Modular Jaw With Independent Spring Contacts
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Solution Overview
Problem
Existing busway systems lack an efficient, cost-effective, and simple solution for installing plug-in units with different electrical load requirements, as they require different jaws, increasing manufacturing costs and leading to alignment issues due to single-line contact points.
Innovation Solution
A modular jaw unit with a spring support member and independently moving support ends, capable of connecting to other modular units, providing multiple contact points and accommodating various ampacity requirements through removably connected modular units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different jaws are used for different ampacity requirements, then the electrical connection reliability is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
A single modular jaw design with configurable contact points (single-line or multi-line) serves multiple ampacity requirements, eliminating the need for multiple different jaw types while maintaining reliable electrical connection for various load requirements
2Ease of manufacture
If a single line of contact is used per side of the stab, then the jaw design is simplified, but the electrical contact reliability deteriorates due to alignment problems
Solution Approach 1:
The jaw incorporates independently movable contact points that can dynamically adjust their position to maintain optimal alignment with the stab, transitioning from static single-line contact to dynamic multi-line contact that adapts to alignment variations
Solution Approach 2:
Multiple contact points are nested within the jaw structure, allowing one or more contact points to be activated based on alignment requirements, with inner contact points providing backup or additional contact paths
3Adaptability or versatility
If multiple different jaws are manufactured for different applications, then the adaptability to different load requirements is improved, but the manufacturing cost increases due to different tooling requirements
Solution Approach 1:
A universal modular jaw design with configurable contact point arrangements serves multiple ampacity requirements, allowing a single tooling setup to produce jaws suitable for various electrical loads through different contact point configurations rather than requiring separate tooling for each ampacity level
4Device complexity
If a single contact point is used, then the jaw structure is simplified, but the thermal performance deteriorates due to higher resistance
Solution Approach 1:
The jaw employs independently movable contact points that can be positioned to distribute current flow across multiple parallel contact paths, dynamically reducing electrical resistance and improving thermal performance while maintaining a relatively simple overall jaw structure
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 modular jaw system reduces manufacturing costs, enhances ease of assembly, and improves electrical contact by providing multiple contact points, reducing resistance and thermal issues, while allowing for flexible ampacity adjustments without needing multiple tooling sets.
Implementation Method 1
a spring support member having a central section. The central section has a plurality of coupling bosses and a plurality of coupling slots
Data Source
AI summary
A modular jaw unit for a busway system includes a spring support member having a central section and four independently moving support ends. The central section has a plurality of bosses and slots for coupling the jaw unit to another jaw unit. The support ends extend from the central section and are independently movable with respect to each other. A pair of wires are positioned within the support member, and each of the wires has wire ends located adjacent to a respective support end of the support member.