Circuit Breaker Terminal Block Front Access Design
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Solution Overview
Problem
Conventional fixed-type circuit breakers face challenges in compact design due to non-front-side accessible secondary control circuits, making it difficult to conduct wiring processes within spatially limited switchboards.
Innovation Solution
A circuit breaker apparatus with a terminal block that includes female and male terminal housings, an access block with inclined apertures for front-side access, and a bracket system for secure mounting, allowing for increased terminal count and improved accessibility while maintaining compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the circuit breaker is designed with compact size using conventional secondary control circuits, then the spatial capacity is reduced, but the terminals become non-front-side accessible making wiring processes difficult
Solution Approach 1:
The terminal block is repositioned from an internal rear-mounted configuration to an external front-side accessible configuration. The terminal block protrudes from the front face of the circuit breaker housing, allowing wiring operations to be performed from the front rather than requiring access to the rear or interior spaces. This dimensional repositioning resolves the contradiction by maintaining compact internal volume while providing front-side accessibility for terminal wiring.
Solution Approach 2:
An access block is introduced as an intermediary component between the terminal block and the external environment. The access block contains openings that provide controlled access to the terminal block while maintaining the compact housing structure. This intermediary element enables front-side wiring operations without compromising the compact design or internal component arrangement.
2Ease of operation
If the terminal block is made front-side accessible, then wiring accessibility is improved, but the device complexity increases
Solution Approach 1:
The terminal block is merged with the circuit breaker housing as an integrated assembly. The terminal block is positioned to protrude from the front face and is structurally combined with the housing, eliminating the need for separate mounting brackets or complex internal routing mechanisms. This merging reduces overall device complexity while maintaining front-side accessibility.
Solution Approach 2:
The access block serves multiple functions: it provides structural support for the terminal block, creates protective enclosures around terminals, and provides access openings for wiring operations. This multi-functionality reduces the need for additional separate components, thereby reducing overall device complexity while achieving the accessibility goal.
3Adaptability or versatility
If more terminals are added to the terminal block, then the functionality is enhanced, but the spatial requirements increase
Solution Approach 1:
The terminal block utilizes a three-dimensional configuration that protrudes from the front face of the circuit breaker. By arranging terminals in multiple levels and orientations within the protruding structure, the design accommodates a higher terminal count without increasing the horizontal footprint on the switchboard. This vertical and depth-wise arrangement allows more terminals within the same spatial envelope.
Solution Approach 2:
The terminal block structure employs a nested arrangement where terminal housings are positioned within the protruding portion of the housing. The access block contains openings that align with nested terminal positions, allowing multiple terminals to be accessed through a compact front-face structure. This nesting approach maximizes terminal density within the available spatial envelope.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A circuit breaker apparatus is provided and includes a circuit breaker, having a housing surface perpendicular to a plane of a front side of the circuit breaker and internal components, a terminal block structurally coupled to the housing surface, first terminal housings arrayed on the terminal block to each support first components and to be receptive of second terminal housings each of which supports second components, at least some of which are electrically coupled to the internal components, to be electrically coupled to at least some of the first components, and an access block. The access block is disposed on the terminal block and has apertures defined therein to provide for front-side access to the first terminal housings.