Load Bank Resistance Modules With Insulated Support Plates
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Solution Overview
Problem
Existing load banks face challenges in efficiency, compactness, safety, longevity, and ease of maintenance due to heat dissipation and contact point management, particularly in preventing overheating and ground faults.
Innovation Solution
A load bank design featuring tubular heating elements with insulated heating wires, straight and curved heat dissipation pipes arranged horizontally to promote efficient heat dissipation and separation of waste heat from contact areas, along with non-conductive support plates and guide plates to prevent ground faults and facilitate easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If heating elements are grouped into modules mounted on strips, then the heat load on contact points is minimized, but the structure becomes complex and maintenance is difficult
Solution Approach 1:
The load bank is divided into multiple independent resistance modules, each with its own support plate and heating elements. This segmentation allows heat to be localized to specific modules rather than concentrating on contact points, while each module can be independently maintained or replaced without affecting the entire system.
Solution Approach 2:
Electrically non-conductive support plates are introduced as intermediary elements between the heating elements and the support frame. These support plates serve as thermal barriers that prevent heat transfer to contact points while providing mechanical support, thus reducing heat load on contacts without requiring complex structural arrangements.
2Duration of action of stationary object
If heating elements are mounted to minimize heat load on contacts, then contact point durability improves, but heat dissipation efficiency decreases
Solution Approach 1:
The support plates are made electrically non-conductive and positioned specifically where heat transfer to contacts would occur. This local modification provides thermal insulation exactly where needed (at the contact interface) while leaving the rest of the heating element structure free to dissipate heat efficiently through convection and radiation.
Solution Approach 2:
The support plates extend in the longitudinal and/or transverse directions to overlap the module openings, creating a three-dimensional barrier structure. This dimensional approach allows the support plates to block heat pathways in multiple directions simultaneously, effectively shielding contact areas while maintaining open spaces for heat dissipation.
3Ease of manufacture
If heat dissipation tubes are arranged vertically, then heat dissipation is simplified, but turbulent flow and heat dissipation efficiency are reduced
Solution Approach 1:
The heat dissipation tubes incorporate curved sections that redirect the flow of air or coolant. These curved geometries create turbulence in the cooling medium, enhancing heat transfer coefficients and improving overall heat dissipation efficiency compared to simple straight vertical arrangements.
Solution Approach 2:
The orientation of heat dissipation tubes is changed from purely vertical to include horizontal sections. This parameter change in tube arrangement optimizes the flow characteristics of the cooling medium, promoting turbulent flow patterns that enhance convective heat transfer while still achieving effective heat dissipation.
4Ease of repair
If modular design is implemented for easy maintenance, then replacement of faulty elements is simplified, but the risk of ground faults increases
Solution Approach 1:
Electrically non-conductive support plates serve as intermediary barriers between the heating elements and the grounded support frame. This intermediary layer prevents direct electrical contact even when modules are being installed or removed, eliminating the ground fault risk associated with modular designs while maintaining ease of maintenance.
Solution Approach 2:
The non-conductive support plates are pre-installed as part of the module structure before the heating elements are attached. This beforehand preparation ensures that electrical insulation is already in place, preventing ground faults during maintenance operations without requiring additional protective measures during the actual maintenance process.
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
The design enhances the practical suitability by focusing heat dissipation, reducing temperature loads on contact points, improving reliability and safety, and allowing for efficient maintenance through modular replacement of faulty elements, while preventing ground faults and enhancing operational safety.
Implementation Method 1
heating elements in which electrical energy is converted into heat
Implementation Method 2
heat is then dissipated by natural or (fan-forced) convection to prevent overheating
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3C
AI summary
The present invention relates to a load bank (1) comprising a support frame (12) and several load bank resistance modules (9) attached to the support frame (12). Each load bank resistance module (9) comprises an electrically non-conductive support plate (10) and several heating resistors designed as tubular heating elements (11), each with a heat dissipation tube (20) having straight tube sections (20a) and at least one curved tube section (20b). The tubular heating elements (11) are each attached to one of the electrically non-conductive support plates (10). The support frame (12) has a corresponding module opening (23) for each load bank resistance module (9), which is dimensioned such that the heat dissipation tubes (20) of a load bank resistance module (9) can pass through the module opening (23) and the support plate (10) of a load bank resistance module (9) overlaps the corresponding module opening (23).The load bank resistance modules (9) are each attached to the support frame (12) by means of the electrically non-conductive support plates (10) of the load bank resistance modules (9) being attached to the support frame (12), such that the support frame (12), together with the support plates (10), separates a heat dissipation area (13) from a contact area (14). The contact points (19) are arranged in the contact area (14). The straight pipe sections (20a) of the heat dissipation pipes (20) are arranged horizontally in the heat dissipation area (13) with respect to their longitudinal extent.