Modular Electrical Device Assembly via Contact Pads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing modular electrical devices face complexities in assembly, reliability, and cost due to the need for intricate conductor routing and adjustments after final assembly, leading to potential scrapping of entire devices during inspection.
Innovation Solution
The modular electrical device design allows separate mounting and adjustment of modules on different production lines, with specific modules supporting terminals and conductors through contact pads and recesses, facilitating simplified assembly and reducing conductor routing constraints, enabling independent assembly and adjustment of functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If modules are assembled separately with conductor routing through walls, then modular assembly is achieved, but assembly complexity and industrial complexity increase greatly
Solution Approach 1:
The device is divided into separate functional modules (differential module and cutting-out module) that can be assembled independently. Each module has its own terminal support structure, allowing separate assembly and adjustment before final integration, thereby reducing overall assembly complexity.
Solution Approach 2:
Contact pads serve as intermediary connection elements between modules. Instead of routing conductors through walls between modules, the contact pads provide direct electrical connection points that simplify the inter-module connectivity and reduce assembly complexity.
2Stability of the object's composition
If adjustments are carried out after final assembly, then module integration is achieved, but the risk of scrapping complete device increases
Solution Approach 1:
Adjustments are performed on individual modules before final assembly. The differential module and cutting-out module can each be adjusted and tested separately on different production lines, eliminating the risk of scrapping the entire device if adjustment issues arise.
Solution Approach 2:
The adjustment process is segmented into module-level operations rather than device-level operations. Each module has its own adjustment capabilities and support structures, allowing independent optimization without affecting other modules.
3Volume of moving object
If differential compartment is arranged laterally, then compact layout is achieved, but heating optimization is compromised
Solution Approach 1:
The terminal support structure extends in multiple dimensions to provide optimal spacing for heating elements. The support comprises contact pads arranged in specific spatial configurations that allow heating optimization while maintaining compact overall device dimensions.
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 approach simplifies the assembly process, increases reliability, reduces industrial costs by allowing module-specific adjustments rather than complete device scrapping, and enhances the quality of finished products by reducing defects and assembly complexities.
Implementation Method 1
the contact pads of the support, called first pads, are electrically connected to the primary conductors of the core by welding
Implementation Method 2
the so-called second contact pads of the support are electrically connected to the contact pads of the breaking poles and to the primary conductors by welding
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The device has two bipolar outage modules (2, 3) for supporting four upstream terminals to which the outage modules are electrically connected. A differential protection module (1) supports downstream terminals (10-13) to which the differential module is electrically connected. The outage modules and the differential module are connected to each other at final assembling of the device. The downstream terminals are fixed on a support (14) having connecting pads.