Low-voltage cabinet full insulation live switching device and switching method

Abstract

The embodiment of the application provides a low-voltage cabinet full-insulation live switching device and a switching method, the device comprising: a socket mechanism comprising an insulating shell and a conductive rod sleeved in the insulating shell, a first end of the conductive rod extending out of a first end of the insulating shell; a clamp mechanism comprising a clamp arm, a sliding assembly and a rotating shaft, the sliding assembly being in sliding connection with the first end of the conductive rod, the clamp arm being connected with the sliding assembly; the rotating shaft being coaxially arranged with the conductive rod and being in threaded connection, the rotating shaft being in rotational connection with the sliding assembly; a large-current terminal without a table belt contact finger comprising a current-carrying sleeve and a pin, the current-carrying sleeve being connected with a second end of the conductive rod, the pin being in plug-in connection with the current-carrying sleeve; an intermediate conversion connector comprising a fixed mounting part and an intermediate conversion locking part, the fixed mounting part being connected with the socket mechanism, the intermediate conversion locking part being used for connecting an external cable interface. The application can realize live clamping installation in a narrow space of a low-voltage cabinet, support power distribution network non-power-off operation and improve power supply reliability.

Description

Technical Field

[0001] This invention belongs to the field of power supply technology for power systems, and particularly relates to a fully insulated live transfer device and transfer method for low-voltage cabinets. Background Technology

[0002] With the increasing demands for power supply reliability and the continuous development of live-line working (LLM) technology, LLM in low-voltage distribution networks has gradually become a key means to improve power supply service quality and ensure users' electricity needs. As the final link in power transmission, the distribution network faces challenges such as complex equipment types, diverse maintenance targets, and complex environments including communities and busy urban areas. These challenges include obstacles, interference from upper-level lines, and compact layouts. In some scenarios, maintenance can only be completed through short-term power outages.

[0003] Currently, live-line work on distribution networks has formed a three-in-one system of "live-line, bypass, and generation," but low-voltage cabinet switching operations still have many technical limitations, mainly in the following aspects:

[0004] 1. Difficulty in live installation: Traditional interfaces require power outage operation and rely on manual phase verification, which can easily lead to operational risks; the existing combiner clamp and other tools have unreasonable structural designs, and the conductive path must pass through multiple components such as copper busbars, clamp arms, and conductive rods, resulting in excessive contact resistance, which can easily cause overheating and burnout. In addition, the clamp head size is too large and cannot be adapted to the narrow space inside the low-voltage cabinet and the scenario with small copper busbar spacing.

[0005] 2. Insufficient scenario adaptability: Existing interfaces are mostly designed for specific equipment, making it difficult to cover the copper busbar layout of low-voltage cabinets of different manufacturers and specifications. Conventional busbar clamps cannot meet the needs of all scenarios. The coverage of quick interface installation is insufficient, which restricts the efficiency improvement of low-voltage power supply and power generation operations.

[0006] 3. Interface technology needs to be upgraded: Existing low-voltage high-speed interfaces mostly adopt a split design, which is bulky, cumbersome to install, and costly; mechanical locking lacks structural error prevention features, posing a risk of incorrect assembly; and the current carrying capacity is insufficient, making it difficult to stably support the transmission of rated current.

[0007] 4. Insufficient protection level, which may easily lead to safety accidents; lack of live and non-live status indication, which cannot provide effective early warning to operators.

[0008] Therefore, there is an urgent need to develop a low-voltage cabinet switching method that can achieve full insulation, live installation, multi-scenario adaptability, and low cost, to solve many pain points of existing technologies and promote the achievement of the "zero power outage" goal for low-voltage distribution network uninterrupted operation. Summary of the Invention

[0009] The embodiments of this application provide a fully insulated live-line transfer device and transfer method for low-voltage cabinets, which can achieve live clamping installation in the confined space of low-voltage cabinets, support uninterrupted power supply operations, and improve power supply reliability.

[0010] In a first aspect, embodiments of this application provide a fully insulated live-line switching device for low-voltage cabinets, comprising:

[0011] A socket mechanism includes an insulating housing and a conductive rod sleeved in the insulating housing, with a first end of the conductive rod extending from a first end of the insulating housing;

[0012] The clamping mechanism includes a clamping arm, a sliding assembly, and a rotating shaft. The sliding assembly is slidably connected to the first end of the conductive rod, and the clamping arm is connected to the sliding assembly, forming a clamping space between the clamping arm and the conductive rod. The rotating shaft is coaxially arranged with the conductive rod and threadedly connected. The rotating shaft is rotatably connected to the sliding assembly to drive the sliding assembly to move the clamping arm.

[0013] A high-current terminal without a strap and contact fingers includes a current-carrying sleeve and a pin. The current-carrying sleeve is connected to the second end of the conductive rod, and the pin is inserted into the current-carrying sleeve.

[0014] An intermediate adapter connector includes a fixed mounting part and an intermediate adapter locking part. The fixed mounting part is connected to a socket mechanism, and the intermediate adapter locking part is used to connect an external cable interface.

[0015] In one alternative embodiment, the clamping mechanism further includes an adjustable guide groove, which is arranged parallel to the conductive rod to guide the sliding assembly to move along a predetermined trajectory.

[0016] In one alternative embodiment, the clamping mechanism further includes a multi-angle adaptation module disposed at the end of the clamping arm for adjusting the angle of the clamping arm relative to the conductive rod.

[0017] In one alternative embodiment, the current-carrying sleeve includes a first part and a second part, the first part having a slotted structure to form a spring sheet for a cantilever beam structure, the spring sheet being inclined along the axis of the first part.

[0018] In one optional embodiment, a temperature measuring mechanism is also included. The temperature measuring mechanism is disposed on the insulating housing and connected to the conductive rod for monitoring the temperature at the contact point. The insulating housing and the intermediate conversion connector constitute a fully insulating protective structure, providing overall insulation protection for the device.

