Modular Power Distribution Terminal With Interchangeable Slices
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power distribution terminals require complete replacement if one of the connectors is damaged, disrupting the entire system and necessitating a solution for modular interconnectivity to allow for easy replacement of faulty modules without affecting others.
Innovation Solution
A modular power distribution terminal design featuring an outer housing with interchangeable module slices, each with its own housing and current bar, input screw connections, and output push-in connections with spring elements, allowing for manual assembly and easy replacement of faulty modules using tongue and groove or dovetail fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a power distribution terminal uses a single integrated structure with multiple connectors, then the terminal provides complete power distribution functionality, but the entire terminal must be replaced if one connector is damaged
Solution Approach 1:
The power distribution terminal is divided into multiple independent module slices, each containing a subset of connectors (input and output connectors). Each module slice can be independently removed and replaced by detaching it from the housing, allowing repair of individual damaged connectors without replacing the entire terminal. This segmentation directly resolves the contradiction by improving repairability while maintaining system reliability through selective replacement.
2Ease of repair
If a power distribution terminal uses a modular design with interchangeable module slices, then individual faulty modules can be replaced without disrupting other modules, but the device structure becomes more complex
Solution Approach 1:
The terminal is segmented into standardized module slices with uniform attachment mechanisms (fasteners) that interface with the housing and adjacent slices. This segmentation enables easy replacement of individual modules while the standardized interface design minimizes the added structural complexity compared to a fully custom modular system.
Solution Approach 2:
The housing and module slices are designed with universal attachment features (fasteners, recesses, protrusions) that allow any module slice to be interchangeably mounted in various positions within the housing. This universality simplifies the overall structure by using repeated standardized components rather than unique connection mechanisms for each module, thereby reducing structural complexity while maintaining ease of repair.
3Reliability
If the terminal uses traditional screw connections for all connectors, then reliable electrical connections are achieved, but installation and modification require more time and effort
Solution Approach 1:
Different connector types are applied at different locations based on functional requirements: screw connections are used for input connectors where high reliability is critical, while push-in spring clip connections are used for output connectors where ease of installation and modification is prioritized. This local differentiation of connection qualities resolves the contradiction by optimizing each connection type for its specific operational context.
Solution Approach 2:
The connector design transitions from traditional screw-only connections to include push-in spring clip connections with modified mechanical parameters (spring force, clip geometry). This parameter change enables faster installation and modification (improving ease of operation) while maintaining sufficient electrical connection reliability through the spring mechanism's clamping force.
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
Enables the modular assembly of power distribution terminals, allowing for the replacement of individual faulty modules without disrupting the entire system, enhancing reliability and reducing maintenance costs by allowing for localized repairs.
Implementation Method 1
the spring elements of at least two output terminals have different cross-sections for receiving different conductors, respectively
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A modular power distribution terminal includes an outer housing containing a chamber and a bottom opening. The outer housing includes a top wall, a pair of spaced end walls and a pair of spaced parallel side walls having first fasteners. At least one module slice is arranged in the outer housing chamber and includes a slice housing including a pair of spaced parallel side walls having first fasteners configured for fastening with the first fasteners of one of the outer housing side walls and a current bar connected with and extending along a length of the slice housing. An input screw connection terminal and at least two output push-in connection terminals are connected with the current bar.