable insulating material based on thermal requirements. Unlike standard low-current and low-voltage PCBs manufactured with placed line conductors, a dedicated grid of line conductors (80) is designed for the electrical cabinet, sandwiched between the insulating sheets (101.i, 101.i+1). An example of this solution can be found in EP2724596B1, which has been cited in the prior art herein. When the line conductors (80) are unevenly distributed on the insulating sheet (100.i), a set of insulating pads with a thickness close to that of the line conductors (80) needs to be distributed around the line conductors (100.i) to form a more robust and dense laminated circuit layer. The thickness of the line conductors (80) used depends primarily on the maximum current expected to flow through them, the type of conductor used (i.e., copper or aluminum), and the heat dissipation requirements that must be met, which is a well-known technique.

[0108] In practice, automated assembly begins with the initial layer, namely the insulating sheet (100.1), which is larger than the size of the grid of all the line conductors (80) used. Bottom kit components, such as insert nuts (10), are placed on this insulating sheet. Then, the custom insulating sheet (100.2) (see...) is... Figure 4 and Figure 5 The insert nut (100.2) is designed with a space for the nested nut (10) and is placed directly on the first insulating sheet (100.1). All insert nuts (10) are provided with an anti-rotation part (11) that prevents them from rotating once they are embedded in the insulating sheet (100.2). A first layer of line conductors (80) is then laid on the insulating sheet (100.2), with insulating pads optionally distributed around it if necessary. Some of the line conductors (80) are connected to the insert nuts (10) in a manner that will be discussed later in this document. Then, the next custom insulating sheet (100.3) is placed. In one variation, the insulating sheet (100.3) has a hole and a nesting part. The hole is designed to receive a stepped bushing (20) or bushing (30), while the nesting part is designed to receive the insert nut (10). In this variation, the nut (10) has a stop step (14), and the hole and nesting part are different. During tightening of the screws (40, 50, 60), the nesting portion prevents the insert nut (10) from passing through the insulating sheet (100.i) covering the nut (10). In another variation of the invention, the insert nut (10) is formed without a stop step (14), and the number of holes formed in the insulating sheet (100.i) is as many as the nesting portion. Each hole / nesting portion has a portion for receiving anti-rotation portions (11, 21, 31) to prevent the corresponding elements (10, 20, 30) from rotating in place.

[0109] How to use an insulating film formed of insulating paper or other convenient material to insulate the various wires (81) from each other within the connection points of the laminate (100), i.e., close to the corresponding holes (82, if necessary), is clear to those skilled in the art. Such insulation should be provided in advance for the automatic or semi-automatic assembly of the laminate.

[0110] Then, a second layer of line conductors (80) are deployed on an insulating sheet (100.3), some of which are connected to the insert nut (10) or the stepped bushing (20) in a manner discussed below.

[0111] In the same manner as described above, the structure is augmented, optionally by using insulating gaskets, adding new custom insulating sheets (100.i, 100.i+1, ...), and corresponding line conductors (80) sandwiched between every two layers. When the desired laminated circuit is formed, it is mechanically secured by a set of fasteners, preferably by external screws or elastic bands, which locks all layers together.

[0112] The kit components for automatically assembling or disassembling laminated circuits are the focus of this invention. These kit components address further technical problems encountered by those skilled in the art when assembling or disassembling laminated circuits using automated or semi-automated methods:

[0113] A, the way corresponding line conductors (80) belonging to the same layer are interconnected.

[0114] B refers to the interconnection method of corresponding line conductors (80) belonging to different layers.

[0115] C. The method of connecting the corresponding line conductor (80) to the standard electrical component (200) directly mounted on the laminated circuit, and

[0116] D. The corresponding line conductor (80) is connected to the slot (400) mounted above the laminated circuit and capable of receiving third-party electrical components.

[0117] In this sense, it is beneficial to delve into the examples and understand the function of all the kit components.

