Modular Motor Starter Bus Layout for Scalable Drive Switching
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Solution Overview
Problem
Existing modular switch apparatuses for controlling electric drives are not scalable in a simple and cost-effective manner, and their wiring is complex.
Innovation Solution
A modular switch apparatus with a mounting rail bus system, a safety relay module, and safety motor starter modules that use a DC supply voltage to generate control signals for series-connected switch devices, allowing for easy scaling and simplified wiring through a modular structure with T-shaped bus connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing modular switch apparatuses are used, then the system can control electric drives, but the system is not scalable in a simple and cost-effective manner and requires complex wiring
Solution Approach 1:
The control apparatus is divided into separate functional modules: a power supply module, a safety relay module, and one or more motor starter modules. Each module can be independently configured and connected via standardized bus connectors, enabling scalable system expansion without increasing wiring complexity. The segmentation allows users to start with a basic configuration and add modules as needed.
Solution Approach 2:
The bus connectors are designed with universal interfaces that can connect different module types (power supply, safety relay, motor starter) in various configurations. The T-shaped bus connectors provide multi-functionality by allowing daisy-chaining of modules and supporting multiple system architectures (linear, star, tree) with the same connector design, simplifying wiring across different scalability scenarios.
2Ease of operation
If existing modular switch apparatuses are used, then the system can control electric drives, but the wiring is complex
Solution Approach 1:
Multiple wiring functions are merged into the bus connector design. The T-shaped bus connectors simultaneously provide power supply connections, control signal routing, and module identification functions through integrated contact arrangements. This merging eliminates the need for separate wiring harnesses for different functions, dramatically simplifying the overall wiring process.
Solution Approach 2:
The bus connector acts as an intermediary component that mediates all electrical connections between modules. Instead of direct point-to-point wiring between control apparatus and each motor starter, the bus connector provides a standardized intermediate interface that simplifies connections and enables plug-and-play module installation.
Data Source
AI summary
A modular switch apparatus for controlling at least one electric drive includes a mounting rail bus system having a control line and two power supply lines, a power supply device, and a safety relay module that is configured to obtain a first, high level control signal from a DC supply voltage applied to the two power supply lines and to feed the first control signal to the control line via the first bus interface if the emergency stop command device has not been actuated. Furthermore, at least one safety motor starter module is provided, which includes a processing device with an input that can be electrically connected to the control line via a bus interface. The processing device is adapted to evaluate a first, high level control signal as transferred via the control line and to provide control signals for controlling the at least two switch devices.