Modular Bus Support System for Motor Control Centers
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Solution Overview
Problem
Existing bus support systems for motor control centers are costly due to the need for extensive bracing to withstand high short circuit currents, requiring different systems for varying current levels and lacking economies of scale for higher rated systems.
Innovation Solution
A bus support system with vertical channels and add-on braces that limit movement of vertical bus conductors during high current events, allowing the same system to be used for different current ratings by incorporating additional braces, reducing material usage and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If extensive bracing is used to withstand high short circuit currents, then the bus support system can handle higher current levels, but the material usage and manufacturing costs increase substantially
Solution Approach 1:
The bus support system is divided into modular components: a base bus support structure and separate add-on braces. These segments can be configured in different combinations to match specific current requirements, avoiding the need to use extensive bracing for all applications. The segmentation allows the system to scale material usage according to actual needs.
Solution Approach 2:
The system allows dynamic configuration by adding or removing add-on braces based on the specific current rating requirements. Instead of a fixed extensive bracing structure, the support system can be adapted to provide exactly the right amount of strength needed for each application, from 42 kA to 100 kA and beyond.
2Strength
If different bus support systems are employed for different current levels, then each system can be optimized for its specific rating, but the inventory complexity and manufacturing costs increase
Solution Approach 1:
A single universal bus support system design serves multiple current rating requirements (42 kA, 65 kA, 100 kA, and higher). The base structure remains the same across all ratings, with add-on braces providing the necessary strength increments. This eliminates the need for completely different support systems for each current level.
Solution Approach 2:
The system accommodates different current ratings by changing the configuration parameters - specifically, the number and arrangement of add-on braces - rather than changing the fundamental support structure. This allows a single design platform to adapt to various electrical loading conditions.
3Quantity of substance
If higher rated bus support systems are manufactured less frequently, then inventory costs decrease, but the economy of scale benefits are lost
Solution Approach 1:
By using one universal bus support design for all current ratings, the manufacturer produces a single base component type in high volume, maintaining economy of scale. The add-on braces are also standardized components that can be manufactured efficiently. This eliminates the need to maintain separate production lines for different support system ratings.
Solution Approach 2:
The segmentation into a common base structure and standardized add-on braces allows the base component to be manufactured in large quantities for all applications, while the add-on braces are produced as needed. This improves manufacturing efficiency by focusing volume production on the universal base element.
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 solution effectively withstands short circuit currents up to 100 kA while reducing material usage and costs, maintaining structural integrity without the need for additional steel backing plates, and allowing for a more compact design.
Implementation Method 1
The vertical bus bars and other supporting structures should be able to withstand magnetic forces created by high circuit currents that pass through the MCC during a short circuit fault, or any other high current event.
Data Source
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AI summary
A bus support system is provided. The bus support system includes a bus support having a plurality of vertical channels configured to receive vertical bus conductors, each of the plurality of vertical channels having a rear protrusion on a rear side of the bus support. The bus support system also includes a plurality of add-on bus support braces disposed on the rear side of the bus support and configured to contact the plurality of channels to limit a movement of the vertical bus conductors during a high current event.