[0118] A. Same-layer connection

[0119] Figure 7 and Figure 7A The scenario depicts the connection of two conductors (80) from the same layer, where the layer is not the bottom layer (i.e., the insulating layer (100.2)). This situation can be seen in... Figure 3 The central part. Two insert nuts (10) are close to each other, along with other components, nested within an insulating layer (100.3), which was previously customized to receive / cover the set of two nuts (10). A grid of line conductors (80) is then placed on the layer (100.3), wherein the connectors (82) of the two line conductors (80) are equipped with contact holes (86) that mate with contact surfaces (13) formed on the insert nuts (10), see Figure 7Then, other connections are formed on the same layer as needed. Subsequently, a new insulating layer (100.4) is deployed. This layer (100.4), excluding others, is formed with holes to receive the stepped bushing (20) and the corresponding anti-rotation portion (21), positioned directly above the previously placed insert nut (10). Above the stepped bushing (20), a jumper (90) is positioned so that its contact hole (96) is on the contact surface (23). Finally, an insulating layer (100.5) is deployed, with two screw plugs (60) extending through the insulating layer (100.5), the jumper (90), the bushing (20), and the line connector (82) formed at the ends of the line conductors (80), and finally screwed into the nut (10). Thus, a same-layer connection is established between the line conductors (80). The screw's stepped neck (63) locks the screw plug (60) into the nesting portion previously provided on the insulating layer (100.5), as... Figure 4 As shown.

[0120] Similarly, other screws (40, 50, 60), i.e., their screw necks (43, 53, 63), can be nested in the corresponding insulating layers. Once the screws (40, 50, 60) are tightened with the desired insert nut (10), the laminated structure (100), 63) is reinforced by pressing the stop step (14) of the corresponding nut (10) against the screw neck (43, 53), see Figure 3 and Figure 4 .

[0121] The above setup can still be implemented well by using a nut (10) without the stop step (14) and screws (40, 50, 60) without corresponding stepped necks (43, 53, 63). In this variation, the external fastening of the laminated structure (100) should be implemented with more care, taking into account the absence of internal reinforcements between the stop steps (14), the layers / elements between them, and the stepped necks (43, 53, 63).

[0122] B. Connections between different layers

[0123] Figure 6 and Figure 6A The scenario depicts the connection of two line conductors (80) from different layers. Figure 4The same situation is depicted at the leftmost position within the layered structure (100). The formation of the layer is the same as described in Case A above; the insert nut (10) is again nested in the insulating layer (100.2), and a corresponding grid of wire conductors (80) is deployed thereon. Wider wire conductors (80) and their wire connectors (82) are placed on the contact surfaces (13) formed on the insert nut (10). Then, other connections are formed on the same layer as needed. Then, a new custom insulating layer (101.3) is deployed, and the bushing (20) is positioned above the wire connectors (82) in the holes already formed in the insulating layer (101.3). Subsequently, a new corresponding grid of wire conductors (80) is deployed on top, with one of its wire connectors (82) placed on the contact surfaces (23) formed on the stepped bushing (20). Then, a new layer (101.4) is deployed with a custom nest for receiving screws (60). Finally, the screw (60) extends out of layer (101.4), the upper line connector (82), the bushing (20) located in layer (101.3), the lower line connector (82), and then is screwed into the nut (10) nested in layer (101.2).

[0124] The above setup can still be implemented well by using a nut (10) in a variant without a stop step (14) and screws (40, 50, 60) without corresponding stepped necks (43, 53, 63).

[0125] The systems described in A and B are generally applicable. A set of jumpers (90) can be identical; however, it is clear in practice that jumpers with various lengths (D) and widths (w) are also available (see...). Figure 14 It can be used for a variety of needs. In addition, it is obvious that stacking more bushings (20) makes it possible to establish three or even four different connections, i.e., connections between line conductors (80) deployed on three or more layers.

