A high current carrying type bus duct capable of detecting an electric signal

Abstract

This invention relates to the field of busbar trunking technology and discloses a high-current-carrying busbar trunking capable of detecting electrical signals. It solves the problems of limited current-carrying capacity, lack of real-time electrical signal detection, and insufficient protection performance of existing busbar trunking. The busbar trunking includes a busbar trunking body, inside which are a detection module mounting cavity and a conductor mounting cavity. The conductor mounting cavity contains a conductor fixing bracket and an insulating partition. The surface of the conductor fixing bracket is coated with a flame-retardant coating, and multiple slots are formed within the bracket. Copper-aluminum composite conductors, comprising a copper core and an aluminum sheath, are engaged within these slots. Several axial heat dissipation grooves are formed on the outer side of the aluminum sheath. Flange connecting plates are fixedly installed at both ends of the busbar trunking body. Each flange connecting plate has a sealing groove containing a sealing gasket. This busbar trunking has high current-carrying capacity, can perform real-time electrical signal detection, and also possesses good protection performance.

Description

Technical Field

[0001] This invention belongs to the field of busbar technology, specifically a high current-carrying busbar capable of detecting electrical signals. Background Technology

[0002] Busbar trunking, as a key piece of equipment for power transmission, is widely used in various large-scale power supply systems. Its current-carrying capacity and operational stability directly affect the reliability of power supply. Existing busbar trunking systems have the following problems:

[0003] 1. Limited current carrying capacity: The conductor structure design of traditional busbar trunking is unreasonable, resulting in poor heat dissipation during current transmission. This can easily lead to a decrease in current carrying capacity due to heat generation, and may even cause safety hazards.

[0004] 2. It lacks effective electrical signal detection functions, making it impossible to monitor voltage fluctuations, current anomalies, and conductor temperature rises in real time during operation. Fault diagnosis relies on manual inspection, which is inefficient and prone to omissions.

[0005] 3. Insufficient protection performance; in harsh environments such as humid and dusty conditions, it is prone to insulation aging, short circuits, and other faults, affecting its service life. Summary of the Invention

[0006] In view of the above situation and to overcome the defects of the prior art, the present invention provides a high current-carrying bus trunking that can detect electrical signals, which effectively solves the problems of limited current-carrying capacity, lack of real-time electrical signal detection, and insufficient protection performance of the existing bus trunking in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a high current-carrying busbar trunking capable of detecting electrical signals, comprising a busbar trunking body, wherein the busbar trunking body has an internal cavity for a detection module and a conductor mounting cavity, wherein the conductor mounting cavity has a conductor fixing bracket and an insulating partition, wherein the surface of the conductor fixing bracket is coated with a flame-retardant coating, and wherein the conductor fixing bracket has multiple slots, wherein a copper-aluminum composite conductor is clamped in the slots, the copper-aluminum composite conductor comprising a copper core and an aluminum sheath, wherein a plurality of axial heat dissipation slots are formed on the outer side of the aluminum sheath; wherein flange connecting plates are fixedly installed at both ends of the busbar trunking body, wherein a sealing groove is formed on both flange connecting plates, a sealing gasket is provided in the sealing groove, and a sealing strip is provided at the joint of the busbar trunking body;

[0008] A waterproof connector is installed on the upper part of one side of the busbar trunking body, and miniature cooling fans are installed at both ends of the busbar trunking body. Dustproof nets are installed on the outside of the miniature cooling fans. The detection module mounting cavity contains a PLC logic controller, a backup battery, and thermally conductive silicone. The thermally conductive silicone is coated on the inner top of the detection module mounting cavity. A data transmission module is installed on the top of the busbar trunking body. The data transmission module includes a wireless transmission unit and a wired transmission interface. Heat dissipation fins are installed on both sides of the busbar trunking body, and a buzzer and an alarm indicator light are installed on the lower part of the other side of the busbar trunking body. A data acquisition component is installed on the copper-aluminum composite conductor to collect operating data. The copper core of the copper-aluminum composite conductor is made of oxygen-free copper with a conductivity of ≥98%. The aluminum sheath is made of 6063 aluminum alloy and is formed by hot extrusion composite process. The maximum current carrying capacity can reach 5000A.