[0019] Secondly, embodiments of this application provide a fully insulated live-line switching method for low-voltage cabinets, including:

[0020] S1. Identify the layout and installation space of the target copper busbar, and adjust the clamp arm angle of the adapter according to the identification result;

[0021] S2. Align the conductive rod of the adapter with the target copper busbar, and drive the clamp arm and the conductive rod to clamp the target copper busbar together;

[0022] S3. A conductive path is formed by the direct contact between the conductive rod and the target copper busbar, and the current is transmitted through the conductive rod to the high-current terminal without the strap contact finger.

[0023] S4. Connect and lock the intermediate conversion connector of the adapter to the external cable interface;

[0024] S5. Real-time monitoring of the status parameters of the contact point between the conductive rod and the target copper busbar; status parameters include temperature, and when the monitored temperature exceeds the preset threshold, an early warning signal is triggered;

[0025] S6. After the operation is completed, disconnect the intermediate conversion connector from the external cable interface in sequence, loosen the clamp on the target copper busbar, and remove the adapter.

[0026] In one optional implementation, in S1, the angle of the clamp arm of the adapter is adjusted, specifically by adjusting the angle of the clamp arm through the multi-angle adaptation module of the adapter so that the clamping surface of the clamp arm is adapted to the arrangement direction of the target copper busbar.

[0027] In one optional implementation, S2 specifically includes: rotating the pivot to drive the sliding assembly to slide along the conductive rod, thereby causing the clamp arm connected to the sliding assembly to move toward the conductive rod until the clamp arm and the conductive rod clamp the target copper busbar.

[0028] In an alternative implementation, in S3, the current-carrying sleeve of the high-current terminal without a strap contact finger forms an annular contact band with the pin through its spring to establish a low-resistance conductive connection.

[0029] In an alternative implementation, S6 includes: first operating the intermediate conversion connector to disconnect from the external cable interface, and then reversing the drive of the clamp arm to release the clamp on the target copper busbar.

[0030] The technical solution provided in this application optimizes the clamping mechanism and conductive path design, allowing the conductive rod to directly contact the copper busbar. This reduces the series contact resistance introduced by the multi-component connection in traditional busbar clamps. By shortening and simplifying the current path, the overall contact resistance and heat generation risk are significantly reduced. This enables the device to achieve safe and reliable live clamping installation in the confined space of low-voltage cabinets without the need for drilling holes or removing bolts from the copper busbar. By integrating an adjustable multi-angle adapter module into the clamping mechanism, the orientation of the clamping arm can be changed through mechanical adjustment, allowing it to precisely fit with copper busbars arranged in different directions, such as horizontal and vertical. This fundamentally solves the problem that existing tools cannot adapt to various cabinet layouts due to their rigid structure, achieving broad coverage of all scenarios with a single device. By designing a high-current terminal without a strap or contact fingers, it utilizes current-carrying... The spring and pin, formed by an integrated slot, replace the traditional complex multi-part watch strap contacts with a minimalist integrated structure. This significantly reduces manufacturing costs while ensuring high current transmission capacity and insertion / removal life. The interface is modularized into a fixed mounting part and an intermediate conversion locking part, separating the permanent mounting parts from the movable connection parts. This allows for large-scale deployment with lower fixed part costs, while the movable part adapts to standard interfaces, balancing economy and versatility. Finally, in terms of operational safety, an integrated temperature measuring mechanism monitors the temperature of electrical connection points in real time, proactively monitoring and warning of potential overheating risks. At the same time, full insulation protection and a direct-insertion locking structure with mechanical foolproof features provide passive dual protection for live operation. These measures together constitute a safety system that combines active monitoring and passive protection, effectively eliminating the risk of misoperation and electric shock. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of a fully insulated live transfer device for a low-voltage cabinet provided in an embodiment of this application;

[0032] Figure 2 This is a schematic diagram of the clamp arm structure of a fully insulated live transfer device for low-voltage cabinets provided in an embodiment of this application;

[0033] Figure 3 This is a schematic diagram of the conductive rod structure of a fully insulated live transfer device for low-voltage cabinets provided in an embodiment of this application;

[0034] Figure 4 This is a schematic diagram of the intermediate conversion connector structure of a fully insulated live transfer device for low-voltage cabinets provided in this application embodiment;

[0035] Figure 5 This is a schematic diagram of a high-current terminal structure without a band contact finger for a fully insulated live transfer device for low-voltage cabinets provided in this application embodiment;

[0036] Figure 6This is a schematic diagram of the high-current terminal structure without contact fingers of a fully insulated live transfer device for low-voltage cabinets provided in this application embodiment;

[0037] Figure 7 This is a flowchart of a fully insulated live-line transfer method for low-voltage cabinets provided in an embodiment of this application.

[0038] In the picture:

[0039] 1. Socket mechanism; 11. Conductive rod; 2. Clamping mechanism; 21. Clamping arm; 22. Rotating shaft; 23. Multi-angle adapter module; 24. Adjustable guide groove; 25. Conductive contact head; 3. High-current terminal without strap contact finger; 31. Current-carrying sleeve; 32. Pin; 33. First part; 34. Second part; 35. Spring; 36. Flared mouth; 37. Spring limit; 38. Terminal insulating shell; 39. Positioning slot; 310. Protective section at the tail of the insulating shell; 311. Tail anti-reverse sealing structure; 312. Conductive contact ring of the pin; 313. Guide head at the front end of the pin; 4. Intermediate conversion connector; 41. Fixed mounting part; 42. Intermediate conversion locking part. Detailed Implementation

[0040] The present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0041] Reference Figures 1-6 The device includes:

[0042] The socket mechanism 1 includes an insulating housing and a conductive rod 11 sleeved in the insulating housing, with the first end of the conductive rod 11 extending from the first end of the insulating housing.

[0043] The clamping mechanism 2 includes a clamping arm 21, a sliding assembly, and a rotating shaft. The sliding assembly is slidably connected to the first end of the conductive rod 11. The clamping arm 21 is connected to the sliding assembly, and a clamping space is formed between the clamping arm 21 and the conductive rod 11. The rotating shaft 22 is coaxially arranged with the conductive rod 11 and threadedly connected. The rotating shaft 22 is rotatably connected to the sliding assembly to drive the sliding assembly to move the clamping arm 21.

