Modular SPD Plug Assembly for Series-Parallel Varistor Scaling
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Solution Overview
Problem
Existing surge protective devices (SPDs) face issues of low repeatability, low universality, long development cycles, and high costs due to separate designs for series and parallel connections of varistors, limiting their adaptability to varying voltage and current demands.
Innovation Solution
A modularized multi-form assembly-type SPD with box core modules that allow for flexible combinations of series and parallel connections using a unified voltage-limiting element, incorporating a tripping mechanism and indication device, enabling conversion between high working voltage and large lightning strike through-current while maintaining a consistent tripping mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate designs are used for series and parallel connections of varistors, then the SPD can handle different voltage and current requirements, but the repeatability, universality, and development efficiency deteriorate
Solution Approach 1:
The SPD is divided into independent modular units (first module and second module), each containing a voltage-limiting element with standardized terminals. These modules can be independently manufactured and then connected in series or parallel configurations to meet different voltage and current requirements, eliminating the need for separate design processes.
Solution Approach 2:
The modular design creates universal building blocks that can serve multiple functions. The same basic module design can be used in both series connections (for higher voltage applications) and parallel connections (for higher current applications), making the design universally applicable across different SPD specifications.
2Power
If multiple varistors are connected in series to handle high working voltage, then the voltage handling capability is improved, but the device complexity and development cost increase
Solution Approach 1:
The high voltage handling is achieved by segmenting the SPD into multiple modular units connected in series. Each module contains a voltage-limiting element rated for a portion of the total voltage, and the series connection of standardized modules achieves the required voltage rating without requiring a completely different design approach.
3Power
If multiple varistors are connected in parallel to handle large impulse current, then the current handling capability is improved, but the device complexity and development cost increase
Solution Approach 1:
The high current handling is achieved by segmenting the SPD into multiple modular units connected in parallel. Each module contains a voltage-limiting element capable of handling a portion of the total current, and the parallel connection of standardized modules achieves the required current rating without requiring a completely different design approach.
4Reliability
If separate designs are used for different connection states, then the performance requirements are met, but the manufacturing cost and part variety increase
Solution Approach 1:
The same modular components and voltage-limiting elements are used across all SPD configurations. The universal module design with standardized terminals and tripping mechanisms can be manufactured using the same processes, and then assembled into different series or parallel configurations to meet various performance requirements, reducing manufacturing cost and part variety.
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 solution provides a modular SPD that achieves adaptable voltage and current handling with consistent tripping behavior, reducing development time and costs, and enhancing market versatility.
Implementation Method 1
The tripping electrode of the voltage-limiting element and one end of the spring electrode are welded using a fusible alloy. The tripping mechanism acts on the spring electrode. The tripping mechanism always separates the tripping electrode from the spring electrode when the fusible alloy is melted.
Data Source
AI summary
A box core module, a plug module, and a surge protective device (SPD) are provided. The plug module includes a housing, bottom plates, a plurality of box core modules with an independent tripping mechanism, a first pin electrode, and a second pin electrode. The plurality of box core modules are vertically arranged on a side of the bottom plates in a side-by-side or opposite manner, and the plurality of box core modules are connected by an internal connection electrode to form a series and/or parallel combined line. The combined line is led out through the first pin electrode and the second pin electrode. The plug module is combined with a base. A modularized multi-form assembly-type SPD is provided. Mutual conversion between a high working voltage of the SPD and a large lightning strike through-current is achieved when the same voltage-limiting element is used and an overall tripping mode remains unchanged.