[0009] Preferably, the acquisition component includes a voltage sensor, a current sensor, and a temperature sensor. The voltage sensor is a voltage divider structure with a measurement range of 0V-10kV and an accuracy of ±0.5%, and is connected in parallel across the two ends of the copper-aluminum composite conductor. The current sensor is a Rogowski coil structure with a measurement range of 0A-6000A and an accuracy of ±0.3%, and is sleeved on the outside of the copper-aluminum composite conductor. The temperature sensor is a PT100 platinum resistance thermometer with a measurement range of -20℃-200℃ and an accuracy of ±0.1℃, and is in close contact with the surface of the copper-aluminum composite conductor.

[0010] Preferably, the miniature cooling fan uses a brushless DC motor, which is electrically connected to a temperature sensor. It automatically starts when the conductor temperature exceeds 80°C and shuts off when it is below 60°C, with the fan speed adaptively adjusted according to the temperature. The sealing strip and gasket are made of silicone rubber, and the sealing strip and gasket together achieve IP67-level waterproof and dustproof protection. The waterproof connector is used to lead out the power cord and signal line.

[0011] Preferably, the insulating partition is made of epoxy resin board, which completely isolates adjacent copper-aluminum composite conductors, with an insulation resistance ≥100MΩ; the bottom of the busbar trunking body is provided with a grounding terminal, which is connected to the copper-aluminum composite conductor through a grounding wire, with a grounding resistance ≤4Ω.

[0012] Preferably, the data transmission module includes a wireless transmission unit and a wired transmission interface. The wireless transmission unit is a LoRa / WiFi dual-mode communication module with a transmission distance ≤3000m and a data transmission rate ≥1Mbps. The wired transmission interface is an RS485 interface. The PLC logic controller can preset electrical signal thresholds. When the detected data exceeds the threshold, it triggers a buzzer and alarm indicator light to start a local alarm, and at the same time controls the data transmission module to send a warning message to the monitoring terminal.

[0013] Compared with the prior art, the beneficial effects of the present invention are:

[0014] (1) The copper-aluminum composite conductor structure with oxygen-free copper core and 6063 aluminum alloy sheath, combined with hot extrusion composite process, has excellent conductivity and a maximum current carrying capacity of 5000A. At the same time, the axial heat dissipation groove on the outside of the aluminum sheath increases the heat dissipation area, effectively reduces the conductor operating temperature, avoids the decrease in current carrying capacity due to overheating, and meets the high load requirements of large power transmission scenarios.

[0015] (2) It integrates three types of high-precision sensors: voltage, current, and temperature. It has a wide measurement range and high accuracy. It can collect key electrical signal data during the operation of the bus trunking in real time. The data is processed and analyzed by the PLC logic controller to realize comprehensive monitoring of the bus trunking's operating status, thus solving the problem of traditional bus trunking lacking effective detection methods.

[0016] (3) By setting a threshold through the PLC logic controller, when the detected data is abnormal, the local buzzer and alarm indicator light will respond immediately. At the same time, the alarm information will be sent to the monitoring terminal through the dual-mode data transmission module, so as to realize the real-time alarm and accurate location of the fault, reduce the cost of manual inspection, improve maintenance efficiency, and ensure the stable operation of the power system. Attached Figure Description

[0017] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0018] In the attached diagram:

[0019] Figure 1 This is a front view schematic diagram of the high current-carrying busbar trunking structure capable of detecting electrical signals according to the present invention;

[0020] Figure 2 This is a front cross-sectional view of the high current-carrying busbar trunking capable of detecting electrical signals according to the present invention.

[0021] Figure 3 This is a top view schematic diagram of the high current-carrying busbar trunking structure capable of detecting electrical signals according to the present invention;

[0022] Figure 4 This is an enlarged structural schematic diagram of the conductor fixing bracket of the present invention;

[0023] Figure 5 This is a schematic diagram of the flange connection disc structure of the present invention;

[0024] Figure 6 For the present invention Figure 2 Enlarged structural diagram at point A in the middle;

[0025] Figure 7 For the present invention Figure 1 Enlarged structural diagram at point B;

