Laminated Busbar Connection Assembly for Lower-Heat Circuit Breaker Mounting
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Solution Overview
Problem
Current low voltage switchgear systems face challenges in directly connecting circuit breakers to laminated busbars due to point-to-point connections, which hinder the integration of circuit breakers with busbars having projecting conducting layers and insulating layers.
Innovation Solution
The arrangement involves cylindrical connecting elements and a distribution bar mounted to their free ends, with a terminal member positioned centrally between them, allowing for efficient electrical connection and heat dissipation, and enabling higher current transfer and flexible mounting configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If point-to-point connections are used to connect circuit breakers to busbars, then the connection structure is simple, but the current density is high and heat dissipation is poor
Solution Approach 1:
The invention divides the connection structure into multiple cylindrical connecting elements (at least two) instead of using a single point-to-point connection. Each cylindrical element provides a separate connection path, segmenting the current flow and reducing current density at each individual connection point. This segmentation approach directly addresses the heat dissipation problem by distributing thermal load across multiple contact surfaces.
Solution Approach 2:
The invention transitions from a point-like connection (0D) to cylindrical connections (1D surface contact). By using cylindrical connecting elements with circular cross-sections that contact the busbar over a curved surface area rather than a single point, the connection moves to a higher dimensional contact interface. This dimensional change increases the effective contact area, reducing current density and improving heat dissipation capability.
2Temperature
If multiple cylindrical connecting elements are used to reduce current density, then heat dissipation improves, but the connection structure becomes more complex
Solution Approach 1:
The cylindrical connecting elements serve multiple functions simultaneously: they provide electrical connection, mechanical support, and heat dissipation pathways. The distribution bar also performs multiple roles by connecting all cylindrical elements and providing a common terminal. This multi-functionality reduces the need for additional specialized components, offsetting the apparent structural complexity with functional integration.
Solution Approach 2:
The invention merges the connecting elements and distribution bar into an integrated assembly that functions as a unified connection system. Rather than treating each cylindrical element as a separate component requiring individual mounting, they are combined through the distribution bar into a coordinated structure that achieves both electrical and thermal management goals while simplifying overall system integration.
3Adaptability or versatility
If circuit breakers are directly connected to projecting conducting layers, then the mounting is flexible, but the connection reliability is insufficient due to point contact
Solution Approach 1:
The invention replaces point contact (0D) with cylindrical surface contact (1D/2D interface). The cylindrical connecting elements provide extended contact surfaces that engage with the busbar over a curved area rather than at a single point. This dimensional enhancement increases connection reliability by distributing mechanical and electrical stresses across a larger interface, reducing the risk of contact failure while maintaining mounting flexibility.
Solution Approach 2:
The connection reliability is enhanced by segmenting the contact interface into multiple cylindrical elements rather than relying on a single point contact. Each cylindrical element provides an independent reliable connection path, and the segmentation allows the system to maintain flexibility while achieving superior reliability through redundant connection paths and distributed stress management.
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
This solution reduces contact current by 50%, enhances heat dissipation, and allows for flexible mounting of circuit breakers, increasing the lifetime and efficiency of the switchgear system by efficiently transferring and dissipating thermal energy.
Implementation Method 1
an electrically conducting distribution bar (12) which is mounted to free end portions of the first and second cylindrical connecting elements (10a, 10b)
Implementation Method 2
enhances heat dissipation, and allows for flexible mounting of circuit breakers, increasing the lifetime and efficiency of the switchgear system by efficiently transferring and dissipating thermal energy
Data Source
AI summary
An arrangement for electrically connecting a circuit breaker to a laminated busbar in a switch gear cabinet in which the circuit breaker has at least one terminal to be contacted by a connecting bar and in which the laminated busbar includes at least one conducting layer for conducting electric current which is covered by adjoining insulating layers attached thereto, the arrangement including: a first cylindrical connecting element and a second cylindrical connecting element which are arranged at a distance to each other at the conducting layer and project away from the conducting layer; an electrically conducting distribution bar which is mounted to free end portions of the first and second cylindrical connecting elements; and a terminal member which is mounted to the distribution bar at a center between the first and second cylindrical connecting elements. The terminal member is to be contacted by the connecting bar.