[0126] C. Connection of special electrical components

[0127] The connection of the electrical components (200) is more complex. Figure 1 and Figure 3A variation is depicted in which a dedicated electrical component (200) is connected to a laminated structure (100) once formed. First, the electrical component (200), such as a circuit breaker, is designed to mate with the disclosed kit. Therefore, each electrical component (200) has two or more electrical contacts (207) positioned such that these contacts can be accessed through screw holes (202) formed above the electrical contacts (207). The aforementioned screw holes (202) allow a specially designed connecting screw (70) to be inserted through the hole (202) and to fasten the electrical contacts (207) to a threaded head screw (40) designed for this purpose. Threads (77) machined on the shank (71) of the connecting screw are designed to mate with threads (47) machined in the head (44) of any of the threaded head screws (40). Essentially, the threaded connection of the connecting screw (70) and the threaded head screw (40) ensures good electrical and mechanical connections, and allows for easy assembly and disassembly simply by tightening and loosening, as... Figure 10 or Figure 10A As shown.

[0128] More importantly, it is the way the threaded head screw (40) interacts with one or more line conductors (80) disposed on one or more insulation layers (101.i). Figure 8 The example depicted shows a threaded head screw (40) that is connected only to a line conductor (80) located three layers below the top surface of the laminated circuit (100), to which some electrical components (200) can be attached. Figure 8A An exploded view of the same structure is depicted. The formation of the layers and the fastening of screws to nuts with or without stop surfaces (14) and stepped necks (43, 53, 63) in one or more variations have already been explained in sections A and B above. Therefore, it is important to connect the line conductor (80) to the embedded nut (10) located at the rightmost position of the insulation layer (101.3), as Figure 3 As shown. Two bushings (30) are positioned above the nut (10), one above the other, one at the insulation layer (101.4) and the other at the insulation layer (101.5). Similarly, Figure 9 and Figure 9A The case with two line conductors (80) is depicted. In this example, the stepped bushing (20) and line conductor (80) setup, which has been described in A. and B. above, are used here to add an additional line conductor (80) connection to the structure, which is fastened to the bottom insert nut (10) by a threaded head screw (40).

[0129] Those skilled in the art will readily recognize that the shank (41) of each threaded head screw has threads for fastening into the insert nut (10), and that the length of the shank (41) of the threaded head screw is designed to accommodate n (n≥1) bushings (20, 30) between the nut (10) and the head stop (42). Therefore, one or more different threaded head screws (40) differing only in their height (h) should be used to implement the invention. In this sense, comparison Figure 8A The threaded head screw (40) uses two bushings (30) between the corresponding head stop (42) and the nut (10) and the corresponding head stop (42). Figure 10A The use of a threaded head screw (40) with three bushings (30) is inspiring.

[0130] To connect the dedicated electrical component (200) to the already disclosed laminated structure (100), other fastening variations can also be used. In yet another variation of the invention, no fastening is used. Figure 12A The threaded head screw (40) shown is instead used Figure 12B The cylindrical head screw (50) is depicted in the image. The difference between the screw (40) and the screw (50) lies in their head construction. The cylindrical head screw (50) has the same connection capability as the threaded head screw (40) already mentioned in the laminated structure (100). However, the cylindrical head screw (50) interacts with the component (200) in a completely different way. The cylindrical head screw (50) has a cylindrical head (54) equipped with a fastening groove (59). The fastening groove (59) is designed to interact with the snap fastener (209) formed in the electrical component (200), for example, as Figures 15 to 17 As shown. The mounting junction box (200) has a mechanism consisting of snap fasteners (209) driven by a spring mechanism (210), see Figure 17 In one variation, the snap fastener (209) can be partially pulled out of the element (200), causing the cylindrical head (54) of the corresponding cylindrical head screw (50) to protrude into the element (200). When the snap fastener is released, a spring retracts it, and the snap fastener (209) locks the cylindrical head (54) into its retaining groove (59). In this way, the element (200), i.e., the mounting junction box (200) designed to mate with the kit according to the invention, is mechanically secured and electrically connected to the laminated circuit (100).

