Modular Grid-Connected Distribution Box for Error-Free Assembly
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Solution Overview
Problem
Existing distribution boxes face issues with misassembly due to complex structures and lack of modular design, making partial component replacement impossible when local failures occur.
Innovation Solution
A modularized grid-connected distribution box with distinct modules for grid, relay, control, and neutral functions, featuring a case with internal components arranged to facilitate assembly and compact design, including a transformer and heat dissipation structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If distribution boxes are assembled by assembling components in the order of the production process, then manufacturing can be completed, but misassembly occurs due to complex structure
Solution Approach 1:
The distribution box is divided into multiple independent modules (power supply module, control module, relay module, grid module, neutral module) that can be assembled independently and then integrated. This segmentation eliminates the complexity of assembling all components in a single sequence, reducing misassembly risks while maintaining manufacturing efficiency.
2Adaptability or versatility
If distribution boxes use complex structure to achieve various functions, then functionality is improved, but partial replacement of components becomes impossible when local failure occurs
Solution Approach 1:
Each functional component (power supply module, control module, relay module, grid module, neutral module) is designed as an independent replaceable unit. When a local failure occurs, only the affected module needs to be replaced rather than the entire distribution box, maintaining ease of repair while preserving all functional capabilities.
3Ease of manufacture
If distribution boxes are modularized by function, then manufacturing and installation are facilitated, but device structure becomes more complex
Solution Approach 1:
The distribution box is segmented into standardized functional modules with uniform connection interfaces. This segmentation simplifies manufacturing and installation processes while the modular design actually reduces overall structural complexity compared to traditional integrated designs, as each module can be independently optimized and assembled.
4Device complexity
If traditional distribution boxes use integrated design, then structural simplicity is maintained, but freedom of design is limited
Solution Approach 1:
The integrated design is replaced with a modular segmented architecture where each functional module can be independently designed, configured, and optimized. This segmentation dramatically increases design freedom and adaptability while maintaining manageable structural complexity through standardized interfaces and configurations.
Data Source
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AI summary
Provided is a grid-connected distribution box (1) including a case (10) having an internal space, a grid module (100) disposed in the internal space and having a main input terminal (110) into which main power is input and at least one output terminal (130, 150) connected to at least one load (Load1, Load2), a relay module (200) arranged at one side of the grid module (100), and a control module (300) disposed in the internal space and having a sub-input terminal (330, 350) to which at least one sub-power source (E1, E2) is input, and configured to provide the at least one sub-power source (E1, E2) to the relay module (200).