Fuse Disconnector Connecting Rail Design for Cost Reduction
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Solution Overview
Problem
Existing fuse-disconnectors face challenges in reducing manufacturing costs without compromising safety and functionality, particularly in the design and assembly of connecting rails and clamping parts.
Innovation Solution
A fuse-disconnector design featuring a base part with three connecting rails, each with a contact element and a clamping part, where the connecting rail is made from a single piece of flat strip, allowing for rotation and easy assembly using an Allen key, and a rail module that can be securely attached to the base part using pressure screws, enabling connection to a rail bridge with downward or upward current drains.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connecting rail is made from a single piece of flat strip, then manufacturing costs are reduced, but the complexity of achieving secure attachment and proper orientation increases
Solution Approach 1:
The connecting rail is divided into functionally distinct segments within a single piece construction: contact elements for electrical connection, clamping parts for mechanical attachment, and fastening parts for securing. This segmentation allows each part to be optimized for its specific function while maintaining manufacturing simplicity through single-piece fabrication from flat strip material.
Solution Approach 2:
Multiple functional elements (contact elements, clamping parts, fastening parts with openings) are merged into a single integrated connecting rail component made from one piece of flat strip. This consolidation eliminates the need for separate manufacturing and assembly of multiple components, reducing manufacturing costs while the integrated design incorporates all necessary functions for secure attachment and proper orientation.
2Ease of operation
If the clamping parts point with their free ends in the direction of a connecting part of the base part, then the rail module can be easily pushed onto the connecting rails, but the structural complexity of the connecting rail increases
Solution Approach 1:
The clamping parts are designed with free ends that point in the direction of the connecting part of the base part, creating a dynamic insertion path that guides the rail module during assembly. This directional configuration allows the rail module to be easily pushed onto the connecting rails in a single motion, transforming a potentially complex multi-step assembly process into a simple dynamic insertion operation.
3Ease of repair
If the fastening part has an opening that allows rotation with an Allen key, then the pressure screw becomes accessible for tightening, but the design complexity of the fastening part increases
Solution Approach 1:
The opening in the fastening part serves as an intermediary access channel that allows the Allen key to reach the pressure screw for tightening and loosening operations. This design provides a controlled access path that enables maintenance and assembly operations without requiring disassembly of the entire connecting rail, while the opening's geometry is optimized to accommodate the Allen key tool.
4Adaptability or versatility
If the connecting rail is designed to enable connection to a rail bridge using rail clamps, then versatility is improved, but the manufacturing complexity increases
Solution Approach 1:
The connecting rail is designed with universal features including contact elements for electrical connection, clamping parts for mechanical attachment, and fastening parts with accessible openings for securing. This multi-functional design enables the same connecting rail structure to be used in various configurations and applications, including connection to rail bridges using rail clamps, while maintaining manufacturing simplicity through single-piece construction from flat strip material.
Data Source
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AI summary
The invention relates to a fuse disconnector with at least three terminal rails with contact elements, which are installed in a base part of the fuse disconnector, wherein the first and the second terminal rails are each provided with a clamping element, the free ends of which point towards a terminal part of the base part. The third terminal rail comprises a contact element, a mounting element, a guide element, and a clamping element, wherein the aforementioned mounting element, the guide element, and the clamping element of the third terminal rail are arranged in the shape of the letter "C", such that the free end of the clamping element now points towards the terminal part of the base part, just like the free ends of the first and second terminal rails.