[0044] The high-current terminal 3 without a strap contact finger includes a current-carrying sleeve 31 and a pin 32. The current-carrying sleeve 31 is connected to the second end of the conductive rod 11, and the pin 32 is inserted into the current-carrying sleeve 31.

[0045] The intermediate conversion connector 4 includes a fixed mounting part 41 and an intermediate conversion locking part 42. The fixed mounting part 41 is connected to the socket mechanism 1, and the intermediate conversion locking part 42 is used to connect an external cable interface.

[0046] In some embodiments, the socket mechanism 1 is the foundation of the entire adapter, and it mainly consists of an outer insulating shell and an inner conductive rod 11. The insulating shell, made of high-strength insulating material, needs to simultaneously meet the requirements of good electrical insulation performance and sufficient mechanical strength. The electrical insulation performance ensures that even when an operator holds the shell during low-voltage live work, there is no risk of electric shock, completely isolating the high voltage within the shell. Sufficient mechanical strength ensures that the shell will not easily break or deform when installed and used in confined spaces, or even when subjected to slight pressure or impact, thus maintaining the reliability of its insulation protection. This insulating shell completely encloses the internal live metal components, forming a safe operating interface.

[0047] The conductive rod 11 is a metal rod encapsulated inside an insulating shell. It is made of copper alloy materials with high conductivity, such as phosphor bronze or nickel-cobalt-silicon copper alloy, to minimize the resistance generated by the current passing through the rod itself, thereby reducing unnecessary power loss and heat generation. The conductive rod 11 is fitted inside the cavity of the insulating shell, with its first end extending from the corresponding end of the insulating shell. The end face of the extended part is provided with a conductive contact head 25 for direct contact with the busbar copper busbar inside the low-voltage cabinet, responsible for the final output of the current. "Direct contact" means that the end face of the conductive rod 11 achieves a large-area, tight physical contact with the surface of the copper busbar.

[0048] This design allows current to flow from the copper busbar into the conductive rod 11 via the shortest path and in the most direct manner, without the need for other intermediate conversion components (such as additional connecting pieces or bolts). This reduces the number of connection points that may generate contact resistance at the source. Contact resistance is a key factor affecting conductivity and heat generation. Its sum can be expressed as the superposition of the resistances of each part; that is, the total contact resistance consists of the volume resistance of the conductive rod 11 itself and the contact resistance of all connection points. By making the conductive rod 11 directly contact the copper busbar, the number of connection points in this summation can be minimized, laying a good foundation for achieving low-resistance, high-current transmission.

[0049] In some embodiments, the clamping mechanism 2 is a key component of the entire device responsible for performing gripping and fixing actions. It securely and stably clamps the conductive parts of the device onto the busbar copper busbar inside the low-voltage cabinet under energized conditions, ensuring good and reliable electrical contact between the two. The clamping mechanism 2 mainly consists of a clamping arm 21, a sliding assembly, and a rotating shaft 22. The clamping arm 21 is a component typically made of metal, used to directly contact the target copper busbar. The sliding assembly is connected to the clamping arm 21 to enable linear movement of the clamping arm 21. Specifically, the sliding assembly is slidably connected to the first end of the conductive rod 11 extending from the insulating housing. In this embodiment, the sliding assembly is specifically a sliding sleeve structure, directly sleeved on the outside of the first end of the conductive rod 11. This connection allows the sliding assembly to move back and forth along the axial direction of the conductive rod 11, carrying the clamping arm 21. An adjustable clamping space is formed between the clamping arm 21 and the relatively fixed conductive rod 11, which is used to accommodate and clamp the target copper busbar.

[0050] The rotating shaft 22 and the conductive rod 11 are positioned on the same central axis and are connected to each other via threads. Simultaneously, the end of the rotating shaft 22 can rotate relative to the aforementioned sliding assembly. When the operator needs to clamp the copper busbar, rotating the rotating shaft 22 causes it to axially feed or retract relative to the conductive rod 11 due to the threaded connection between the shaft 22 and the conductive rod 11. This axial movement pushes or pulls the sliding assembly, which is rotatably connected to it, thereby moving the entire clamping arm 21 along the axis of the conductive rod 11, thus clamping or releasing the copper busbar. This threaded drive method allows the operator to generate a sufficiently large and stable clamping force with a relatively small rotational force. More importantly, the thread itself has a self-locking characteristic; once clamped, the clamping arm 21 will not loosen due to vibration or other external forces without reverse rotation, ensuring a durable and stable connection.

[0051] Furthermore, to ensure more precise and smooth movement of the clamping arm 21 and prevent skewing or jamming during movement, the clamping mechanism 2 is also designed with an adjustable guide groove 24. The adjustable guide groove 24 is parallel to the axis of the conductive rod 11. The sliding assembly may have protrusions or sliders that engage with the adjustable guide groove 24 to restrict and guide the sliding assembly and the connected clamping arm 21 to move only along a pre-set straight trajectory, ensuring that the clamping arm 21 maintains good parallel alignment with the conductive rod 11 throughout the opening and closing process. In this way, when the clamping arm 21 finally clamps the copper busbar, the clamping surface can be evenly stressed, avoiding poor contact or excessive local pressure caused by skewing.

[0052] Furthermore, to address the complexities of varying copper busbar arrangements (horizontal, longitudinal, or diagonal) on-site, the clamping mechanism 2 integrates a multi-angle adaptation module 23 at the end of the clamping arm. This module allows manual adjustment of the clamping arm 21's orientation angle, which can be adjusted within a 0° to 180° range. This enables the clamping surface of the clamping arm 21 to adapt to horizontal, longitudinal, and diagonally arranged copper busbars. For example, when the copper busbar is arranged horizontally, the clamping arm 21 is adjusted to a horizontal position; when it is arranged vertically, it is adjusted to a vertical position. This adjustment capability ensures that regardless of the copper busbar's arrangement, the clamping arm 21 can clamp it with the maximum effective contact area, a crucial prerequisite for achieving low contact resistance and stable connection.

