Modular Power Distributor with Resistor Chain Addressing
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Solution Overview
Problem
Conventional power distributors are labor-intensive to assemble and navigate due to single wiring, making repairs and changes disadvantageous, and lack efficient addressing and fault detection in modular designs.
Innovation Solution
A modular power distributor with serially connected modules on a supporting rail, featuring a resistor chain for addressing and fault detection, where each module has a circuit breaker that interrupts loads in case of overload or short-circuit, and internal controllers for voltage monitoring and communication, allowing for flexible configuration and low wiring costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single wiring is used to connect circuit breakers to power supply and load, then the power distributor can be assembled, but the assembly becomes labor intensive and the switching system becomes hard to navigate for repairs and changes
Solution Approach 1:
The power distributor is divided into modular units, each containing a circuit breaker, terminals, and housing. This segmentation allows for easier assembly and replacement of individual modules without affecting the entire system, directly addressing the labor-intensive assembly issue while maintaining navigability through standardized module interfaces.
Solution Approach 2:
A bus bar is introduced as an intermediary component to connect multiple circuit breakers in parallel. This eliminates the need for complex single wiring connections between each circuit breaker, power supply, and load, thereby simplifying both assembly and future repairs while maintaining electrical connectivity.
2Ease of manufacture
If modular power distribution modules are used with conductor rails, then wiring costs are reduced, but the system lacks efficient addressing and fault detection capabilities
Solution Approach 1:
Testing means are integrated into each modular power distribution unit to provide feedback on the operational status of circuit breakers and electrical connections. This feedback mechanism enables efficient fault detection and diagnosis without requiring complex external testing equipment, thereby maintaining the wiring cost advantages of modular design while adding diagnostic capability.
Solution Approach 2:
The modular units are designed with multi-functionality, combining power distribution, circuit protection, and diagnostic testing capabilities within a single standardized module. This universality allows the same module type to serve multiple functions across the entire power distributor system, reducing wiring complexity while enabling comprehensive fault detection through integrated testing features.
3Adaptability or versatility
If circuit breakers are inserted into modular slots, then the power distributor becomes more flexible and adaptable, but address allocation becomes complex when empty slots exist
Solution Approach 1:
The system employs self-addressing circuit breakers that automatically determine their own address based on their physical position in the modular configuration. This self-service addressing mechanism eliminates the need for manual address assignment and automatically adapts to changes in module configuration, including the addition or removal of modules, thereby maintaining configuration flexibility while simplifying addressing to a basic level.
Data Source
AI summary
A power distributor having a first controller and having a number of connection modules which are connected thereto and are intended to be mounted on a supporting rail. The connection module has a number of lateral coupling contacts for the electrical and/or signalling contact connection to at least one further connection module which is attached or can be attached to the particular connection module, wherein a base resistor is connected in each case between two coupling contacts inside the module in such a manner that the base resistors of the attached connection modules form a resistor chain which is connected in series. The connection modules are each equipped or can be equipped with an actuatable circuit breaker. The circuit breakers have a second controller inside the circuit breaker for recording a voltage dropped across the respectively associated base resistor.