Flexible Conductor Assembly for Variable Breaker Spacing
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Solution Overview
Problem
Rigid bus bars in power distribution systems restrict flexibility in breaker panel configurations, leading to increased maintenance costs, logistical challenges, and safety hazards due to inconsistent pole spacings and thermal hotspots, especially in hazardous locations.
Innovation Solution
A partially flexible electrical conductor assembly with a main conductive portion and flexible branch members, enclosed in casings that allow for adjustable configurations and insulation, enabling flexible positioning and connection of different breaker types within a single system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid bus bars are used in power distribution systems, then structural strength and electrical conductivity are improved, but flexibility in breaker panel configurations is reduced and thermal hotspots occur due to inconsistent pole spacings
Solution Approach 1:
The bus bar system is divided into modular sections that can be independently positioned and configured. Each module contains connection points that can accommodate different breaker types and pole spacings, allowing the system to be segmented and reconfigured without replacing entire bus bar assemblies.
Solution Approach 2:
The bus bar system incorporates adjustable and reconfigurable elements that allow dynamic adaptation to different breaker configurations. Connection points and support structures can be repositioned to accommodate inconsistent pole spacings in hazardous area circuit breakers and other varying breaker types.
2Reliability
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 bus bar modules are designed with universal connection points that can serve multiple functions and accommodate different breaker types. A single modular design can be used across various configurations, reducing the number of unique parts needed and simplifying manufacturing and assembly processes.
Solution Approach 2:
The system allows for parameter changes in connection point positioning and configuration without requiring different bus bar designs. Adjustable parameters such as connection point location and orientation enable the same bus bar module to adapt to various breaker types, reducing manufacturing complexity.
3Stability of the object's composition
If rigid bus bars are used, then structural stability is improved, but maintenance cost increases due to joint loosening and thermal hotspots from temperature cycling
Solution Approach 1:
The modular bus bar design incorporates compensation mechanisms for thermal expansion and contraction before they cause damage. Expansion joints and flexible connection points accommodate temperature cycling without creating excessive stress that would lead to joint loosening or thermal hotspots.
Solution Approach 2:
The modular design allows individual bus bar sections to be easily replaced if they become damaged or loose, without requiring replacement of the entire bus bar system. This enables selective maintenance and recovery of functional sections, reducing overall maintenance costs.
4Reliability
If rigid bus bars are used, then electrical conductivity is improved, but adaptability to different breaker types is reduced
Solution Approach 1:
The bus bar modules are designed with universal connection points that can serve multiple functions and accommodate different breaker types. A single modular design can be used across various configurations, reducing the number of unique parts needed and simplifying manufacturing and assembly processes.
Solution Approach 2:
The system allows for parameter changes in connection point positioning and configuration without requiring different bus bar designs. Adjustable parameters such as connection point location and orientation enable the same bus bar module to adapt to various breaker types, reducing manufacturing complexity.
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. A casing covers at least a portion of the electrical conductor. The casing insulates the at least a portion of the electrical conductor.