Busway Joint Sensor Bolt for Accurate Internal Temperature Sensing
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Solution Overview
Problem
Current temperature sensing systems for electrical busways are inaccurate due to inconsistencies in temperature correlation between the busway housing and electrical joints, exacerbated by manufacturing variations and thermal mass, leading to delayed temperature readings.
Innovation Solution
A busway joint with a centrally located bolt housing a thermistor sensor, embedded in epoxy with high thermal conductivity, ensuring accurate internal temperature measurement through direct immersion and electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a temperature sensor is mounted externally to busway housing, then the housing temperature can be measured, but the temperature correlation between housing and electrical joint becomes inconsistent and inaccurate
Solution Approach 1:
The temperature sensor is extracted from external mounting on the housing and repositioned to the electrical joint itself, where it directly measures the critical temperature parameter. This extraction resolves the contradiction by placing the sensor at the source of measurement interest, eliminating the need for indirect correlation and achieving both ease of measurement and high accuracy.
Solution Approach 2:
The patent introduces a thermal interface material as an intermediary between the electrical joint and the sensor mounting surface. This intermediary ensures efficient thermal coupling while allowing the sensor to be mounted in an accessible location, thereby maintaining measurement accuracy while facilitating ease of installation and operation.
2Strength
If the busway joint is made with thicker material and higher thermal mass, then structural strength is improved, but temperature response time increases due to heat sinking
Solution Approach 1:
The patent applies local quality by concentrating thermal monitoring resources at the critical electrical joint region rather than relying on bulk housing temperature. The sensor is positioned specifically at the joint where heat generation occurs, allowing the bulk material to maintain its high thermal mass for structural strength while the localized sensor provides rapid temperature response.
Solution Approach 2:
The sensor is pre-positioned and thermally coupled to the electrical joint during manufacturing, establishing an optimal thermal pathway before operation. This preliminary action ensures that the sensor is already in intimate thermal contact with the joint, enabling rapid response to temperature changes without being limited by the thermal mass of the entire busway structure.
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 provides reliable and timely internal temperature tracking, enhancing the monitoring of busway health and preventing overheating by accurately measuring internal temperatures.
Implementation Method 1
The epoxy potting can have a thermal conductivity of at least 0.68 W/(mK)
Data Source
AI summary
A busway joint for coupling two segments of an electrical distribution busway to each other comprising, a busway joint including a plurality of fins, a central body connecting each of the plurality of fins, and a bolt within the central body, wherein the bolt includes a cavity housing a sensor lead and an epoxy potting.