[0053] Furthermore, considering the reliability and electrical performance of actual operation, the surface of the clamp arm 21 that contacts the copper busbar is usually specially treated. On the one hand, the surface is machined with anti-slip textures to increase friction and prevent slippage or displacement due to external force or vibration after clamping. On the other hand, the surface is coated with an anti-oxidation coating, which prevents the oxide layer on the surface of the copper busbar from affecting the direct conductive contact between metals during clamping, ensuring smooth current flow and reducing contact resistance.

[0054] In summary, the clamping mechanism 2 can control the clamping arm 21 to perform stable and reliable linear clamping action by rotating the shaft 22. Combined with the precise guidance of the adjustable guide groove 24 and the flexible adjustment of the multi-angle adaptation module 23, it can adapt to various narrow spaces and copper busbars with different arrangement directions, realizing safe, efficient, and fully insulated live clamping operation, providing a solid foundation for subsequent current transmission.

[0055] In some embodiments, the high-current terminal 3 without a band contact is the core electrical connection component for achieving efficient and reliable current transmission in this device. One end of the high-current terminal 3 without a band contact is connected to the conductive rod 11, which is in direct contact with the copper busbar, and the other end is used to connect to the plug from an external cable. Its core function is to provide a repeatedly pluggable and stably connected electrical contact interface while ensuring extremely low contact resistance and excellent current carrying capacity, thereby replacing the traditional complex and expensive connector structure. The high-current terminal 3 without a band contact mainly consists of two parts: a current-carrying sleeve 31 and a pin 32. The current-carrying sleeve 31 is a cylindrical metal part. One end of it is the end of the conductive rod 11 that does not directly contact the copper busbar, i.e., the second end, achieving both electrical and mechanical connection. In this way, the current introduced from the copper busbar can flow directly into this current-carrying sleeve 31. The pin 32 is a cylindrical metal conductor, which is usually part of an external standard cable connector. When a conversion operation is required, this pin 32 is inserted into the current-carrying sleeve 31 to complete the circuit connection.

[0056] In this embodiment, the high-current terminal 3 without a strap-shaped contact finger eliminates the complex process of assembling multiple independent spring contact fingers in traditional connectors. Elastic contact is achieved through an integrated spring. Specifically, the current-carrying sleeve 31 is divided into two parts. This division aims to achieve functional decoupling, process adaptation, and optimal performance, balancing elastic conductive current carrying and mechanical fixed connection. This resolves the contradiction between elasticity and rigidity in traditional integrated current-carrying structures. The first part 33 is the elastic conductive core segment. Through slotting, a cantilever beam-like spring 35 and a horn-shaped guide structure are formed, undertaking elastic contact, precise guidance, and high-current low-resistance transmission, directly forming the current-carrying structure to reduce contact resistance. A series of longitudinal slots are formed on the wall of the first part 33 (the end used to insert the pin 32). These slots divide the wall material into several independent, elastic strips. The roots of these strips are connected to the body of the current-carrying sleeve 31, while the heads remain free, forming a "cantilever beam" structure. These strips forming a "cantilever beam" structure are springs 35, which are key to achieving elastic contact in the high-current terminal 3 without a strap or contact fingers. These springs 35 are not installed later, but are directly machined from the current-carrying sleeve 31 as a whole.

[0057] Furthermore, during manufacturing, these reeds are radially tapered to give them an inwardly tilted profile along the axis of the current-carrying sleeve 31. This pre-set tilt angle guides the insertion of the pin 32 and pre-sets the contact pressure. At the head of the reed, its inner surface is designed as a "flared mouth" shape composed of multiple small arc segments. This flared mouth 36 structure has two important functions: first, it guides and centers the pin 32 upon insertion, ensuring smooth alignment; second, the multiple arc segments better adapt to the shape of the pin 32, ensuring a wider and more continuous contact area. In addition, to further enhance contact stability and flow equalization, shallow grooves can be machined on the outer surface of the reed head for mounting auxiliary reeds or miniature springs.

[0058] The second part 34 of the current-carrying sleeve 31 is a mechanically fixed transition section, responsible for a stable connection with components such as the pin 32 and the conductive rod 11, providing structural support and enabling modular docking, ensuring stable assembly and extended electrical path. When the pin 32 of the external cable is inserted into this specially designed current-carrying sleeve 31, its working process is as follows: The pin 32 first contacts the flared end 36 guide surface of the spring head. During continued insertion, the outer surface of the pin 32 presses against these springs with pre-tilt angles, forcing the springs to elastically deform and open outward. Since the springs are cantilever beam structures, this deformation generates a continuous and uniform normal contact pressure pointing towards the center of the pin 32 at its head. This pressure creates a tight metal-to-metal contact between the inner surface of the springs and the outer surface of the pin 32. As multiple springs surround the pin 32, a continuous, annular, high-quality electrical contact band is formed. Current flows from the conductive rod 11 into the body of the current-carrying sleeve 31, and then through this annular contact band, is efficiently transmitted to the pin 32, and then flows to the external cable.

