Portable 400 Hz Power Distribution Unit with Foot-Hold Housing
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Solution Overview
Problem
Current power distribution solutions for 400 Hz power, such as the W-5 connector, lack a circuit breaker or current-limiting device and are difficult to use, especially in harsh environments, due to high connection forces and small, hard-to-grasp connectors, which are inadequate for safely and efficiently distributing high wattage power to lower power test adapter units like CMBRE systems.
Innovation Solution
A portable power distribution unit with a structurally rigid housing, a 400 Hz power connector, and a circuit breaker to securely connect and convert high wattage 3-phase power from mobile generators to low power equipment, featuring a step portion for secure footing and a 30 amp circuit breaker between the high wattage 3-phase and low wattage power receptacles, facilitating safe and easy power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple cable pigtail with W-5 connector is used to connect power supply to test adapter unit, then the device complexity is reduced, but the safety is compromised due to lack of circuit breaker or current-limiting device
Solution Approach 1:
The patent combines the connector and circuit breaker into a single integrated power distribution unit. The housing contains both the W-5 connector for 400 Hz power connection and a circuit breaker with test adapter unit connections, merging previously separate components into one unified device that provides both connectivity and protection.
Solution Approach 2:
The circuit breaker acts as an intermediary protective device between the high-power 400 Hz supply and the low-power test adapter unit. It mediates the power flow, providing current limiting and protection while allowing the simple connector to maintain electrical connection functionality.
2Adaptability or versatility
If a standard 400 Hz connector is used for power connection, then the adaptability to existing power systems is improved, but the ease of operation deteriorates due to high connection force and small, difficult to grasp connector
Solution Approach 1:
The patent adds a mechanical dimension to the connection process by incorporating a handle that extends from the housing. This handle provides a larger grasping surface and mechanical leverage, transforming the connection operation from a difficult direct connector manipulation to an easier handle-based operation while maintaining the standard W-5 connector for electrical compatibility.
3Reliability
If high connection force is used to make proper electrical connection, then the reliability of electrical connection is improved, but the ease of operation worsens due to difficulty in connection and disconnection
Solution Approach 1:
The handle functions as a mechanical lever that provides counterbalancing force to overcome the high connection force required by the W-5 connector. By applying force to the handle rather than directly to the connector, operators gain mechanical advantage that reduces the perceived effort while maintaining the necessary connection force for reliable electrical contact.
Data Source
AI summary
A portable power distribution unit for safely distributing high wattage power supplied from mobile generators to lower power test adapter units and systems. Embodiments disclosed include a structurally rigid housing shaped to facilitate secure holding by an operator's foot, a 400 Hz power connector adapted for connection to a mobile power generator, a circuit breaker matched to the rating of the system to be powered and connections for conversion of the six-pin output from the mobile generator to a three or four-pin input for the system to be powered.