[0131] D. Connection of non-standard electrical components

[0132] Those skilled in the art will immediately recognize that, as described in Section C, there are significant drawbacks to securing specially designed electrical components (200) with threaded head screws (40) or cylindrical head screws (50). The system is closed and dedicated, and only electrical components (200) specifically designed for this system are compatible. In practice, this means limited availability of spare parts and a lack of versatility. To overcome this difficulty, a universal slot (400) is designed that interacts with the laminated circuit (100) on one side and serves as an interface for connecting standardized third-party electrical components (300) to the circuit (100), see [see section C]. Figures 18 to 24 .

[0133] exist Figures 21 to 24 The method by which the slot (400) is connected to the laminated circuit (100) is described. As described in the previous sections, a pair of threaded head screws (40) are first installed on the laminated circuit (100). Then, a pair of connecting screws (70) passing through the hole (407) at the bottom of the slot (400) body secure the slot (400) to the laminated circuit (100) both electrically and mechanically.

[0134] The slot (400) has an electromechanical mechanism developed for receiving a third-party electrical component (300). For simplicity, a variant with a U-shaped slot will be described in this specification. However, other variants of the slot (400) are also possible, while still being able to accommodate a dedicated third-party electrical component (300).

[0135] The mechanism consists of a pair of trigger pins (410), a component insertion rod (420), a pin (430), a contact (440), and a spring (450). The situation before inserting the component (300) is as follows: Figure 22 and Figure 24 As shown. A trigger pin (410) extends from the profile of the U-shaped slot (400) and passes through a pair of trigger pin holes (401) inside the slot (400). Each trigger pin (410) is driven by a spring (450), which also presses a corresponding component insertion rod (420) to be concealed within the U-shaped housing, see... Figure 22 and Figure 24 The component insertion rod (420) is pivotally mounted to the pin (430), allowing the rod (420) to be inserted from... Figure 24 Rotate to the position shown Figure 23 The component insertion rod (420) can also extend through the contact ejection hole (404) inside the slot (400), see... Figure 22 .

[0136] The electrical component (300) is inserted into the slot (400) and engaged with the trigger pin (410), pushing the spring (450) towards the bottom of the slot (400). This action causes a pair of component insertion rods (420) to rotate and be secured to the corresponding pins (430) via pin receiving portions (423), resulting in the component insertion rods (420) extending through the ejector holes (404). If the electrical component (300) is correctly inserted into the slot (400), the component insertion rods (420) enter the corresponding contact holes (320) of the component (300). Once the component insertion rods (420) are in the desired holes, electrical contact is established by standard electrical component screws, which enter through screw holes (302), typically located on top of the component (300), and secure the rods (420) within the component (300). In this way, excellent electrical contact is formed between the component insertion rods (420) and the third-party electrical component (300). On the opposite side, within the slot (400), the component insertion rod (420) makes permanent elastic electrical contact with the corresponding contact portion (440). That is, as... Figure 24 As shown, one side of each resilient contact (444) is connected to the corresponding component insertion rod (420), and the other side is connected to the aforementioned contact portion (440). Each contact portion (440) is further fixed to the corresponding threaded head screw (40) by a connecting screw (70), and thus also fixed to the laminated circuit (100).

[0137] The pair of holes (402) formed at the top of the U-shaped profile serve a dual purpose. First, during the insertion of the element (300), they help to push the element insertion rod (420) into the contact hole (320) if necessary. Second, and more importantly, the holes (402) serve as maintenance holes in case of disassembly failure. That is, after many years, the spring (450) may weaken, and the element (300) may loosen from the slot (400), causing the element insertion rod (420) to fail to return to the U-shaped profile. For this reason, the pair of holes (402) are designed to provide assistance in such a hypothetical failure scenario of the electromechanical mechanism.

