Flexible Conductor Assembly for Configurable Breaker Panels
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Solution Overview
Problem
Rigid bus bars in power distribution systems restrict flexibility in breaker panel configurations, require multiple unique assemblies for different breaker layouts, and lead to increased maintenance costs and safety hazards due to thermal hot spots and loose connections.
Innovation Solution
A partially flexible electrical conductor assembly with a main conductor portion and flexible branch members, housed within casings that apply compressive force using a spring member, allowing for customizable configurations and reduced electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid bus bars are used in power distribution systems, then structural stability and electrical conductivity are improved, but flexibility in breaker panel configurations is reduced and thermal hot spots increase due to loose connections
Solution Approach 1:
The patent applies the dynamics principle by transitioning from rigid bus bars to flexible bus bars that can dynamically adapt to different breaker configurations. The flexible bus bar includes a main body portion and multiple branch portions that can be positioned at different angles and locations to accommodate various breaker arrangements, thereby improving adaptability while maintaining reliable electrical connections through proper contact pressure.
Solution Approach 2:
The patent applies parameter changes by modifying the physical properties of the bus bar material and geometry. The flexible bus bar uses materials with appropriate flexibility characteristics and designs branch portions with specific lengths, angles, and positions that can be adjusted to match different breaker pole spacings and configurations, resolving the contradiction between structural stability and configuration flexibility.
2Adaptability or versatility
If multiple unique rigid bus bar assemblies are created for different breaker layouts, then adaptability to various configurations is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a single flexible bus bar assembly that can serve multiple breaker configurations. The main body portion with multiple adjustable branch portions allows one assembly to accommodate various breaker layouts by repositioning the branches, eliminating the need for multiple unique rigid assemblies and reducing device complexity while maintaining broad adaptability.
Solution Approach 2:
The patent applies segmentation by dividing the bus bar into a main body portion and multiple separate branch portions that can be independently positioned and configured. This segmented structure allows each branch to be adjusted to different angles and locations to match various breaker pole spacings, enabling one assembly to serve multiple configurations without increasing overall complexity.
3Reliability
If rigid bus bars with multiple connection points are used, then electrical conductivity is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent applies preliminary action by pre-configuring the flexible bus bar with branch portions that are already positioned and angled to match standard breaker configurations. This preliminary setup reduces the need for complex field assembly and adjustments, thereby decreasing assembly time and cost while maintaining reliable electrical conductivity through proper contact alignment.
4Strength
If breakers are bolted directly to rigid bus bars, then structural stability is improved, but electrical resistance increases creating thermal hot spots
Solution Approach 1:
The patent applies parameter changes by modifying the contact interface parameters between the bus bar and breaker. The flexible bus bar design allows for optimized contact pressure and contact area at each connection point, improving electrical conductivity while maintaining structural stability. The flexibility enables better conformity to the breaker contact surfaces, reducing contact resistance and preventing thermal hot spots.
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
Enables flexible positioning of switching apparatuses, reduces maintenance costs by allowing different breaker configurations within a single system, and enhances safety by minimizing thermal hot spots and electrical interference.
Implementation Method 1
A spring member is mounted to the casing and configured to apply a compressive force to the electrical conductor
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An electrical conductor assembly for use in a power distribution assembly includes an electrical conductor and a casing covering at least a portion of the electrical conductor. A spring member is mounted to the casing and configured to apply a compressive force to the electrical conductor.