Dual Plug-In Bus Plug Layout for High-Current Temperature Limits
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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 connectors and an elevated circuit breaker that splits current flow through two plug-in ports, allowing each connector to handle less than the full rating, reducing temperature rise and enabling 100% utilization of the rated current capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single plug-in connector is used in a conventional bus plug, then the device complexity is low, but the current capacity is limited to 80% of the rated capacity due to temperature rise restrictions
Solution Approach 1:
The single plug-in connector is divided into two separate plug-in connectors (first and second plug-in connectors), each connecting to consecutive plug-in ports on the busway. This segmentation allows the current to be split into two separate connection paths, reducing the temperature rise at each connector while maintaining or increasing the overall current capacity of the bus plug assembly.
2Power
If the current rating is increased beyond 800A, 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 path is segmented into two separate connection paths through the first and second plug-in connectors. Each connector handles a portion of the total current, reducing the current density and resulting temperature rise at each individual connector contact point, thereby complying with safety regulatory temperature limits while supporting higher overall current ratings.
Solution Approach 2:
The current distribution is transitioned from a single-dimensional path to a two-dimensional configuration by utilizing two separate plug-in ports on the busway. This dimensional expansion allows parallel current flow paths, effectively distributing thermal load across multiple contact points.
3Productivity
If a dual plug-in connector design is implemented, then the current capacity utilization is improved to 100%, but the device complexity increases
Solution Approach 1:
The bus plug assembly is segmented into two functional connection units (first and second plug-in connectors), each responsible for a portion of the total current transfer. This segmentation enables both connectors to be actively utilized, achieving 100% capacity utilization rather than leaving 20% capacity unused as in conventional single-connector designs.
Solution Approach 2:
Two separate plug-in connectors and their associated connection paths are merged into a single integrated bus plug assembly that functions as one cohesive unit. The housing structure combines both connectors, and the circuit breaker integrates protection for the combined current path, achieving high capacity utilization while maintaining operational simplicity.
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 design allows for increased current capacity beyond 800A without exceeding temperature limits, maintaining safety compliance and being retrofittable to existing systems with minimal modifications.
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 FIG. 1) from the busway 10 to the loads 5 via the circuit breaker 110
Data Source
AI summary
A dual plug-in bus plug for use in a busway system including a busway and a first and second consecutive plug-ins disposed on the busway. The dual plug-in bus plug includes: a housing including a base, a first plug-in connector structured to be inserted into the first plug-in and a second plug-in connector structured to be inserted into the second plug-in, wherein the first and second plug-in connectors are structured to distribute current from the busway upon being inserted into the plug-ins; line side busbars electrically connected to the first and second plug-in connectors; and a circuit protection device disposed within the housing and electrically connected to the first and second plug-in connectors via the line side busbars and to a load, the circuit protection device structured to provide the current to the load during normal operation and interrupt the current from flowing to the load during a fault.