Busbar Snap-In Switching Device for Photovoltaic Fuse Assembly
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Solution Overview
Problem
Conventional switching devices for electronic components, such as fuses in photovoltaic systems, require tedious and error-prone manual wiring, especially when dealing with a large number of connection lines, which complicates the assembly process and increases the risk of errors.
Innovation Solution
A switching device with a housing that snaps onto a busbar, featuring a pivotable holding device and a single connection terminal connected to a spring contact that bears against the busbar, allowing for simple and error-resistant assembly without the need for tools, enabling easy insertion and switching of electronic components into a current path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional switching devices are wired using box terminals and screwdrivers, then electrical connections can be established, but the assembly process becomes tedious and time-consuming
Solution Approach 1:
The switching device is designed to self-connect to the busbar through a snapping mechanism that automatically establishes electrical contact when the device is mounted. The spring contact automatically engages with the busbar, eliminating the need for manual wiring operations by installers.
Solution Approach 2:
The manual mechanical wiring process using screwdrivers and box terminals is replaced by a mechanical snapping connection system. The housing snaps onto the busbar while spring contacts automatically establish electrical connection, substituting complex manual wiring with a simple mounting action.
2Reliability
If manual wiring with box terminals is used, then electrical connections can be made, but the process becomes error-prone
Solution Approach 1:
The spring contact automatically engages with the busbar in the correct position when the device is snapped onto the busbar. This self-aligning mechanism eliminates human error in connection positioning, ensuring reliable electrical contact without requiring installer skill or attention to detail.
Solution Approach 2:
The spring contact is pre-positioned and pre-tensioned within the housing before installation. When the housing is snapped onto the busbar, the spring contact is already in the correct position and orientation to make immediate electrical contact, eliminating the need for precise manual alignment during installation.
3Productivity
If multiple connection lines are wired manually, then complete electrical connections are achieved, but installation time increases significantly
Solution Approach 1:
Multiple electrical connection functions are merged into a single housing unit that snaps onto the busbar. The housing integrates the spring contact, the holding device for the electrical component, and the mounting structure, allowing all connections to be established simultaneously through one installation action rather than multiple separate wiring operations.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides structural support, houses the spring contact for electrical connection, contains the pivotable holding device for the electrical component, and provides the snapping mounting mechanism to the busbar. This multi-functionality eliminates the need for separate components for each function, reducing installation time.
4Reliability
If conventional fuse holders are used in photovoltaic systems, then overcurrent protection is provided, but the assembly process is complicated
Solution Approach 1:
The switching device is segmented into distinct functional modules: the housing with spring contact for busbar connection, the pivotable holding device for the electrical component (fuse), and the locking mechanism. This segmentation allows each module to be independently designed and manufactured, simplifying the overall assembly process while maintaining complete protection functionality.
Solution Approach 2:
The holding device is designed to be pivotable, allowing the electrical component (fuse) to be easily inserted and removed by pivoting the holder. This dynamic design simplifies maintenance and replacement operations compared to fixed conventional fuse holders, reducing the complexity of service operations while maintaining overcurrent protection.
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
The solution simplifies and streamlines the assembly process, reducing the risk of errors and installation time, allowing for quick and reliable connection of multiple electronic components in photovoltaic systems, ensuring efficient operation and minimizing the risk of electrical hazards.
Implementation Method 1
at least one spring contact (16) provided on the housing (2), which rests directly on the current busbar (4) when the housing (2) is in a snapped-on state
Implementation Method 2
at least two essentially parallel ribs (6A, 6B; 7A, 7B) which are formed onto the housing (2) of the switching device (1) and which are elastic
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The device (1) has a housing (2) including a locking unit (3) for locking the housing onto a busbar (4). A pivotable holding unit (11) into which an electric component (10) is inserted, is connected into a current path by pivoting the holding unit. A terminal clamp (13) is connected directly through the component, which is connected into the current path. An L-shaped/U-shaped spring contact (16) is provided in the housing, and contacts the bus bar when the housing is locked. A leaf spring (17) presses the spring contact against the busbar when the housing of the connection device is locked. An independent claim is also included for a photovoltaic installation.