Plug-in Circuit Breaker Assembly with Removable Plate
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Solution Overview
Problem
Current circuit breaker assemblies are cumbersome and time-consuming to maintain, requiring extensive hardware and wiring, which complicates access and increases the risk of errors and reduced efficiency in high-density aircraft electrical systems.
Innovation Solution
A circuit breaker assembly featuring a plug-in design with a housing, electrical bus structure, and a removable plate member that eliminates the need for threaded connections and external wiring, allowing for quick installation and removal of circuit breakers without additional hardware, using a thermally conductive thermoplastic and epoxy-based structural tape for bonding and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional threaded bezel and nut-washer fasteners are used to mount circuit breakers, then secure mounting is achieved, but maintenance time and complexity increase significantly
Solution Approach 1:
The circuit breaker assembly is segmented into modular components: the circuit breaker unit, the electrical bus structure with integrated plug-in members, and the plate member with apertures. This segmentation allows the circuit breaker to be quickly removed and replaced without dealing with threaded connections and external fasteners, directly reducing maintenance time and hardware complexity.
Solution Approach 2:
The plug-in members are merged into the electrical bus structure, eliminating the need for separate threaded bezels and nut-washer fasteners. The plate member integrates the apertures and positioning features directly into its structure, combining multiple functions (mounting, alignment, and retention) into a single component, thereby reducing the overall hardware complexity.
2Reliability
If extensive external wiring and threaded connections are used, then reliable electrical connection is achieved, but error risk and maintenance difficulty increase
Solution Approach 1:
The electrical connections are pre-configured through the integrated plug-in members that are permanently attached to the electrical bus structure. The circuit breaker's plug-in member is designed to mate with these pre-positioned contacts, ensuring reliable electrical connection while eliminating the need for on-site wiring and connection adjustments during maintenance, thereby reducing error risk and simplifying repair procedures.
Solution Approach 2:
The complex external wiring and threaded connection system is extracted and replaced with a simplified plug-in interface. The essential electrical connection function is retained through the integrated plug-in members, while the cumbersome external wiring and fastening hardware are removed, making maintenance easier and reducing error potential.
3Area of stationary object
If high-density circuit breaker layout is implemented, then space efficiency is improved, but access and maintenance become more difficult
Solution Approach 1:
The high-density layout is achieved through segmented, modular circuit breaker units that can be tightly packed. The plate member with its array of apertures provides uniform access points for each circuit breaker's manual operator, ensuring that even in a compact arrangement, each component remains individually accessible for operation and maintenance without requiring disassembly of neighboring units.
Data Source
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AI summary
A circuit breaker assembly includes a housing, an electrical bus structure coupled to the housing, and a number of first plug-in members coupled to the electrical bus structure. A number of circuit breakers include a first surface and a second plug-in member disposed opposite the first surface. The second plug-in member of each of the number of circuit breakers is mated with a corresponding one of the number of first plug-in members. A plate member is removably coupled to the housing. The plate member includes a first surface and an opposite second surface. The first surface of the number of circuit breakers engages the opposite second surface of the plate member in order to maintain mating of each of the number of circuit breakers with the corresponding one of the number of first plug-in members.