[0026] In the diagram: 1. Busbar trunking body; 2. Detection module mounting cavity; 3. Conductor mounting cavity; 4. Conductor fixing bracket; 5. Insulating partition; 6. Flame-retardant coating; 7. Slot; 8. Copper core; 9. Aluminum sheath; 10. Axial heat dissipation groove; 11. Flange connection plate; 12. Sealing groove; 13. Sealing gasket; 14. Sealing strip; 15. Waterproof joint; 16. Miniature cooling fan; 17. Dustproof net; 18. Data transmission module; 19. Wireless transmission unit; 20. Wired transmission interface; 21. PLC logic controller; 22. Backup battery; 23. Thermally conductive silicone; 24. Heat dissipation fins; 25. Buzzer; 26. Alarm indicator light; 27. Copper-aluminum composite conductor. Detailed Implementation

[0027] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0028] Example 1, by Figures 1 to 7 The present invention includes a busbar trunking body 1, which is formed by stamping high-strength cold-rolled steel plate and the surface is treated with electrostatic spraying, giving it good corrosion resistance and impact resistance. The busbar trunking body 1 has an independent detection module mounting cavity 2 and a conductor mounting cavity 3 inside, which realizes the physical isolation between the detection element and the conductive conductor, and avoids electromagnetic interference from affecting the detection accuracy. The conductor mounting cavity 3 is equipped with a conductor fixing bracket 4 and an insulating partition 5. The conductor fixing bracket 4 is injection molded from flame-retardant PA66 material and coated with a flame-retardant coating 6 with a thickness of ≥0.5mm, achieving a flame-retardant rating of V0, which can effectively prevent the spread of fire. The conductor fixing bracket 4 has multiple evenly distributed slots 7, and the inner wall of the slots 7 has anti-slip textures to enhance the fit with the conductor. A copper-aluminum composite conductor 27 is clamped in the slots 7. The copper-aluminum composite conductor 27 includes a copper core 8 and an aluminum sheath 9. Several axial heat dissipation grooves 10 are opened on the outer side of the aluminum sheath 9. The axial heat dissipation grooves 10 are evenly distributed along the length of the conductor, with no less than 8 grooves. The groove width is 3-5mm and the groove depth is 2-3mm, which can increase the heat dissipation surface area and improve the heat dissipation efficiency.

[0029] Both ends of the busbar trunking body 1 are fixedly equipped with flange connecting plates 11, which are welded to the busbar trunking body 1. The weld seams are treated with anti-corrosion. Each flange connecting plate 11 has a sealing groove 12, and a sealing gasket 13 is installed in the sealing groove 12. Sealing strips 14 are also provided at the joints of the busbar trunking body 1. The double sealing structure ensures the overall airtightness. A waterproof connector 15 is installed on the upper part of one side of the busbar trunking body 1. The waterproof connector 15 is made of brass and has a protection level of IP68. Both ends of the busbar trunking body 1 are equipped with miniature cooling fans 16. Dustproof nets 17 are made of stainless steel and have a mesh size of ≤1mm to prevent dust from entering the conductor mounting cavity 3.

[0030] The detection module mounting cavity 2 houses a PLC logic controller 21, a backup battery 22, and thermally conductive silicone 23. The thermally conductive silicone 23, coated on the inner top of the detection module mounting cavity 2, has a thermal conductivity ≥2.0W / (m・K), which can quickly dissipate the heat generated during the operation of the detection module, preventing high temperatures from affecting the performance of electronic components. A data transmission module 18 is installed on the top of the busbar trunking body 1. The data transmission module 18 includes a wireless transmission unit 19 and a wired transmission interface 20, enabling diversified data transmission. Heat dissipation fins 24 are provided on both sides of the busbar trunking body 1. The heat dissipation fins 24 are integrally formed with the busbar trunking body 1, made of 6063 aluminum alloy, with a thickness of 2-3mm and a spacing of 5-8mm, further improving heat dissipation. A buzzer 25 and an alarm indicator light 26 are installed on the lower part of the other side of the busbar trunking body 1. The buzzer 25 has an alarm volume ≥85dB, and the alarm indicator light 26 is a tri-color LED that displays different colors according to the fault type.

[0031] The copper-aluminum composite conductor 27 is equipped with a data acquisition component for collecting operational data. The copper core 8 of the copper-aluminum composite conductor 27 is made of oxygen-free copper with a conductivity ≥98% and low resistance loss. The aluminum sheath 9 is made of 6063 aluminum alloy, formed by hot extrusion composite process, with high bonding strength, interface resistance ≤5mΩ / m, and a maximum current carrying capacity of up to 5000A, meeting the high current carrying capacity requirements of large power systems.

