Integrated Current Transformer and Mechanical Lug Assembly
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Solution Overview
Problem
Current transformer installations in electrical apparatus require separate support brackets and additional conductor routing, leading to increased space and material usage.
Innovation Solution
A combined transformer assembly where a current transformer is mounted directly to a mechanical lug, eliminating the need for a secondary support bracket and reducing conductor routing by integrating current sensing and wire termination functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a current transformer is separately mounted with a support bracket, then the current transformer can be physically supported, but additional space and structural elements are required
Solution Approach 1:
The patent combines the current transformer housing with the mechanical lug into a single integrated assembly. The housing of the current transformer serves dual purposes: containing the toroidal coil and providing structural support through integrated mounting features (ears with slots) that directly attach to the electrical apparatus. This eliminates the need for separate support brackets and reduces overall space requirements.
2Measurement precision
If conductor wires are routed through a separately mounted current transformer, then current sensing is achieved, but additional conductor material and routing complexity are required
Solution Approach 1:
The patent integrates the current transformer winding path with the conductor wire termination points. The housing includes mounting ears with slots that allow conductor wires to be secured while passing through the toroidal coil. This integration eliminates the need for separate conductor routing through a distant current transformer, reducing conductor material length and simplifying the electrical connections.
3Ease of manufacture
If a mechanical lug and current transformer are separate components, then each component can be optimized independently, but assembly complexity and number of parts increase
Solution Approach 1:
The patent merges the mechanical lug and current transformer into a single integrated housing assembly. The housing includes integrated mounting features (ears with slots) that combine the structural support function with the current transformer containment. This reduces the total number of parts and simplifies assembly while maintaining the ability to optimize the overall design for manufacturing efficiency.
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 configuration reduces electrical conductor material, eliminates the need for separate support elements, and minimizes space requirements within the electrical apparatus.
Implementation Method 1
a current transformer (106) for sensing electrical current in the electrical apparatus
Data Source
AI summary
A transformer assembly for mounting a current transformer to an electrical apparatus. The generally toroidal current transformer senses electrical current in conductors of the electrical apparatus and has a housing. A mechanical lug for conductors of the electrical apparatus is mounted directly to the housing of the current transformer, within the central opening of the toroid. The mechanical lug has one or more conductor bores located within a main body of the mechanical lug for receiving respective conductor wires.