Insulated Busbar Interconnection Module for Safer Switchgear Assembly
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Solution Overview
Problem
Traditional low voltage electrical switchgear and control gear assemblies rely on open bare air insulated busbar systems, which are labor-intensive to install, prone to contamination, and pose safety risks due to exposed busbars, and lack standardized repetitive assembly techniques.
Innovation Solution
An insulated busbar assembly with modular interconnection and insulation modules that provide continuous phase-to-phase and phase-to-earth isolation, using a matrix system with 50mm spacing to house and connect busbars, eliminating the need for extensive bolted connections and reducing the risk of short circuits and arcing faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If open bare air insulated busbar systems are used, then assembly is simpler and more accessible, but safety is compromised due to exposed busbars and contamination risk
Solution Approach 1:
The patent applies encapsulation modules that completely cover the busbars with insulating material, forming a protective shell that eliminates exposure to contaminants and prevents accidental contact. This thin film/shell approach maintains the busbar system's functionality while providing continuous insulation and protection against foreign matter accumulation.
Solution Approach 2:
The busbars are nested within encapsulation modules that contain them completely. The modular design allows the busbars to be housed inside protective insulating structures, creating a nested configuration where the active electrical components are contained within safety-providing enclosures.
2Adaptability or versatility
If custom built switchboards with little repetitive assembly are used, then design flexibility is improved, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent divides the busbar system into standardized modular encapsulation units that can be manufactured independently and then assembled in various configurations. Each module is a self-contained unit with standardized dimensions and connection interfaces, enabling repetitive manufacturing while maintaining design flexibility through different arrangement patterns.
Solution Approach 2:
The encapsulation modules are designed as universal components that can serve multiple functions: electrical insulation, mechanical support, contamination protection, and structural organization. This multi-functionality reduces the need for specialized custom components while maintaining adaptability to different switchboard configurations.
3Quantity of substance
If busbar supports are fitted at maximum spacings with minimal insulation, then material cost is reduced, but labor intensity for installation increases
Solution Approach 1:
The patent merges multiple functions into the encapsulation module: insulation support, mechanical mounting structure, and contamination barrier are combined into a single integrated component. This eliminates the need for separate insulators and mounting brackets, reducing material quantity while improving installation efficiency through pre-assembled units.
Solution Approach 2:
The encapsulation modules are pre-assembled with busbars and insulation structures before installation at the installation site. This preliminary preparation of complete modules reduces on-site assembly labor while maintaining adequate insulation coverage, as the insulation and support structures are already in place during manufacturing.
4Reliability
If significant inter-bar spacing is provided for air insulated busbars, then contamination and arcing risk is reduced, but space utilization decreases
Solution Approach 1:
The patent uses continuous insulating encapsulation shells that provide contamination protection and arcing prevention without requiring large spacing between busbars. The insulating film/shell creates an effective barrier that allows closer busbar spacing while maintaining safety, thereby improving space utilization within the switchboard enclosure.
Data Source
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AI summary
An interconnection and insulation module is provided that is arranged to locate about a plurality of busbar pairs. Each busbar pair includes first and second busbars with an inter-busbar gap in between. The module includes opposed sides which accommodate the busbar pairs between them. Corresponding windows are formed through the opposed sides of the module and busbar separators extend from interior surfaces of the opposed sides. The bus bar separators locate inter- busbar gaps for each busbar pair between one or more of the corresponding windows. Passages are defined between the corresponding windows of the opposed sides via the inter-busbar gaps for insertion of an electrical interconnection member. In use busbars can be readily interconnected by aligning their respective modules against each other and applying electrical interconnection members through the windows.