[0059] Furthermore, the spring limiter 37 provides space for the elastic deformation of the cantilever beam spring 35, while limiting the maximum deformation of the spring 35. This prevents excessive deformation of the spring 35 during insertion and removal, which could lead to yielding damage and significantly improves the insertion and removal life and reliability of the high-current terminal 3 without a dial indicator contact finger. The terminal insulating shell 38 is a high-strength insulating shell that fits over the current-carrying sleeve 31 to achieve full insulation protection, meeting the IP65 / IP67 waterproof and dustproof rating requirements and avoiding the risk of live exposure. The positioning slot 39 is a structure that fixes the terminal insulating shell 38 and the metal current-carrying sleeve 31, preventing axial and radial movement between the two, ensuring structural stability during insertion and removal, and preventing the insulating shell 38 from falling off and the current-carrying sleeve 31 from shifting. The protective section 310 at the tail of the insulating shell protects the cable connection part at the tail, preventing cable bending and impact damage, while further improving the insulation protection performance at the tail. The tail-end anti-reverse sealing structure 311 is used to prevent the current-carrying sleeve 31 from axially retracting within the insulating housing 38, preventing the current-carrying sleeve 31 from being pulled out during insertion and removal; it works in conjunction with the sealing ring to achieve a waterproof and dustproof seal at the tail. The pin conductive contact ring 312 is a high-precision polished contact surface on the pin 32, which fits tightly with the cantilever beam spring 35 to form a stable conductive contact. The pin front guide head 313 is the guiding structure at the very front of the pin 32, which cooperates with the flared opening 36 of the current-carrying sleeve 31 to further reduce the coaxiality requirement for insertion, allowing for smooth insertion even with slight deviations and preventing damage to the elastic spring from misalignment.

[0060] The core advantage of this design lies in its significantly optimized current path and contact resistance. Traditional connection methods may require multiple series mechanical contacts, resulting in a large cumulative resistance. In this embodiment, the conductive rod 11 directly abuts against the copper busbar, reducing the number of contact points at the front end. Furthermore, the slotted spring 35 forms a large-area, high-pressure annular contact with the pin 32, reducing the resistance of this sliding contact interface to a very low level. The one-piece molded spring eliminates another point of additional contact resistance between the independent contact finger and the base. Therefore, the overall contact resistance is very low, and heat generation is minimal when carrying large currents, achieving stable high-current transmission capability and improving product lifespan and reliability. Simultaneously, the minimalist integrated structure reduces the number of components, significantly lowers manufacturing and assembly costs, and makes the product more compact, perfectly suited to the limited space requirements of low-voltage cabinets.

[0061] In some embodiments, the core purpose of the intermediate adapter connector 4 is to reliably and conveniently connect the simplified dedicated interface of this device, optimized for confined spaces, to a wide variety of common cable tools with varying standards used on construction sites (such as the output plug of a generator vehicle, quick-connect cable connectors for bypass operations, etc.). The intermediate adapter connector 4 includes a fixed mounting part 41 and an intermediate adapter locking part 42. The fixed mounting part 41 is the part that makes a permanent or semi-permanent connection to the socket mechanism 1 of this device. It can be understood as a standardized output port of the adapter device itself, designed to be firmly connected to the socket mechanism 1 to form a whole. The intermediate adapter locking part 42 is the external interface end of the intermediate adapter connector 4, specifically used for quick docking and locking with various external standard cable interfaces.

[0062] During installation, the fixed mounting part 41 is assembled with the device's socket mechanism 1 (typically connected to the high-current terminal 3 without a strap or contact fingers), and pre-installed as a single component on the copper busbar of the low-voltage cabinet. When operators need to perform switching operations, there is no need to carry or modify the entire device; they only need to directly insert or align the existing, industry-standard generator plug or cable quick connector into or with this intermediate conversion locking part 42. This design achieves a smooth transition between dedicated interfaces and general-purpose tools, eliminating the need to customize a dedicated adapter for each set of standard tools or to modify any existing, numerous, and expensive standard operating tools. This greatly improves the compatibility and flexibility of the equipment and significantly reduces the overall equipment cost for users.

[0063] The target components to be connected are the high-current busbar inside the low-voltage cabinet and the external standard cable. The entire device adopts a two-stage connection structure: on the equipment side, the fixed mounting part 41 and the socket mechanism 1 (which integrates a high-current terminal 3 without a strap contact finger) are assembled as a whole, pre-clamped and installed on the target copper busbar inside the cabinet; on the cable side, the intermediate conversion locking part 42 is used for quick docking and locking with various standard cable interfaces. Through this design, a safe, reliable, and fully insulated high-current transfer from the copper busbar inside the cabinet to the external standard cable is achieved.

[0064] Furthermore, to achieve a fast and reliable connection, the intermediate adapter connector 4 employs a direct-insertion locking mechanism as the primary connection method. Operators simply insert the standard plug axially into the corresponding port of the intermediate adapter locking part 42. Upon insertion into the predetermined position, the internal mechanical structure (such as a snap-fit, spring, or rotating slot) automatically locks, ensuring a secure and reliable electrical connection. To cope with harsh environments where vibrations or other factors could cause accidental loosening, an optional secondary locking mechanism is designed as a higher level of safety. This secondary locking structure is a dedicated design for the intermediate adapter connector 4, specially customized for use in confined spaces in low-voltage cabinets and fully insulated live-line work scenarios. It is integrated with the intermediate adapter connector 4 and, combined with mechanical foolproof features, forms a double locking mechanism on top of the direct-insertion locking, preventing accidental connection detachment. After the initial direct-insertion locking is completed, the secondary locking mechanism can be operated again, providing double insurance for the connection and fundamentally eliminating the risk of accidental disconnection due to external forces. This is crucial for ensuring the continuity and safety of live-line work.

[0065] In addition, connectors typically integrate mechanical error prevention designs. Through physical structural asymmetry (such as a specific shaped socket or misaligned positioning keyway), they ensure that the external plug can only be inserted in the single correct direction and position, thereby completely avoiding the risk of electrical short circuits or equipment damage caused by incorrect insertion, and improving the safety and fault tolerance of the operation.

[0066] In summary, the intermediate conversion connector 4, through a series of designs including direct-insertion locking, optional secondary locking, and foolproof features, achieves fast, safe, and reliable connection in confined and complex operating environments. This design effectively solves problems such as interface incompatibility, high construction costs, and difficulty in operation within limited spaces associated with traditional solutions, making it a key component for the large-scale, low-cost promotion and application of low-voltage cabinet conversion operations.

