Flexible Conductor Assembly to Prevent Bus Bar Hot Spots
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rigid bus bars in power distribution systems restrict flexibility in breaker panel configurations, lead to increased maintenance costs due to thermal hot spots and loose connections, and require complete replacement for changes in breaker layouts, complicating inventory and manufacturing logistics.
Innovation Solution
A flexible electrical conductor assembly with a main conductive portion and bendable branch members, insulated by casings, allowing for customizable configurations and multiple connections to different switching apparatuses without the need for unique bus bar assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid bus bars are used in power distribution systems, then structural strength and electrical conductivity are improved, but flexibility in breaker panel configurations is restricted and thermal hot spots occur due to loose connections
Solution Approach 1:
The rigid bus bar is divided into multiple modular sections that can be independently positioned and connected. Each section can be separately adjusted to accommodate different breaker configurations, while maintaining overall structural integrity through standardized connection interfaces.
Solution Approach 2:
The bus bar system incorporates adjustable and reconfigurable elements that allow dynamic adaptation to different breaker panel layouts. The modular sections can be repositioned along the panel to match varying breaker spacings and configurations, transforming a static structure into a adaptable system.
2Reliability
If rigid bus bars with multiple connection points are used, then electrical conductivity is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The modular bus bar sections are designed with universal connection interfaces that can accommodate multiple breaker types and configurations using the same standardized components. This multi-functionality reduces the need for custom-designed bus bars for different applications, simplifying manufacturing and inventory management.
Solution Approach 2:
The bus bar system allows adjustment of connection parameters such as spacing, positioning, and configuration through modular assembly rather than requiring custom manufacturing for each parameter set. This enables a single standardized design to serve multiple applications with varying electrical and spatial requirements.
3Stability of the object's composition
If rigid bus bars are used, then structural stability is improved, but complete replacement is required for changes in breaker layouts increasing maintenance cost
Solution Approach 1:
The bus bar is segmented into modular sections that can be independently removed, added, or repositioned. This allows partial reconfiguration for maintenance or layout changes without requiring complete replacement of the entire bus bar assembly, reducing maintenance costs and complexity.
Solution Approach 2:
The modular design enables individual bus bar sections to be removed, recovered, and reused in new configurations. Rather than discarding the entire bus bar system when reconfiguration is needed, specific sections can be extracted and reused, reducing material waste and maintenance expenses.
4Reliability
If joints between attached conductors are used, then electrical connection is achieved, but electrical resistance increases creating thermal hot spots
Solution Approach 1:
The modular bus bar sections are designed to be electrically and mechanically integrated into a unified continuous conductor. The connection interfaces are engineered to minimize contact resistance through optimized contact surfaces and compression mechanisms, effectively merging multiple sections into a single low-resistance electrical path.
Data Source
AI summary
An electrical conductor assembly for use in a power distribution assembly includes an electrical conductor. A casing covers at least a portion of the electrical conductor. The casing insulates the at least a portion of the electrical conductor.