Modular Power Panel with Bullet-Nosed Connectors
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Solution Overview
Problem
Existing power distribution panels have complex wiring arrangements and time-consuming screw-type mounting for circuit protection elements, making installation, replacement, and component exchange difficult.
Innovation Solution
A modular power distribution panel design with bullet-nosed connectors and a chassis featuring slots for interchangeable circuit modules, reducing wiring requirements and allowing for customizable functionality with bullet-nosed connectors and output terminals for simplified connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw-type mounting is used for circuit protection elements, then secure mechanical connection is achieved, but installation and replacement become time-consuming
Solution Approach 1:
The circuit protection element is divided into separate modular components: a removable circuit protection device and a mounting structure with bullet-nosed connectors. This segmentation allows the circuit protection element to be quickly inserted and removed without screw-type fastening, reducing installation and replacement time while maintaining secure electrical connection through the bullet-nosed connector design.
Solution Approach 2:
The traditional screw-type mechanical fastening system is replaced with a bullet-nosed connector system that uses insertion and engagement mechanics. The bullet-nosed shape provides self-centering and secure mechanical connection without requiring threaded fasteners, thereby eliminating the time-consuming screw tightening process while maintaining connection strength.
2Reliability
If complex wiring arrangements are used to interconnect circuit protection elements and terminals, then complete electrical connectivity is achieved, but installation and component exchange become difficult
Solution Approach 1:
The circuit protection element, input connector, and output terminal are merged into a single integrated circuit module. This consolidation eliminates the need for separate wiring connections between these components, as they are pre-connected within the module. The module simply needs to be inserted into the chassis slot, providing complete electrical connectivity while greatly simplifying installation and component exchange.
Solution Approach 2:
The circuit module design provides universal connectivity through standardized bullet-nosed connectors that interface with the chassis connection apertures. This universal interface design allows the same module type to be easily replaced or upgraded without modifying the wiring infrastructure, maintaining electrical connectivity while improving ease of operation for installation and maintenance.
3Strength
If specific mounting sizes and layouts are used in power panels, then structural integrity is maintained, but component exchange becomes difficult
Solution Approach 1:
The circuit protection element is segmented into a removable module that interfaces with the panel through standardized connection apertures. This segmentation allows the circuit protection device to be exchanged independently without affecting the panel's structural integrity, as the module simply engages with pre-formed connection points rather than requiring custom mounting configurations.
Solution Approach 2:
The connector design uses bullet-nosed geometry with specific dimensional parameters that provide both secure mechanical engagement and ease of insertion/removal. The parameters of the bullet-nosed connector and corresponding aperture are designed to maintain structural integrity during operation while allowing simple component exchange by changing the insertion and engagement parameters.
Data Source
AI summary
A power panel and modules for use in a power panel are disclosed. One disclosed chassis includes a top, a bottom, a front, a rear, and left and right sides, and an input power bus having a plurality of connection apertures therethrough. A plurality of circuit modules are mounted within the chassis. Each circuit module includes a circuit protection element including first and second bullet-nosed connectors, and a body element having first and second holes positioned to receive the first and second bullet-nosed connectors. The body element includes a bullet-nosed input connector sized to be received by one of the plurality of connection apertures. Each circuit element also includes an output terminal extending rearwardly from the body element.