Plug-In Summation Current Transformer Assembly for Easier DIN Rail Mounting
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Solution Overview
Problem
The assembly of summation current transformers in multi-pole residual current circuit breakers is complex due to the need to manually thread thick primary conductors through a ring-shaped magnetic core, especially in compact devices with limited installation space.
Innovation Solution
A plug-in summation current transformer assembly with a tubular design and a primary conductor holder that moves between fixing and release positions, allowing pre-assembly of conductors outside the housing and simplified insertion into a cross-module installation space, avoiding collisions with connection contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual threading of thick primary conductors through a ring-shaped magnetic core is used, then the summation current transformer can be assembled, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The primary conductors are pre-threaded through the tubular summation current transformer core during manufacturing, creating a pre-assembled unit. This preliminary action eliminates the need for manual threading during installation, directly resolving the contradiction by simplifying the assembly process while maintaining the required magnetic core structure
Solution Approach 2:
The device is divided into modular components: the summation current transformer assembly (with pre-installed conductors) and the housing. This segmentation allows the complex conductor-threading operation to be performed separately during manufacturing, then the complete assembly is installed as a single unit, reducing on-site assembly complexity
2Volume of moving object
If compact device design is used, then space is saved, but the installation space becomes limited making manual threading difficult
Solution Approach 1:
The conductors are pre-positioned through the core during manufacturing, transforming a difficult installation operation into a simple plug-in action. This allows the device to maintain compact dimensions while preserving installation ease, as the time-consuming threading operation is performed beforehand when access is not constrained
3Productivity
If pre-assembly of conductors outside the housing is allowed, then assembly time is reduced, but additional handling steps are required
Solution Approach 1:
The conductor threading, magnetic core assembly, and transformer winding operations are merged into a single integrated manufacturing process. The conductors are threaded through the core and simultaneously prepared for connection, combining multiple discrete steps into one efficient operation that increases productivity without adding complexity
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
This design significantly simplifies the assembly process by allowing pre-assembly of primary conductors and automatic positioning, reducing manual effort and increasing efficiency in compact devices.
Implementation Method 1
a tubular summation current transformer and at least one first and one second primary conductor, which are each passed through the tubular summation current transformer at least once
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The plug-in summation current transformer assembly (100) according to the invention for insertion into a module-spanning installation space (9) of a multi-pole DIN rail mounting device (1) formed from several housing modules (11, 12, 13, 14) has a summation current transformer (101) and at least one first and one second primary conductor (110, 120, 130, 140), which are each passed at least once through the tubular summation current transformer (101) and each have a first and a second primary conductor end (111, 112, 121, 122, 131, 132, 141, 142).Furthermore, the plug-in summation current transformer assembly (100) has a primary conductor holder (102) attached to the summation current transformer (101), which is movable between a fixing position and a release position and is designed to fix the first and second primary conductor ends (111, 112, 121, 122, 131, 132, 141, 142), and which is designed to hold the first and second primary conductor ends (111, 112, 121, 122, 131, 132, 141, 142) in their respective mounting positions in the fixing position during insertion into the module-spanning installation space (9), and to release the first and second primary conductor ends (111, 112, 121, 122, 131, 132, 141, 142) after insertion by moving them into the release position. to be moved into a respective joining position. The modular design and the insertion of the large-volume plug-in summing current transformer assembly (100) into the cross-module installation space (9) significantly simplifies the assembly effort.