Feed-through Terminal Block Module with Nested Contact Plug
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Solution Overview
Problem
Current shorting blocks used for disconnecting current transformers from relays during maintenance pose a risk of electrical shock to maintenance personnel due to potential arcing potentials.
Innovation Solution
A feed-through terminal block module design featuring a first and second current bar within a terminal housing, where the second current bar is initially non-connected but electrically connected via a contact plug that engages both bars only when fully inserted, reducing the risk of inadvertent electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shorting blocks are used to protect current transformers during maintenance, then current transformer protection is achieved, but maintenance personnel are exposed to arcing potentials and electrical shock risks
Solution Approach 1:
The contact plug is nested within the terminal housing during insertion, with the electrical contact contained inside the housing until the plug is fully inserted. This nesting approach allows the harmful electrical contact to be made inside the protected housing rather than exposed to personnel, resolving the contradiction between achieving electrical connection and preventing electrical shock exposure.
Solution Approach 2:
The terminal housing acts as an intermediary barrier between the electrical contact components and maintenance personnel. The housing contains the arcing potentials and electrical shock risks within its structure, while still allowing the shorting function to be achieved through the controlled insertion of the contact plug. This mediator approach protects personnel while maintaining the protective shorting capability.
2Reliability
If the contact plug is designed to engage both current bars simultaneously, then electrical connection reliability is improved, but the risk of inadvertent electrical shock during insertion increases
Solution Approach 1:
The contact plug is designed to be fully inserted into the terminal housing before the electrical contact engages with the current bars. This preliminary action of positioning the plug inside the housing ensures that the housing contains any potential arcing or electrical shock hazards before contact is made, while still achieving reliable electrical connection once insertion is complete.
Solution Approach 2:
The electrical contact of the contact plug is nested within the terminal housing during the insertion process. This nesting ensures that even though the plug is designed to engage both current bars simultaneously for reliable connection, the harmful electrical phenomena are contained within the housing rather than exposed to personnel during the connection process.
3Ease of operation
If modular terminal block modules are used to form shorting blocks, then ease of assembly and configuration is improved, but device complexity increases
Solution Approach 1:
The terminal block is segmented into modular terminal block modules, each containing a housing, current bars, and contact portions. This segmentation allows for easy assembly and configuration by simply connecting multiple identical modules together, while the standardized design of each module keeps individual module complexity manageable. The bridging pins provide a simple interface for connecting modules without requiring complex assembly procedures.
Solution Approach 2:
Each terminal block module is designed as a universal unit that can be configured for different shorting applications by simply arranging and connecting the modules in different configurations. The same basic module design with standardized bridging pins allows for flexible assembly to create shorting blocks of various sizes and configurations, reducing the need for multiple specialized component designs and thereby managing overall complexity.
Data Source
AI summary
A feed-through terminal block module includes first and second electrical terminals, a first current bar, and a second current bar, the terminals and current bars in a terminal housing. The first current bar permanently electrically connects the first and second terminals. The first current bar includes a first contact portion of the module. The second current bar includes a second contact portion of the module and a third contact portion of the module. A removable contact plug is inserted into the housing to selectively electrically connect the first and second contact portions. Removable bridge pins or a bridging current bar electrically connects the third contact portions of adjacent modules when modules are placed side-by-side to form a terminal block.