[0032] The data acquisition components include a voltage sensor, a current sensor, and a temperature sensor. The voltage sensor is a voltage divider structure with a measurement range of 0V-10kV and an accuracy of ±0.5%. It is connected in parallel across the copper-aluminum composite conductor 27 and features a fully sealed encapsulation design with an insulation strength ≥20kV. The current sensor is a Rogowski coil structure with a measurement range of 0A-6000A and an accuracy of ±0.3%. It is fitted onto the outside of the copper-aluminum composite conductor 27, exhibits no magnetic saturation, and has a response time ≤1μs. The temperature sensor is a PT100 platinum resistance thermometer with a measurement range of -20℃-200℃ and an accuracy of ±0.1℃. It is tightly attached to the surface of the copper-aluminum composite conductor 27 and fixed with high-temperature thermally conductive adhesive to ensure accurate temperature acquisition.

[0033] The miniature cooling fan 16 uses a brushless DC motor with a rated voltage of 24V and a power of ≤10W. It is electrically connected to a temperature sensor and adopts an intelligent temperature control strategy. It automatically starts when the conductor temperature exceeds 80℃ and shuts off when it is below 60℃. The fan speed is adaptively adjusted according to the temperature. It operates at low speed when the temperature is 80℃-120℃, at medium speed when the temperature is 120℃-160℃, and at high speed when the temperature is above 160℃, so as to reduce energy consumption while ensuring heat dissipation effect.

[0034] The sealing strip 14 and sealing gasket 13 are made of silicone rubber and are resistant to high and low temperatures ranging from -40℃ to 200℃. The sealing strip 14 and sealing gasket 13 together achieve IP67-level waterproof and dustproof protection, which can effectively prevent rainwater, dust and other impurities from entering the bus trunking and adapt to harsh working environments such as humid and dusty conditions. The waterproof connector 15 is used to lead out power lines and signal lines to prevent water from entering at the cable connection.

[0035] The insulating partition 5 is made of epoxy resin board with a thickness of ≥5mm and a dielectric strength of ≥30kV / mm. It completely isolates the adjacent copper-aluminum composite conductors 27 and has an insulation resistance of ≥100MΩ to prevent short circuit faults between conductors. The bottom of the bus trunking body 1 is equipped with a grounding terminal made of copper material, which is connected to the copper-aluminum composite conductors 27 through a grounding wire. The grounding resistance is ≤4Ω to ensure the safety of personnel and equipment.

[0036] The data transmission module 18 includes a wireless transmission unit 19 and a wired transmission interface 20. The wireless transmission unit 19 is a LoRa / WiFi dual-mode communication module with a transmission distance of ≤3000m, a data transmission rate of ≥1Mbps, and supports breakpoint resume function. The wired transmission interface 20 is an RS485 interface that supports the Modbus communication protocol and can be wired to the on-site monitoring system to ensure the stability of data transmission.

[0037] The PLC logic controller 21 adopts an industrial-grade PLC with high-speed data processing capabilities. It can preset electrical signal thresholds such as voltage over-limit, current overload threshold, and temperature safety threshold. It receives voltage, current, and temperature data transmitted by the acquisition components in real time. When the detected data exceeds the threshold, it immediately triggers the buzzer 25 and alarm indicator 26 to start the local alarm. At the same time, it controls the data transmission module 18 to send a warning message to the monitoring terminal. The warning message includes the fault type, fault location, and real-time data, which facilitates the staff to quickly locate and handle the fault. The backup battery 22 is a lithium battery with a capacity of ≥5000mAh. When the external power is interrupted, it can automatically supply power to the detection module and alarm components for a power supply time of ≥8 hours to ensure that fault information is not lost.

