Dual Plug-In Bus Plug Layout for Full Current Capacity
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Solution Overview
Problem
Conventional bus plugs are limited by safety regulatory standards that restrict temperature rise at plug-in contacts, preventing them from achieving higher current ratings, thus they can only operate at 80% of their rated capacity.
Innovation Solution
A dual plug-in bus plug design with two plug-in connectors and an elevated circuit breaker that splits current flow through two ports, allowing each connector to handle less than the rated current, reducing temperature rise and enabling operation at 100% capacity while maintaining compatibility with existing busway systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single plug-in connector is used in a bus plug, then the device complexity is low, but the current capacity is limited to 80% of rated capacity due to temperature rise restrictions
Solution Approach 1:
The bus plug is divided into multiple independent plug-in connectors (first and second plug-in connectors), each capable of independently connecting to separate plug-in ports on the busway. This segmentation allows the current load to be distributed across multiple connection points, reducing the temperature rise at each individual connector while enabling the bus plug to achieve its full rated current capacity without violating safety standards.
2Power
If the current rating of a bus plug is increased, then the power delivery capability is improved, but the temperature rise at plug-in contacts exceeds safety regulatory limits
Solution Approach 1:
The high current load is segmented into multiple parallel connection paths through the first and second plug-in connectors. Each connector handles a portion of the total current, reducing the current density and associated heat generation at each contact point. This allows the bus plug system to deliver its full rated power while keeping individual contact temperatures within safe operational limits.
Solution Approach 2:
The solution transitions from a single-point electrical connection to a multi-point distributed connection architecture. By adding the dimensional aspect of multiple spatially separated connectors along the busway, the system distributes thermal load across multiple locations rather than concentrating it at a single point, enabling higher overall current capacity without exceeding temperature limits at any individual connector.
3Productivity
If a conventional single plug-in bus plug is used, then the device simplicity is maintained, but the utilization of rated current capacity is limited to 80%
Solution Approach 1:
The bus plug incorporates multiple plug-in connectors that can be independently installed in separate plug-in ports along the busway. This segmentation enables the system to fully utilize the rated current capacity by distributing the electrical load across multiple connection points, achieving 100% utilization of the bus plug's current rating while maintaining modular installation flexibility.
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 dual plug-in bus plug effectively increases current capacity beyond conventional limits, adhering to safety standards by reducing temperature rise at contacts and allowing full utilization of rated current without requiring modifications to existing busway systems.
Implementation Method 1
The fingers 121 are spring-loaded and protrude transversely outward from the base 102 through a bus plug opening. The fingers 121 are structured to be inserted into the first plug-in port 12 and contact busway stabs 11. That is, a pair of fingers 121 become electrically connected upon insertion and compress respective busway stabs 11 between the fingers 121 and maintain the electrical connection by a constant spring force
Implementation Method 2
The fingers 121 and the stabs 11 are made of conductive materials (e.g., without limitation, copper or brass) to facilitate the flow of the electrical current 7 (as shown in Figure 1) from the busway 10 to the loads 5 via the circuit breaker 110
Data Source
Figure 1~1A
Figure 2
Figure 3
AI summary
A dual plug-in bus plug (200) for use in a busway system (2) including a busway (10) and a first and second consecutive plug-ins (12, 13) disposed on the busway (10). The dual plug-in bus plug (200) includes: a housing (201) including a base (202), a first plug-in connector (220) structured to be inserted into the first plug-in (12) and a second plug-in connector (230) structured to be inserted into the second plug-in (13), wherein the first and second plug-in connectors (220, 230) are structured to distribute current from the busway (10) upon being inserted into the plug-ins (12, 13); line side busbars (222) electrically connected to the first and second plug-in connectors (220, 230); and a circuit protection device (210) disposed within the housing (201) and electrically connected to the first and second plug-in connectors (220, 230) via the line side busbars (222) and to a load, the circuit protection device (210) structured to provide the current to the load during normal operation and interrupt the current from flowing to the load during a fault.