Modular Power Distribution Assembly With Tool-Less Plug-In Wiring
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Solution Overview
Problem
Existing power distribution systems in industrial control systems require extensive manufacturing and assembly time due to numerous electrical interconnections, which are prone to wiring errors and require tools for connection, complicating the installation process.
Innovation Solution
A modular power distribution device with a base featuring tool-less, snap-fit connections for a circuit protection device and an electronically actuated power distribution device, along with an electronic control module, allowing for plug-in interconnections without the need for tools, reducing the complexity of wiring and assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate mounting of circuit breaker and contactor on control panel is used, then flexibility in component selection is maintained, but the number of electrical interconnections increases significantly requiring extensive manufacturing and assembly time
Solution Approach 1:
The circuit breaker and contactor are merged into a single integrated module mounted on a common base. The circuit breaker is mounted on a first mounting section and the contactor on a second mounting section of the base, with electrical interconnections established through conductors that connect output connections of the circuit breaker to input connections of the contactor within the same module, thereby reducing the number of interconnections required between separate components.
Solution Approach 2:
The power distribution system is segmented into modular components including a base with mounting sections, circuit breaker module, contactor module, and electronic control module. Each component can be independently selected and mounted on the base, allowing flexibility in component selection while maintaining reduced interconnection requirements within the integrated module.
2Reliability
If multiple separate electrical interconnections are made between circuit breaker, contactor, and control circuits, then complete control and monitoring functionality is achieved, but wiring errors increase and assembly complexity increases
Solution Approach 1:
The circuit breaker, contactor, and electronic control module are combined into a single integrated power distribution module. The electronic control module receives control signals and feedback signals and establishes electrical interconnections with both the circuit breaker and contactor through conductors within the module, reducing wiring errors by minimizing the number of external connections required.
3Ease of operation
If tool-based electrical interconnections are used between components, then reliable electrical connections are established, but installation time increases and installation complexity increases
Solution Approach 1:
The electrical interconnections between the circuit breaker, contactor, and electronic control module are pre-established through conductors within the integrated module during manufacturing. This preliminary configuration of electrical connections eliminates the need for on-site wiring and tool-based connections during installation, significantly reducing installation time and complexity.
Data Source
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AI summary
A modular power distribution device includes a base that is snap-fit onto DIN rail. The base includes a first mounting section, configured to receive a circuit protection device, and a second mounting section configured to receive an electronically actuated power distribution device, The circuit protection device slides on to the first mounting section and includes multiple output connections. The power distribution device slides on to the second mounting section and includes multiple input connections configured to engage the output connections of the circuit protection device as the power distribution device slides on to the second mounting section. An electronic control module is snap-fit to the assembly establishing electrical connections between the electronic control module and both the circuit protection device and the power distribution device. The electronic control module includes a port by which control signals are received and feedback signals may be transmitted.