Switchgear Bus Assembly Flat Conductor Segmentation
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Solution Overview
Problem
Existing electrical switchgear bus systems face issues with thermal dissipation and uneven current distribution due to the skin and proximity effects, leading to increased power losses and temperatures, which necessitate excessive copper usage.
Innovation Solution
A unique arrangement of multiple flat conductors in each bus phase, where each conductor's longitudinal edge surfaces are opposed and spaced from adjacent conductors, with all side surfaces being co-planar and electrically connected by multiple connectors, improves current distribution and reduces power losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple flat conductors are stacked together to counteract thermal effects, then temperature control is improved, but the amount of copper increases
Solution Approach 1:
The bus conductor is divided into multiple individual flat conductors (e.g., three conductors per phase) that are spaced apart rather than stacked together. This segmentation allows improved thermal dissipation while using less copper material compared to traditional stacked configurations.
Solution Approach 2:
The conductors are arranged in a spaced-apart configuration that utilizes three-dimensional space more efficiently, positioning conductors at different locations rather than stacking them in layers. This dimensional arrangement improves thermal dissipation and current distribution while reducing material usage.
2Power
If multiple flat conductors are used to increase current rating, then power handling capacity is improved, but power loss increases due to skin and proximity effects
Solution Approach 1:
Each phase conductor is segmented into multiple individual flat conductors that are spaced apart, which reduces the skin effect and proximity effect compared to a single solid conductor or stacked configuration. This segmentation improves current distribution uniformity and reduces power losses while maintaining the required current rating.
Solution Approach 2:
The conductors are positioned asymmetrically in space with specific spacing relationships between phases, which helps minimize the proximity effect by optimizing the geometric arrangement. This asymmetric spacing reduces electromagnetic interference between adjacent phase conductors and improves overall current distribution.
3Temperature
If conductor volume is increased to improve thermal dissipation, then temperature control is improved, but current distribution uniformity worsens due to skin and proximity effects
Solution Approach 1:
The conductor system is segmented into multiple thin flat conductors spaced apart, which eliminates the current distribution non-uniformity problems associated with thick solid conductors. The segmentation ensures uniform current distribution across all conductors while providing adequate thermal dissipation surface area.
Solution Approach 2:
Each individual flat conductor within a phase has optimized local dimensions and spacing characteristics that promote uniform current distribution. The local geometry of each conductor is designed to minimize skin and proximity effects, ensuring consistent current density across all conductors in the system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This arrangement achieves a 25% reduction in conductive material needed, lowering the cost, size, and weight of the bus assembly while reducing 'hot spots' and power losses, enhancing thermal dissipation.
Implementation Method 1
Because of increased conductor volume, laminated flat conductors exhibit relatively poor current distribution due to the 'skin effect' phenomenon, which holds that the current density near the surface of the conductor is greater than at its core.
Implementation Method 2
in multi-phase systems, adjacent conductors of different phases are subjected to another phenomenon called the 'proximity effect,' which relates to how current flowing through one phase interferes with current flowing through an adjacent phase
Implementation Method 3
the temperature of the surrounding air increases due to natural convection, resulting in poor thermal dissipation and higher temperatures in the switchgear current distribution
Data Source
AI summary
Electrical switchgear comprising electrical switching equipment for a multi-phase electrical power distribution system, a supporting structure for a bus assembly for supplying electrical current to the switching equipment, and a plurality of spaced buses mounted on the supporting structure each for connecting the switching equipment to respective phases of the multi-phase electrical power distribution system. Each bus comprises a plurality of substantially co-planar, spaced, elongated flat conductors arranged with at least one longitudinal edge surface of each conductor in that bus opposed to and spaced from a longitudinal edge surface of another conductor in that same bus, and a connector at each end of said conductors for connecting the plurality of flat conductors in each bus to each other.