Cross Connection Link with Insulated Conductor Rails
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Solution Overview
Problem
Existing cross connection link systems are limited by the current carrying capacity of stranded conductors, restricting the number of modularly connected switching devices that can be powered simultaneously.
Innovation Solution
The use of conductor rails with large cross sections in a housing made of insulation material, arranged in a comb-like fashion with tabs corresponding to the grid distance of connector holders, allows for increased current capacity and modular connections by providing a multi-phase cross connection link system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If stranded conductors are used in cross connection links, then the system is easy to manufacture and install, but the current carrying capacity is limited
Solution Approach 1:
The patent changes the conductor cross-section parameter from small stranded conductors to large solid conductors with cross-sections of 50 mm², 70 mm², or 95 mm². This parameter change directly increases the current carrying capacity while the housing encloses these large conductors to manage the structural complexity.
Solution Approach 2:
The patent uses composite construction by enclosing large solid conductors within an insulating housing material. The housing made of insulating material combines with the solid conductors to create a composite structure that provides both high current capacity and electrical insulation, resolving the complexity issue.
2Quantity of substance
If more switching devices are connected in parallel to increase system capacity, then the total current demand is met, but the voltage distribution becomes uneven due to conductor impedance
Solution Approach 1:
The patent changes the conductor impedance parameter by using large cross-section solid conductors (50-95 mm²) which have lower resistance. This reduces voltage drops and ensures more uniform voltage distribution across multiple parallel-connected switching devices, allowing more devices to be connected reliably.
3Quantity of substance
If the connector holder grid distance is reduced to accommodate more devices, then the number of modular connections increases, but the tabs become too close together making manufacturing difficult
Solution Approach 1:
The patent transitions from planar tab arrangement to a three-dimensional configuration where tabs extend from the housing in a comb-like structure. This spatial arrangement in multiple dimensions allows for adequate spacing between tabs while maintaining a compact overall structure that can accommodate more connector holders.
Data Source
AI summary
A multi-phase cross connection link for carrying potential between at least two switching devices modularly connected on a support member, each switching device having connector holders for accepting the potential, includes a conductor rail associated with each phase and disposed in a housing, the housing being made of insulation material and extending in a lengthwise direction. A plurality of tabs is associated with the conductor rail, the tabs extending outward in a comb-like manner in a shared plane perpendicular to the lengthwise direction of the housing. The plurality of tabs is arranged next to each other in a sequence having a row distance that corresponds to a first grid distance of the connector holders of the switching device. At least one end, relative to the lengthwise extending, of the cross connection link has incoming contact openings leading to the conductor rail.