Circuit Breaker Control Unit With Front-Insert Wireless Module Insulation
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Solution Overview
Problem
Existing electrical circuit breakers with wireless communication interfaces require the control unit to be removed from its receptacle for connection, leading to impractical and potentially damaging solutions, and lack sufficient insulation for high voltage applications.
Innovation Solution
A modular control unit design with a communication module that can be installed from the front, ensuring sufficient insulation distances and creepage distances, maintaining compact size and safety without disassembling the control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a wireless communication interface is added to the control unit, then communication functionality is improved, but the device complexity and insulation safety are worsened
Solution Approach 1:
The control unit is divided into separate functional modules: a main control unit and a detachable communication module. The communication module can be independently attached or detached from the housing, allowing communication functionality to be added without permanently increasing device complexity. This modular approach enables users to add communication capability only when needed.
Solution Approach 2:
The communication module is designed to be nested within the existing housing structure of the control unit. The module fits into a dedicated receptacle in the housing, utilizing the existing spatial framework rather than requiring a completely separate external attachment. This integration maintains a compact form factor while adding functionality.
2Adaptability or versatility
If an external communication module with box and cable is used, then communication functionality is improved, but ease of operation and device safety are worsened
Solution Approach 1:
The communication module integrates the antenna, connectors, and connection interface into a single unified component that attaches directly to the housing. This eliminates the need for separate external boxes and cables, allowing users to establish communication connectivity through a single attachment action rather than multiple separate connection steps.
3Ease of operation
If contact pads are placed close to the front plane for easy connection, then ease of operation is improved, but insulation safety under high voltage is worsened
Solution Approach 1:
The contact pads are positioned in a recessed area of the housing that is set back from the front plane along the depth axis. This creates a three-dimensional arrangement where the connection interface is accessible from the front direction while maintaining sufficient spatial separation from the front plane to satisfy insulation requirements for high voltage applications.
Solution Approach 2:
The housing structure incorporates a localized recessed region specifically designed to house the contact pads. This local structural modification provides the necessary insulation clearance in high-voltage areas while maintaining ease of connection access. The recess creates a differentiated spatial zone that simultaneously achieves both safety and operational convenience.
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3b
AI summary
This control unit (20) comprises a housing (30) defining a front plane (P22), where a housing (401) opens out, configured to receive a communication module (400) in the assembled position. Contact pads (36) are arranged at the bottom of the housing set back from the front plane (P22), such that a clearance in the air between each contact pad and the front plane is greater than a class 2 insulation distance, according to standard IEC947-1:2019, under a voltage greater than 690 V. The communication module comprises an enclosure (410), which delimits a cavity (411) configured to receive a wireless communication card (414) and which, in a position assembled to the housing, closes the housing, such that a creepage distance between each contact pad and the front plane is greater than a class 2 insulation distance under a voltage greater than 690 V according to standard IEC947-1:2019.