[0067] Furthermore, a low-voltage cabinet fully insulated live-line adapter also includes a temperature measuring mechanism. This mechanism is mounted on the insulating housing and connected to the conductive rod 11, used to monitor the contact point temperature. The insulating housing and the intermediate conversion connector 4 form a fully insulated protective structure, providing overall insulation protection for the device. Specifically, the insulating housing completely covers the conductive rod 11 and the metal parts of the clamping mechanism 2. The intermediate conversion connector 4 is also fully insulated, with a sealed structure at the connection between its fixed mounting part 41 and the socket mechanism 1, ensuring that after docking, the entire outer surface of the device forms a continuous, complete, and fully insulated protective structure without exposed conductors.

[0068] In some embodiments, during low-voltage live-line switching operations, temperature is a key indicator reflecting the quality of electrical connections and the stability of operation. A temperature measuring mechanism continuously monitors the temperature changes at the critical connection point in the current path—the contact area between the conductive rod 11 and the copper busbar inside the low-voltage cabinet—throughout the switching and power supply process. This contact point is a crucial interface in the entire current path. If the contact resistance increases due to improper installation, oxidation of the contact surface, or loosening, abnormal Joule heating will be generated when a large current flows, causing a rapid rise in local temperature. Excessive temperature not only accelerates material oxidation and damages insulating components, but in extreme cases, it may even trigger welding or fire, posing a serious threat to equipment and operators. Therefore, continuous monitoring of this temperature point is a core measure for achieving preventative safety assurance.

[0069] The temperature sensing mechanism is typically integrated into the insulating housing of the device and forms an effective connection with the internal conductive rod 11 to sense its temperature. Exemplarily, the temperature sensing mechanism may include a temperature sensor, a signal processing unit, and an alarm indication unit. The temperature sensor can be installed at a location capable of sensitively and accurately capturing temperature changes in the contact area between the conductive rod 11 and the copper busbar. To achieve direct and rapid measurement, the sensor's probe end is tightly thermally coupled to the corresponding part of the conductive rod 11 through a dedicated channel on the insulating housing or using a method with good thermal conductivity, ensuring that it reflects the real temperature of the contact point in real time, rather than the ambient temperature. The signal processing unit is responsible for receiving the temperature signal from the sensor and converting it into a recognizable and identifiable electrical signal. This unit internally presets one or more temperature thresholds, which are safety limits set based on the allowable operating temperature rise of the conductive material, the tolerance of the insulating material, and safety regulations.

[0070] From the moment the adapter successfully clamps the copper busbar and is powered on, the temperature sensor begins monitoring. It continuously converts the sensed temperature data into electrical signals and transmits them to the signal processing unit. The processing unit constantly compares and judges the received real-time temperature values ​​with internally preset safety thresholds. As long as the real-time temperature is below the safety threshold, the system is in normal monitoring mode and will not trigger any alarms, allowing the operation to continue safely. However, if, for any reason, the contact point overheats, causing the real-time monitored temperature value to reach or exceed the preset warning threshold, the signal processing unit will immediately trigger an alarm command. Upon receiving the command, the alarm indicator unit will issue a warning signal, such as a red indicator light, a buzzer, or wirelessly transmit the signal to a remote monitoring terminal. Once a warning signal is received, the operator must immediately interrupt the ongoing power-saving or maintenance work and check the connection status of the adapter. Work can only continue after the potential hazard has been eliminated and the temperature has returned to normal.

[0071] In some embodiments, the insulating housing and the intermediate adapter connector constitute a fully insulated protective structure. The intermediate adapter connector follows a fully insulated design concept; in its unloaded state when not plugged into an external plug, its live metal contacts are completely shielded by insulating material, achieving an IP2X protection rating against accidental contact. When fully plugged into and locked with a standard plug, it achieves an IP65 / IP67 waterproof and dustproof rating, with an operating temperature range of -40°C to 105°C. It withstands long-term vibration and mechanical shock, exhibiting excellent weather resistance and environmental adaptability. This design, which dynamically adapts to different protection levels depending on usage conditions, balances ease of operation with operational safety.

[0072] Figure 5 This is a flowchart illustrating a fully insulated live-line switching method for low-voltage switchgear provided in an embodiment of this application. The method can be executed based on a fully insulated live-line switching device for low-voltage switchgear, and includes the following steps:

[0073] S1. Identify the layout and installation space of the target copper busbar, and adjust the angle of the clamp arm 21 of the adapter according to the identification result.

[0074] Specifically, the operator arrives at the work site with the adapter and, ensuring safety, opens the door of the low-voltage cabinet to be operated on, carefully inspecting its interior: First, the layout of the target copper busbars must be determined, i.e., whether the copper busbars are arranged horizontally (lateral), vertically (longitudinal), or at other angles; second, the dimensions of the copper busbars themselves, including their width and thickness, which are related to the adjustment range of the clamp arm 21 opening; finally, the installation space inside the cabinet must be assessed, i.e., whether there are other electrical components, cables, or structural parts around the copper busbars that may obstruct or hinder their operation, evaluating whether the space available for operating and installing the adapter is sufficient, and determining which direction is the most convenient and safest to approach the copper busbars.

[0075] After identifying the site conditions, the operator needs to adjust the adapter device based on the observations, primarily adjusting its clamping mechanism 2. The operator changes the angle of the clamping arm 21 by rotating the multi-angle adapter module 23, based on the observed copper busbar arrangement. For example, if the copper busbars are arranged horizontally, the clamping arm 21 is adjusted to a horizontal position; if the copper busbars are arranged vertically, the clamping arm 21 is adjusted to a vertical position. This is to ensure that the clamping plane of the clamping arm 21 achieves maximum parallel contact with the wide surface of the copper busbar. Only with a large area of ​​parallel contact can uniform and sufficient pressure be generated during subsequent clamping, ensuring good electrical contact, minimizing contact resistance, and ensuring clamping stability. The adjustment angle of the multi-angle adapter module 23 is also important. Satisfying 0°≤ ≤180°, adjustment deviation ≤5°, adaptability is quantified and controlled by a formula:

[0076] ;

[0077] in, For the angle of the copper busbar arrangement, To adjust the deviation and ensure With an angle of ≤5°, it achieves precise adaptation to copper busbars with different layout orientations. By accurately identifying the layout, size, and installation space of the copper busbars on site, the clamping angle between the clamp arm 21 and the copper busbar is calibrated, solving the problem of adapting to scenarios where existing technologies cannot adapt to horizontal / vertical copper busbars, laying the foundation for subsequent stable clamping and reliable conductivity.