[0038] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0039] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-current-carrying busbar trunking capable of detecting electrical signals, comprising a busbar trunking body (1), characterized in that: The busbar trunking body (1) has a detection module installation cavity (2) and a conductor installation cavity (3) inside. The conductor installation cavity (3) has a conductor fixing bracket (4) and an insulating partition (5). The surface of the conductor fixing bracket (4) is coated with a flame-retardant coating (6). The conductor fixing bracket (4) has multiple slots (7) inside. The slots (7) are fitted with copper-aluminum composite conductors (27). The copper-aluminum composite conductors (27) include a copper core (8) and an aluminum sheath (9). The aluminum sheath (9) has several axial heat dissipation slots (10) on its outer side. Both ends of the busbar trunking body (1) are fixedly installed with flange connecting plates (11). Both flange connecting plates (11) have sealing slots (12). The sealing slots (12) have sealing gaskets (13) inside. The joints of the busbar trunking body (1) are all provided with sealing strips (14). A waterproof connector (15) is installed on the upper part of one side of the bus trunking body (1), and a miniature cooling fan (16) is provided at both ends of the bus trunking body (1). A dustproof net (17) is provided on the outside of the miniature cooling fan (16). A PLC logic controller (21), a backup battery (22) and thermally conductive silicone (23) are provided in the detection module mounting cavity (2). The thermally conductive silicone (23) is coated on the inner top of the detection module mounting cavity (2). A data transmission module (18) is installed on the top of the bus trunking body (1). The data transmission module (18) includes a wireless transmission unit (19) and a wired transmission interface (20). Heat dissipation fins (24) are provided on both sides of the bus trunking body (1), and a buzzer (25) and an alarm indicator (26) are installed on the lower part of the other side of the bus trunking body (1). A data acquisition component is provided on the copper-aluminum composite conductor (27). The data acquisition component is used to acquire operating data.

2. The high-current-carrying busbar trunking capable of detecting electrical signals according to claim 1, characterized in that: The copper core (8) of the copper-aluminum composite conductor (27) is made of oxygen-free copper with a conductivity of ≥98%, and the aluminum sheath (9) is made of 6063 aluminum alloy and formed by hot extrusion composite process, with a maximum current carrying capacity of 5000A.

3. The high-current-carrying busbar trunking capable of detecting electrical signals according to claim 1, characterized in that: The acquisition components include a voltage sensor, a current sensor, and a temperature sensor. The voltage sensor is a voltage divider structure with a measurement range of 0V-10kV and an accuracy of ±0.5%, and is connected in parallel across the two ends of the copper-aluminum composite conductor (27). The current sensor is a Rogowski coil structure with a measurement range of 0A-6000A and an accuracy of ±0.3%, and is sleeved on the outside of the copper-aluminum composite conductor (27). The temperature sensor is a PT100 platinum resistance thermometer with a measurement range of -20℃-200℃ and an accuracy of ±0.1℃, and is in close contact with the surface of the copper-aluminum composite conductor (27).

4. A high-current-carrying busbar trunking capable of detecting electrical signals according to claim 1, characterized in that: The miniature cooling fan (16) uses a brushless DC motor and is electrically connected to a temperature sensor. It automatically starts when the conductor temperature exceeds 80°C and shuts off when it is below 60°C. The fan speed is adaptively adjusted according to the temperature.

5. A high-current-carrying busbar trunking capable of detecting electrical signals according to claim 1, characterized in that: The sealing strip (14) and sealing gasket (13) are made of silicone rubber. The sealing strip (14) and sealing gasket (13) together achieve IP67 waterproof and dustproof protection. The waterproof connector (15) is used to lead out the power line and signal line.

6. A high-current-carrying busbar trunking capable of detecting electrical signals according to claim 1, characterized in that: The insulating partition (5) is made of epoxy resin board, which completely isolates the adjacent copper-aluminum composite conductor (27) with an insulation resistance ≥100MΩ; the bottom of the bus trunk body (1) is provided with a grounding terminal, which is connected to the copper-aluminum composite conductor (27) through a grounding wire with a grounding resistance ≤4Ω.

7. A high-current-carrying busbar trunking capable of detecting electrical signals according to claim 1, characterized in that: The data transmission module (18) includes a wireless transmission unit (19) and a wired transmission interface (20). The wireless transmission unit (19) is a LoRa / WiFi dual-mode communication module with a transmission distance ≤3000m and a data transmission rate ≥1Mbps. The wired transmission interface (20) is an RS485 interface.

8. A high-current-carrying busbar trunking capable of detecting electrical signals according to claim 7, characterized in that: The PLC logic controller (21) can preset an electrical signal threshold. When the detected data exceeds the threshold, it triggers the buzzer (25) and alarm indicator (26) to start a local alarm, and at the same time controls the data transmission module (18) to send a warning message to the monitoring terminal.

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