[0138] Industrial applicability

[0139] The industrial applications of this invention are readily apparent. This invention discloses a kit for automating the assembly or disassembly of laminated circuits and their corresponding electrical components, preferably implemented using an industrial robot specifically designed for such purposes. For this application, a high degree of uniformity in the components used is required; this invention discloses such a closed system, yet it still allows for the integration of third-party components, offering high flexibility and reliability.

Claims

1. A kit for automatically assembling or disassembling a laminated circuit (100) and its corresponding electrical components (200) and third-party electrical components (300); -in, The laminated circuit (100) is based on two or more insulating sheets (100.i) and multiple line conductors (80) sandwiched between two adjacent insulating sheets (100.i, 100.i+1), in the same layer, having a set of insulating pads with a thickness close to that of the line conductors (80) to reinforce the structure, and the entire laminated circuit (100) is mechanically fastened once formed; - wherein each of the line conductors (80) has at least one line (81) equipped with a line connector (82), the line connector (82) having a central hole (86) for forming electrical contact with other kit components. - wherein one or more of the electrical components (200) are connected to the laminated circuit (100) in an electrical and mechanical manner, or a third-party electrical component (300) is pre-inserted into a slot (400) and connected to the laminated circuit (100) in an electrical and mechanical manner, such that its electrical contacts are connected to the desired line conductors (80) within the laminated circuit (100) via the other kit components. The kit includes the following components: - A jumper (90), wherein each of the jumpers (90) has a jumper wire (91) of arbitrary width, the jumper wire (91) being equipped with two or more jumper wire connectors (92), each of the jumper wire connectors (92) being equipped with a center hole (96) for forming electrical contact with other kit elements distributed on the same layer; - An insert nut (10) for receiving a threaded head screw (40) and a cylindrical head screw (50) of a compatible kit, wherein the contact surface (13) of each of the insert nuts (10) is sized to receive the line connector (82) or the jumper connector (92). - Stepped bushings (20), wherein each of the stepped bushings (20) is sized to receive the line connector (82) or the jumper connector (92) through its contact surface (23), and has holes (26) through which the threaded head screw (40) and the cylindrical head screw (50) can pass freely. - Bushing (30), wherein each of the bushings (30) has a hole (36) through which the threaded head screw (40) and the cylindrical head screw (50) pass freely. When used in the same insulating layer, the embedded nut (10), the stepped bushing (20), and the bushing (30) are of equal height. One or more anti-rotation portions (11) are formed on the outer surface (15) of the embedded nut (10), one or more anti-rotation portions (21) are formed on the outer surface (25) of the stepped bushing (20), and one or more anti-rotation portions (31) are formed on the outer surface (35) of the bushing (30). The anti-rotation portions are nested in the corresponding insulating layer. - Threaded head screws (40), wherein each of the threaded head screws (40) has a head thread (48) formed on its head (44) to receive a connecting screw (70), to which an electrical component (200) or slot (400) is fastened; - Cylindrical head screws (50), wherein each of the cylindrical head screws (50) has a cylindrical head (54) with a fastening groove (59) for receiving a snap fastener (209) of the electrical component (200). The shank (41) of each of the threaded head screws (40) or the shank (51) of the cylindrical head screws (50) has threads for fastening the threaded head screws (40) and the cylindrical head screws (50) into the insert nut (10), and the length of the shank (41, 51) is designed to accommodate n of the stepped bushings (20) and bushings (30) between the insert nut (10) and the head stop (42, 52), where n ≥ 1; - Plug (60), wherein each of the plugs (60) has at least a partially threaded rod (61) for fastening the plug (60) into the insert nut (10), the rod (61) being sized to accommodate n of the stepped bushings (20) and bushings (30) between the insert nut (10) and the flat head (64), n≥1; - Connecting screws (70), wherein each connecting screw (70) has at least a partially threaded shank (71) for screwing the connecting screw (70) into the threaded head screw (40); and One or more of the slots (400) have electromechanical mechanisms designed to facilitate the insertion and ejection of the third-party electrical component (300) in the slots (400), wherein each of the slots (400) provides the third-party electrical component (300) with a locked mechanical position and forms good electrical contact with the laminated circuit (100) by means of the threaded head screws (40) securing the slots (400) and the third-party electrical component (300).