[0078] S2. Align the conductive rod 11 of the adapter with the target copper busbar, and drive the clamp arm 21 to clamp the target copper busbar together with the conductive rod 11.

[0079] Specifically, based on the identification results of S1, the operator has pre-adjusted the angle of the clamp arm 21 of the adapter and is wearing a full set of insulated protective gear. Holding the insulating shell of the adapter, the operator aligns the first end of the conductive rod 11 with the copper busbar to be clamped, ensuring precise alignment between the conductive rod 11 and the copper busbar. The operator then rotates the shaft 22, driving the sliding component to slide along the conductive rod 11, causing the clamp arm 21 to move towards the conductive rod 11 until the clamp arm 21 and the conductive rod 11 together clamp the copper busbar, completing the live clamping. To enhance connection reliability, the surface of the clamp arm 21 is provided with anti-slip textures, which effectively prevent slippage or displacement caused by vibration or cable traction after clamping, ensuring the mechanical stability of the connection. The anti-oxidation coating prevents the copper busbar oxide layer from affecting conductivity. To ensure that the contact resistance of the conductive structure meets design requirements after clamping, the contact resistance is quantified and calculated using the following formula:

[0080] ;

[0081] in, Total contact resistance, The resistance of the conductive rod. This is the sum of the contact resistances of all connection points. This method enables fully insulated live clamping of copper busbars without drilling or unplugging, while quantitatively controlling the conductive contact resistance. It solves the problems of difficult live installation and high contact resistance leading to overheating in existing technologies, ensuring the safety and conductivity of live work.

[0082] S3. A conductive path is formed by the direct contact between the conductive rod 11 and the target copper busbar, and the current is transmitted through the conductive rod 11 to the high-current terminal 3 without the watch strap contact finger.

[0083] Specifically, after clamping, the conductive rod 11 directly abuts against the copper busbar, forming a simplified conductive path. Current flows out from the busbar copper busbar of the low-voltage cabinet, directly into the interior of the conductive rod 11 through the tightly contacted interface, and then is conducted to the intermediate conversion connector 4 through the current-carrying sleeve 31 and pin 32 of the high-current terminal 3 without a watchband contact finger. The slotted spring 35 of the current-carrying sleeve 31 automatically corrects the positive pressure of the contact point according to the size of the pin 32. The multi-segment arc structure achieves precise guidance of the pin 32, forming an effective annular contact band, ensuring that the contact resistance is controlled within 25~30μΩ, and achieving stable transmission of high current. This step replaces the traditional watchband contact finger structure, and achieves stable transmission of high current and low resistance through the minimally sized slotted spring 35, meeting the requirements of high current and short-time withstand, and solving the problems of unstable current carrying capacity, high cost, and large size of existing technologies.

[0084] S4. Connect and lock the intermediate conversion connector 4 of the adapter to the external cable interface.

[0085] Specifically, the operator holds the standard generator plug or the bypass cable plug and connects it to the intermediate conversion locking part 42 of the intermediate conversion connector 4. Fixation is achieved through a direct-insertion locking method, with an optional secondary locking structure to prevent accidental detachment. The intermediate conversion connector 4 provides a transitional connection between the fixed mounting part 41 and the standard interface, eliminating the need to modify existing equipment and reducing installation costs. Considering the extremely limited internal space of low-voltage cabinets, the cable routing direction is often severely restricted by surrounding equipment; therefore, the intermediate conversion connector 4 also features directional adjustment capabilities. Its interface (usually the junction of the intermediate conversion locking part 42 and the fixed mounting part 41) can rotate relative to each other. After completing the electrical connection and locking, the operator can manually rotate the cable and its connector according to the actual space layout within the cabinet, guiding the cable to the most reasonable and smoothest routing path, avoiding excessive cable bending or interference with other components inside the cabinet, facilitating flexible construction. The interface protection level meets the anti-accidental contact standard when not inserted and the waterproof and dustproof standard when inserted.

[0086] By achieving a simplified interface for the device and compatibility with standard generator plugs and cables, a modular design is adopted to reduce fixed installation costs. At the same time, the rotation and locking design adapts to operation in confined spaces, solving the problems of poor interface compatibility and high construction costs.

[0087] S5. Real-time monitoring of the status parameters of the contact point between the conductive rod 11 and the target copper busbar; the status parameters include temperature, and when the monitored temperature exceeds the preset threshold, an early warning signal is triggered.

[0088] Specifically, the temperature measuring mechanism monitors the temperature change at the contact point between the conductive rod 11 and the copper busbar in real time. As long as the monitored temperature remains below the safety threshold, the signal processing unit will not trigger any action. This indicates that the electrical contact at the entire connection point is good, the contact resistance is maintained at a low level, and the generated heat is within a safe range. At this time, the operators can carry out subsequent low-voltage power protection, temporary power supply, or maintenance work as planned. However, if certain abnormal conditions occur, such as insufficient clamping force during installation, dirt or oxidation on the contact surface, loosening due to vibration in the later stages of connection, or the load current unexpectedly exceeding the design capacity, the resistance at the contact point may increase. According to Joule's law, with a constant current, increased resistance will lead to increased heat generation power at that point, thereby increasing the temperature. Once the real-time temperature reaches or exceeds the preset warning threshold, the signal processing unit will immediately determine an abnormal state and trigger an alarm command. Once the warning is triggered, the operators must stop work and conduct inspections and adjustments; after confirming that all connections are reliable and in normal condition, low-voltage power protection, power generation, or maintenance work can be carried out. By monitoring the temperature of conductive contact points in real time, the risk of overheating can be warned in a timely manner, ensuring the safety of live-line work throughout the process and solving the problems of lack of status monitoring and prominent safety hazards in existing technologies.

