Configurable Multi-Capacitor Assembly with Tiered Jumper Connections
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Solution Overview
Problem
Existing capacitor assemblies for electromechanical equipment lack configurability, volumetric efficiency, and safety compliance, making it difficult for service technicians to meet diverse replacement needs while adhering to space limitations and safety standards.
Innovation Solution
A modular capacitor assembly with multiple wound capacitor elements arranged in tiers within a housing, allowing for various capacitance configurations through jumper connections and optimized spatial arrangement, including flattened cross-sections for improved efficiency, and featuring a pressure-interrupting mechanism for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple capacitor elements are arranged in various configurations to provide a range of capacitance values, then adaptability is improved, but device complexity increases
Solution Approach 1:
The capacitor assembly is divided into multiple discrete capacitor elements (first, second, third, and fourth capacitor elements) that can be independently connected through jumper wires. Each capacitor element has specific capacitance values, and by selectively connecting them in series or parallel configurations, a wide range of total capacitance values can be achieved. This segmentation allows the system to provide adaptability without requiring a single complex variable capacitor.
Solution Approach 2:
The capacitor assembly is designed with universal terminals and jumper wire connections that enable multiple capacitance configurations from a single fixed assembly. The same physical assembly can be reconfigured to provide different capacitance values by changing the connection topology, making it universally applicable to replace various different capacitor types without needing multiple specialized components.
2Volume of stationary object
If capacitor elements are compactly arranged to improve volumetric efficiency, then volume is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The capacitor elements are arranged in a three-dimensional configuration within the housing, utilizing vertical stacking and layered positioning rather than simple linear arrangement. The first and second capacitor elements are positioned in a first plane, while the third and fourth capacitor elements are positioned in a second plane at a different height, effectively using the Z-dimension to achieve compact packaging without requiring excessive precision in two-dimensional placement.
Solution Approach 2:
The capacitor elements are arranged in a nested-like configuration where smaller capacitor elements are positioned in the spaces between and around larger capacitor elements. The terminals and jumper wire connections are integrated into the existing structure rather than adding external bulk, allowing efficient use of internal volume while maintaining manufacturability through standardized mounting positions.
3Area of stationary object
If terminals are arranged with minimum spacing to prevent arcing, then area is reduced, but reliability requirements increase
Solution Approach 1:
Jumper wires serve as intermediary conductive elements that connect the capacitor elements to the terminals. These jumper wires are specifically designed with adequate length and routing to maintain proper spacing between terminals while establishing reliable electrical connections. The jumper wires act as mediators that allow terminal spacing to be minimized for compactness while still preventing arcing through proper geometric arrangement and insulation.
Data Source
AI summary
A capacitor assembly is provided with a plurality of wound capacitor elements aligned horizontally in a longitudinally extended housing, whereby the largest capacitor element solely occupies a tier in the housing, another tier in the housing is solely occupied by two of the capacitor elements, and wherein the capacitor elements are configurable to provide various capacitance values.