2. The kit according to claim 1, wherein, The insert nut (10) makes electrical contact with the line connector (82) or the jumper connector (92) such that the geometry of the center hole (86, 96) matches the external geometry of the threaded cylinder (12) formed inside the insert nut (10), and wherein the distance from the contact surface (13) to the top of the insert nut (10) is determined according to the thickness of the line connector (82) or the jumper connector (92).

3. The kit according to claim 1, wherein, The stepped bushing (20) forms an electrical contact with the line connector (82) or the jumper connector (92) such that the geometry of the center hole (86, 96) matches the external geometry of the cylinder (22) formed within the stepped bushing (20), and wherein the distance from the contact surface (23) to the top of the stepped bushing (20) is determined according to the thickness of the line connector (82) or the jumper connector (92), all the stepped bushings (20) and the bushing (30) have the same height, and each of the center holes (86, 96) has a circular geometry.

4. The kit according to claim 2, wherein, All of the stepped bushings (20) and bushings (30) have the same height, and each of the central holes (86, 96) has a circular geometry.

5. The kit according to claim 1, wherein, Each of the threaded head screws (40) is equipped with a drive portion formed on the top of the head (44), in which the head (44) has machined head threads (48), wherein the drive portion is capable of screwing the threaded head screw (40) into or out of the insert nut (10).

6. The kit according to claim 1, wherein, Each of the cylindrical head screws (50) is equipped with a drive portion formed on the top of the head (54), wherein the drive portion is capable of screwing the cylindrical head screw (50) into or out of the insert nut (10).

7. The kit according to claim 1, wherein, Each of the screw plugs (60) is equipped with a drive portion formed in the flat head (64), wherein the drive portion is capable of screwing the screw plug (60) into or out of the insert nut (10).

8. The kit according to claim 1, wherein, Each slot (400) profile is sized to accommodate a dedicated third-party electrical component (300), wherein the profile has a set of holes (401, 402, 404, 407) distributed thereon, wherein: - The screw hole (407) allows the slot (400) to be fastened to the corresponding threaded head screw (40) protruding from the laminated circuit (100) by inserting a pair of connecting screws (70) through the screw hole (407); - Assembly hole (402), during the assembly / disassembly of the third-party electrical component (300) in the slot (400), the assembly hole (402) enables top tool operation by using the component insertion rod (420); - Contact pop-out hole (404), through which the component insertion rod (420) pops out or retracts; and - Trigger pin hole (401), trigger pin (410) extends through the trigger pin hole (401) and makes mechanical contact with the third-party electrical component (300); The electromechanical mechanism is composed of the trigger pin (410), the component insertion rod (420), the pin (430), the contact part (440), and the spring (450); - In this process, the third-party electrical component (300) is inserted into the slot (400), engaging the trigger pin (410), which pushes the spring (450) towards the bottom of the slot (400) and rotates a pair of component insertion rods (420), which are fixed above the corresponding pin (430) by the pin receiving portion (423), so that the component insertion rods (420) extend from the contact pop-out hole (404) and enter the component contact hole (320), and are then fixed with the electrical component screw. Each component insertion rod (420) is permanently electrically contacted by an elastic contact (444) with the corresponding contact portion (440) electrically connected to the threaded head screw (40) by the connecting screw (70), and is then connected to the laminated circuit (100).

9. The use of the kit according to any one of claims 1 to 8 for automating or semi-automating the assembly or disassembly of the laminated circuit (100).

10. The use of the kit according to claim 9, wherein, The automatic assembly or disassembly of the laminated circuit is performed by an industrial robot.

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