Modular Power Distribution Apparatus with Height Controller

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Solution Overview

Problem

Existing power distribution apparatuses face challenges such as increased manufacturing costs, reduced productivity, and safety hazards due to complex assembly processes, incompatible breaker heights, and exposure of connection terminals, which lead to potential short-circuits and heat issues.

Innovation Solution

A modulated block type power distribution apparatus with a natural connection part, riveted coupling of main and sub breaker terminals, a height controller for compatibility with different terminals, and a preassembled design with buried screw threads and ventilating openings to reduce heat and improve conductivity, along with a transparent cover for safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional bus bar connection method is used, then power distribution is achieved, but gaps are generated allowing foreign substance insertion causing safety hazards

Engineering Contradiction:

ImprovesafetyVSAvoidforeign substance insertion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent merges the main breaker terminal and sub breaker terminal into a single integrated connection structure. The terminal is formed as one piece that simultaneously connects to both breakers, eliminating gaps between separate connection points where foreign substances could enter. This unified structure ensures continuous electrical contact and prevents safety hazards from foreign object insertion.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If conventional cabinet panel manufacturing is used, then power distribution is achieved, but manufacturing costs increase and delivery is delayed due to complex processes

Engineering Contradiction:

Improvepower distribution functionVSAvoidmanufacturing cost and delivery time

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent segments the power distribution system into modular components: a standardized terminal unit that can be independently manufactured and then assembled with breakers. This terminal module can be produced separately using optimized processes without requiring complex bus bar processing equipment, reducing manufacturing costs and enabling faster production while maintaining the complete power distribution function when assembled.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal design is universal and can be used with various breaker types and configurations. The same terminal structure serves multiple functions: electrical connection, mechanical support, and alignment guidance. This multi-functionality eliminates the need for specialized components for each application, simplifying manufacturing and reducing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If breaker heights are standardized, then manufacturing is simplified, but compatibility with various breaker heights is reduced

Engineering Contradiction:

ImprovestandardizationVSAvoidbreaker height compatibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The terminal incorporates adjustable or flexible mounting features that can adapt to different breaker heights. The connection structure allows for height variation while maintaining proper electrical contact and mechanical stability. This dynamic adaptability enables the same standardized terminal design to work with breakers of various heights without requiring custom manufacturing for each height specification.

Inventive Principle:

Principle #15Dynamics

4Ease of operation

If connection terminals are exposed for easy connection, then ease of operation is improved, but short-circuits and heat issues occur due to exposure

Engineering Contradiction:

Improveconnection accessibilityVSAvoidshort-circuit and heat generation

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The terminal is nested within a protective housing or casing that encloses the connection points. The housing provides physical protection while allowing access for connection operations. This nested structure shields exposed terminals from environmental hazards and prevents short-circuits, while the design maintains ease of operation by providing accessible connection points within the protective enclosure.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS8664805B2Power distribution apparatus

Publication Date: 2014.03.04 LC POWER KOREA

AI summary

A power distribution apparatus is provided. The apparatus may include a modulated block type power distribution apparatus capable of reducing a space by consequently connecting a main breaker to a sub breaker as a block not to form a gap while installing. The apparatus may include a multifunctional block type power distribution apparatus capable of easily connecting breakers with one another, the breaker having different height, by additionally installing a height controller able to control a height of a branch breaker on the apparatus manufactured in one mold and preventing wrong coupling while connecting a plurality of branch breakers with one another. The apparatus may include a preassembled power distribution apparatus capable of increasing coherence between terminals while coupling a main breaker terminal, a branch breaker terminal, and an additional breaker terminal, forming the preassembled power distribution apparatus, with various terminals of another preassembled power distribution apparatus.