Modular Circuit Breaker Frame Segmentation

Solution Overview

Problem

The manufacturing of large-sized circuit breakers is costly and time-consuming due to the need for larger molds and complex resin joining methods, which also complicates component separation and maintenance.

Innovation Solution

A modular frame design comprising multiple unit frames connected via a connection unit with bolts, a fixing member, and a distance-maintaining member, allowing for easy assembly and disassembly, and manufactured by injection-molding to reduce production costs and time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a large-sized body frame is manufactured by injection-molding to increase conducted current capacity, then the conducted current capability is improved, but the manufacturing cost increases and the manufacturing time increases due to larger molds and injection equipment

Engineering Contradiction:

Improveconducted currentVSAvoidmanufacturing cost

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The body frame is divided into multiple small-sized unit frames that can be manufactured separately using standard injection-molding equipment, then connected together to form the complete frame structure. This segmentation allows the use of smaller, more economical molds while achieving the same overall conducted current capacity through parallel current paths in multiple units.

Inventive Principle:

Principle #1Segmentation

2Power

If a large-sized body frame is manufactured by injection-molding to increase conducted current capacity, then the conducted current capability is improved, but the manufacturing time increases due to larger molds and injection equipment

Engineering Contradiction:

Improveconducted currentVSAvoidmanufacturing time

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The body frame is divided into multiple small-sized unit frames that can be manufactured separately using standard injection-molding equipment, then connected together to form the complete frame structure. This segmentation allows the use of smaller, more economical molds while achieving the same overall conducted current capacity through parallel current paths in multiple units.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If resin joining method is used to connect two small-sized body frames, then the manufacturing cost is reduced, but the manufacturing time increases due to resin molding process and hardening time

Engineering Contradiction:

Improvemanufacturing costVSAvoidmanufacturing time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The resin joining method is replaced with a mechanical connection system using connection units that feature connecting members inserted into insertion recesses and secured with bolts. This mechanical fastening method eliminates the time-consuming resin molding and hardening processes while maintaining strong structural integrity and electrical connectivity between unit frames.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If two small-sized body frames are joined together to form a large frame, then the manufacturing cost is reduced, but the ease of separation and maintenance deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoidcomponent separation

Core Design Contradiction:

Ease of manufactureVSEase of repair

Solution Approach 1:

The resin joining method is replaced with a mechanical connection system using connection units that feature connecting members inserted into insertion recesses and secured with bolts. This mechanical fastening method eliminates the time-consuming resin molding and hardening processes while maintaining strong structural integrity and electrical connectivity between unit frames.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The body frame is divided into multiple small-sized unit frames that can be manufactured separately using standard injection-molding equipment, then connected together to form the complete frame structure. This segmentation allows the use of smaller, more economical molds while achieving the same overall conducted current capacity through parallel current paths in multiple units.

Inventive Principle:

Principle #1Segmentation

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 modular design reduces manufacturing costs and time by eliminating the need for large molds and simplifies the assembly process, while enabling easy component replacement and adjustment, thus enhancing productivity and maintenance efficiency.

Implementation Method 1

a connection unit coupled between two adjacent unit frames among the unit frames and connecting the two unit frames to each other

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Data Source

PatentEP2015335B1Frame for circuit breaker

Publication Date: 2018.05.16 LG INDUSTRIAL SYSTEMS CO LTD

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AI summary

Disclosed is a frame for a circuit breaker, including: a plurality of unit frames having a plurality of inner spaces, and a connection unit coupled between two adjacent unit frames among the unit frames and connecting the two unit frames to each other, thereby reducing the manufacturing cost as well as facilitating its manufacture and reducing the manufacturing time.