Flexible Conductor Assembly for Reconfigurable Bus Bar Layouts
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Solution Overview
Problem
In power distribution systems, rigid bus bars restrict the positioning of switching apparatuses, require unique assemblies for inconsistent breaker layouts, and lead to increased maintenance costs due to high electrical resistance and potential ignition hazards in hazardous environments.
Innovation Solution
A flexible electrical conductor assembly with a main conductive portion and bendable branch members, covered by casings with spring members to apply compressive force, allowing for adaptable configurations and reduced electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid bus bars are used to deliver electricity, then structural strength and electrical conductivity are improved, but positioning flexibility of switching apparatus and adaptability to different breaker layouts deteriorate
Solution Approach 1:
The bus bar assembly transitions from a rigid structure to a flexible one by incorporating elastomeric material. The flexible bus bar can bend and conform to different positions, allowing switching apparatus to be positioned flexibly while maintaining structural integrity through the elastomeric material's inherent strength properties.
Solution Approach 2:
The bus bar is constructed with an elastomeric material that provides flexibility, allowing it to bend and adapt to different configurations. This flexible construction enables the bus bar to accommodate various breaker layouts and positioning requirements while maintaining its structural function.
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 assembly is divided into modular components: a flexible bus bar portion and separate rigid bus bar portions that can be attached as needed. This segmentation allows the system to have connection points only where required, reducing manufacturing complexity and assembly time while maintaining necessary electrical conductivity through the modular connection design.
3Adaptability or versatility
If joints between attached conductors are created, then adaptability to different configurations is improved, but electrical resistance increases creating thermal hot spots
Solution Approach 1:
The flexible bus bar portion eliminates the need for rigid joints between conductors by providing a continuous, bendable electrical path. This dynamic flexible connection maintains low electrical resistance while allowing the bus bar to adapt to different configurations through bending rather than through resistant joints.
4Adaptability or versatility
If breaker layout changes are needed during system life, then system adaptability is improved, but replacement cost and complexity increase
Solution Approach 1:
The flexible bus bar can be repositioned and reconfigured without replacement by simply bending it to new positions. This dynamic flexibility allows layout changes during system operation without the high costs and complexity of replacing rigid bus bar assemblies, maintaining adaptability while reducing repair difficulty.
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 for different breaker configurations without replacing bus bars, and minimizes electrical resistance and ignition risks.
Implementation Method 1
A spring member is mounted to the casing and configured to apply a compressive force to the electrical conductor
Data Source
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.