[0089] S6. After the operation is completed, disconnect the intermediate conversion connector 4 from the external cable interface in sequence, loosen the clamp on the target copper busbar, and remove the adapter.

[0090] Specifically, after the operation is completed, first disconnect the intermediate conversion connector 4 from the standard plug and cable. After confirming that the external connection is completely disconnected, the operator holds the insulating housing of the adapter again and rotates the shaft in the clamping mechanism in the opposite direction. The reverse rotation of the shaft will drive the sliding component along the conductive rod 11 away from the conductive rod 11 through the thread, thereby driving the clamping arm to move synchronously, so that the clamping space between the clamping arm and the conductive rod 11 gradually increases. As the clamping arm is released, the pressure on the copper busbar that was originally firmly clamped is released, and the end face of the conductive rod 11 is also separated from the surface of the copper busbar. At this point, all mechanical and electrical connections between the adapter and the live copper busbar in the low-voltage cabinet have been safely disconnected. Controlling the release of the clamp by rotating the thread in the opposite direction protects the surface flatness and conductivity of the copper busbar, protects the copper busbar and the cabinet equipment from damage, enables the reuse of the device, and completes the closed loop of the entire adapter process.

[0091] The entire method and device realize a repeatable, standardized, safe and reliable low-voltage live-line switching operation process, supporting the achievement of the goal of uninterrupted power supply operation in the distribution network.

[0092] The above embodiments are merely illustrative examples and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations. However, obvious variations or modifications derived therefrom are still within the scope of protection of this application.

Claims

1. A fully insulated live-line switching device for low-voltage cabinets, characterized in that, include: The socket mechanism (1) includes an insulating housing and a conductive rod (11) sleeved in the insulating housing, with the first end of the conductive rod (11) extending from the first end of the insulating housing; The clamping mechanism (2) includes a clamping arm (21), a sliding assembly, and a rotating shaft (22). The sliding assembly is slidably connected to the first end of the conductive rod (11). The clamping arm (21) is connected to the sliding assembly, and a clamping space is formed between the clamping arm (21) and the conductive rod (11). The rotating shaft (22) is coaxially arranged with the conductive rod (11) and threadedly connected. The rotating shaft (22) is rotatably connected to the sliding assembly to drive the sliding assembly to move the clamping arm (21). The high-current terminal (3) without a strap and contact fingers includes a current-carrying sleeve (31) and a pin (32). The current-carrying sleeve (31) is connected to the second end of the conductive rod (11), and the pin (32) is inserted into the current-carrying sleeve (31). The intermediate conversion connector (4) includes a fixed mounting part (41) and an intermediate conversion locking part (42). The fixed mounting part (41) is connected to the socket mechanism (1), and the intermediate conversion locking part (42) is used to connect an external cable interface.

2. The apparatus according to claim 1, characterized in that, The clamping mechanism (2) further includes an adjustable guide groove (24), which is arranged parallel to the conductive rod (11) and is used to guide the sliding component to move along a predetermined trajectory.

3. The apparatus according to claim 2, characterized in that, The clamping mechanism (2) further includes a multi-angle adaptation module (23), which is located at the end of the clamping arm (21) and is used to adjust the angle of the clamping arm (21) relative to the conductive rod (11).

4. The apparatus according to claim 1, characterized in that, The current-carrying sleeve (31) includes a first part (33) and a second part (34). The first part (33) is provided with a slotted structure to form a spring (35) of a cantilever beam structure. The spring (35) is inclined along the axis of the first part (33).

5. The apparatus according to claim 1, characterized in that, It also includes a temperature measuring mechanism, which is disposed on the insulating housing and connected to the conductive rod (11) for monitoring the temperature at the contact point; the insulating housing and the intermediate conversion connector (4) constitute a fully insulating protective structure, providing overall insulation protection for the device.

6. A method for fully insulated live-line switching of low-voltage cabinets, implemented based on the fully insulated live-line switching device for low-voltage cabinets as described in any one of claims 1-5, characterized in that, Includes the following steps: S1. Identify the layout and installation space of the target copper busbar, and adjust the clamp arm angle of the adapter according to the identification result; S2. Align the conductive rod of the adapter with the target copper busbar, and drive the clamp arm to clamp the target copper busbar together with the conductive rod; S3. A conductive path is formed by the direct contact between the conductive rod and the target copper busbar, and the current is transmitted to the high-current terminal without the watch strap contact finger through the conductive rod. S4. Connect and lock the intermediate conversion connector of the adapter to the external cable interface; S5. Monitor the status parameters of the contact point between the conductive rod and the target copper busbar in real time; the status parameters include temperature, and when the monitored temperature exceeds a preset threshold, a warning signal is triggered; S6. After the operation is completed, disconnect the intermediate conversion connector from the external cable interface in sequence, release the clamp on the target copper busbar, and remove the adapter.

7. The method according to claim 6, characterized in that, In step S1, adjusting the angle of the clamp arm of the adapter device specifically involves adjusting the angle of the clamp arm through the multi-angle adaptation module of the adapter device so that the clamping surface of the clamp arm is adapted to the arrangement direction of the target copper busbar.

8. The method according to claim 6, characterized in that, S2 specifically includes: rotating the shaft to drive the sliding assembly to slide along the conductive rod, thereby causing the clamp arm connected to the sliding assembly to move toward the conductive rod until the clamp arm and the conductive rod clamp the target copper busbar.

9. The method according to claim 6, characterized in that, In S3, the current-carrying sleeve of the high-current terminal without a strap contact finger forms an annular contact band with the pin through its spring to establish a low-resistance conductive connection.

10. The method according to claim 6, characterized in that, S6 includes: first operating the intermediate conversion connector to disconnect from the external cable interface, and then driving the clamp arm in reverse to release the clamp on the target copper busbar.

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