Modular Power Factor Correction Assembly with Integrated Busbars
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Solution Overview
Problem
Existing reactive power compensation systems are bulky, heavy, and require significant assembly effort due to numerous discrete components, leading to high weight, size, and cost, with inadequate safety monitoring and complex wiring.
Innovation Solution
A modular arrangement integrating busbar systems, safety elements, switching devices, chokes, and capacitors with self-healing windings and temperature fuses, allowing for compact, back-to-back assembly and solder-free connections using spring-loaded contacts, with chokes and power electronics integrated for efficient reactive power compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete components (busbar supports, busbars, fuse elements, switching devices, chokes, capacitors) are assembled into compensation modules, then the system can be constructed with standard components, but the total weight and dimensions become considerable
Solution Approach 1:
The patent combines multiple discrete components (busbar supports, busbars, fuse elements, switching devices, chokes, and capacitors) into an integrated module assembly where components are mounted directly on capacitor housings and choke cores, eliminating the need for separate busbar supports and chassis, thereby reducing overall weight while maintaining modular assembly benefits
Solution Approach 2:
The capacitor housing serves multiple functions: it encloses the capacitor winding, provides mounting surface for switching devices and fuse holders, and acts as structural support element, replacing the need for separate busbar supports and chassis components, thus reducing weight while maintaining ease of manufacture
2Ease of manufacture
If discrete components are assembled into compensation modules, then the system can be constructed with standard components, but the dimensions and volume increase
Solution Approach 1:
The patent nests switching devices, fuse holders, and other components directly on or within the capacitor housing and choke core structures, allowing components to occupy the same spatial envelope rather than requiring separate mounting space, thereby reducing overall module volume while maintaining modular assembly capability
Solution Approach 2:
The patent utilizes the three-dimensional space around and within existing components by mounting switching devices on capacitor housings and using choke cores as mounting surfaces, effectively utilizing vertical and lateral dimensions rather than requiring additional horizontal space, thus reducing module volume
3Ease of manufacture
If individual assembly and discrete wiring are performed, then the system can be constructed with standard components, but the assembly effort becomes high
Solution Approach 1:
The patent pre-integrates switching devices, fuse holders, and wiring into the module assembly during manufacturing, so that when modules are installed, they are already pre-assembled and pre-wired units requiring minimal on-site assembly, thereby maintaining standard component benefits while dramatically reducing assembly effort
Solution Approach 2:
The patent combines multiple assembly steps into a single integrated module manufacturing process, where busbars, fuse elements, switching devices, and capacitors are assembled together as one unit, eliminating the need for separate assembly of each component and reducing overall assembly effort and time
4Reliability
If more components are used for safety monitoring, then system safety improves, but device complexity increases
Solution Approach 1:
The patent integrates temperature monitoring functionality into existing components such as the capacitor housing and choke cores, allowing these components to serve both their primary functions and safety monitoring functions simultaneously, thereby improving safety without significantly increasing device complexity
Solution Approach 2:
The patent combines safety monitoring functions with existing structural components, where the capacitor housing and choke cores serve dual purposes as both functional elements and safety monitoring platforms, reducing the need for separate monitoring devices and keeping system complexity manageable
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 design results in smaller, lighter, safer, and more manageable systems with reduced assembly complexity, enhanced safety through comprehensive temperature monitoring, and cost-effective production while maintaining high performance and planning security.
Implementation Method 1
with several temperature fuses distributed over the longitudinal axes of the winding core tubes so that the critical areas of each two windings are monitored by a temperature fuse
Implementation Method 2
using a new type of spring-loaded contact using a resilient material
Implementation Method 3
reactive power compensation filter and absorption circuit systems
Implementation Method 4
power capacitors divided in the power
Data Source
Figure 1
Figure 2
Figure 3.4
AI summary
The invention relates to a module assembly for the application-specific construction of power factor correction systems, filter systems, and absorption circuit systems in selectively non-choked, choked, protective or thyristor-connected design, comprising a busbar system, fuse holders, switch components, at least one choke, and power capacitors. According to the invention, a first module unit is provided, comprising a first section for receiving busbars, standard fuse holders, fuses, a busbar cover as protection against accidental contact with the busbar and/or fuses, and a second, trough-like section for receiving switch components or switch means such that they can be mechanically fixed and electrically contacted. A second module unit is designed to receive one or more in particular switchable capacitor winding blocks, wherein the second module unit encloses the at least one winding block, insulating the same. The first and the second module unit each have a base region, wherein mechanical and/or electrical connections are led via apertures or openings in the respective base regions, such that either a back-to-back assembly with direct docking of the first and second module units can be effected, or a compact choke set with connecting elements can be mechanically received in an electrically insulated manner between the first and second module units using the apertures or openings in the respective base region of the first or second module unit, and can be electrically connected.