Modular Grid-Connected Distribution Box for Error-Proof Assembly
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Solution Overview
Problem
Traditional distribution boxes face issues with misassembly due to complex structures and lack of modular design, making partial replacement of components impossible when local failures occur.
Innovation Solution
A modularized grid-connected distribution box design featuring a case with internal modules for grid, relay, control, and neutral functions, allowing for separate assembly and easy installation, with distinct terminal arrangements and connectors to facilitate assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional distribution boxes are assembled by assembling components in production process order, then the structure 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, neutral module, blocking module, communication module) that can be assembled separately and then integrated. This segmentation reduces the complexity of the overall assembly process and minimizes misassembly risks.
Solution Approach 2:
Each module is pre-assembled and tested independently before being integrated into the complete distribution box. The modules come with pre-installed components and pre-configured connections, allowing for quality control at the module level and reducing assembly errors during final integration.
2Ease of manufacture
If traditional distribution boxes use a unified structure, then manufacturing is straightforward, but partial replacement of components is impossible when local failures occur
Solution Approach 1:
The distribution box employs a modular architecture where each functional module is independent and can be replaced separately. When a local failure occurs in a specific module, only that module needs to be replaced rather than the entire distribution box, significantly improving ease of repair.
Solution Approach 2:
The modular design allows defective modules to be quickly identified and replaced, while functional modules can be recovered and reused. This approach optimizes resource utilization and reduces waste by enabling selective replacement rather than discarding the entire system.
3Adaptability or versatility
If distribution boxes are designed with complex structures to achieve various functions, then functionality is enhanced, but assembly errors increase
Solution Approach 1:
Complex functions are distributed across multiple specialized modules, each responsible for a specific function. This segmentation allows each module to be designed and assembled with focused precision, reducing overall assembly errors while maintaining high functional versatility.
Solution Approach 2:
The modular design enables universal interfaces and standardized connection methods across all modules. This universality simplifies the assembly process for complex multi-functional systems by providing consistent assembly procedures regardless of the specific functional requirements.
Data Source
AI summary
Provided is a grid-connected distribution box including a case having an internal space, a grid module disposed in the internal space and having a main input terminal into which main power is input and at least one output terminal connected to at least one load, a relay module arranged at one side of the grid module, and a control module disposed in the internal space and having a sub-input terminal to which at least one sub-power source is input, and configured to provide the at least one sub-power source to the relay module.