High-Current Power Switch Welded Busbar Connections
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Solution Overview
Problem
Existing high-current circuit breakers face limitations in current-carrying capacity due to temperature constraints at screw connections, which affect mechanical stability and efficiency.
Innovation Solution
The use of welded connections between busbars and contacts, specifically electron beam welding, creates non-positive and material-locking areas, eliminating the need for screw connections and enhancing mechanical stability and current-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If screw connections are used to connect busbars and contacts, then the assembly is mechanically stable, but the temperature at connection points rises excessively (65-75 degrees Kelvin above ambient), limiting current-carrying capacity
Solution Approach 1:
The patent replaces the mechanical screw connection system with a welding system. Instead of using screws to create electrical and mechanical connections between busbars and contacts, the invention employs welding processes that fuse the components together, eliminating the mechanical fastening system and its associated temperature rise problems while maintaining both electrical conductivity and mechanical strength
Solution Approach 2:
The invention changes the fundamental connection parameter from mechanical fastening (screws) to thermal bonding (welding). This parameter change transforms the connection method, allowing for lower operating temperatures at connection points while maintaining or improving current-carrying capacity through the creation of non-positive, material-locking connection areas
2Reliability
If welded connections are used between busbars and contacts, then current-carrying capacity increases and temperature is controlled, but manufacturing complexity increases due to welding requirements
Solution Approach 1:
The patent replaces the mechanical screw connection system with a welding system. Instead of using screws to create electrical and mechanical connections between busbars and contacts, the invention employs welding processes that fuse the components together, eliminating the mechanical fastening system and its associated temperature rise problems while maintaining both electrical conductivity and mechanical strength
Solution Approach 2:
The invention changes the fundamental connection parameter from mechanical fastening (screws) to thermal bonding (welding). This parameter change transforms the connection method, allowing for lower operating temperatures at connection points while maintaining or improving current-carrying capacity through the creation of non-positive, material-locking connection areas
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 solution significantly increases the circuit breaker's current-carrying capacity by maintaining mechanical stability and controlling temperature within safe limits, thereby improving overall performance.
Implementation Method 1
the connection means are electron beam welded
Implementation Method 2
the first connection means are welded to the first busbar and the fixed contact, and the second connection means are welded to the second busbar and the moving contact
Data Source
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AI summary
The invention relates to a power switch, especially a high-current switch, comprising at least one pole unit (2) with a pole head (3) and a pole base (4) and a vacuum switching tube (5) interposed therebetween, said vacuum switching tube having a stationary contact (12) and a mobile contact (8, 20), the stationary contact (12) being connected to a first conductor rail (6) of the pole unit (2) via a first connecting element (13) and the mobile contact (8) being connected to a second conductor rail (7) of the pole unit (2) via a second connecting element (11). The aim of the invention is to provide a power switch of the aforementioned type which has a higher current carrying capacity. For this purpose, the first connecting element (13) is welded to the first conductor rail (6) and the stationary contact (12) and the second connecting element (11) is welded to the second conductor rail (7) and the mobile contact (8, 20).