Rail-Mounted Connection Device with Integrated Current Sensor
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Solution Overview
Problem
The installation of current measurement sensors between two modular devices on a rail-type fixing member is hindered by space constraints and safety issues due to the presence of supply conductors and pre-existing devices, making it difficult to add additional devices without compromising electrical insulation.
Innovation Solution
A connection device with conductive tabs spaced apart by the pitch of a bridging bar, incorporating a current sensor and an insulating separating member that replaces a portion of the bridging bar, ensuring electrical insulation and minimal space usage, while allowing for reliable measurement of electrical parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a current measurement sensor is installed between two modular devices on a rail, then electrical parameter measurement capability is improved, but space availability deteriorates due to presence of supply conductors and pre-existing devices
Solution Approach 1:
The connection device merges multiple functions into a single integrated component: it provides electrical connection through conductive tabs, incorporates a current measurement sensor, and includes an insulating separating member. This consolidation allows the device to perform measurement functions without requiring separate dedicated space for a standalone sensor, thus resolving the space constraint while enabling electrical parameter measurement.
Solution Approach 2:
The connection device is designed as a multi-functional element that serves both as an electrical connector and a measurement point. The conductive tabs establish electrical connections while the integrated sensor measures current, and the insulating member provides separation. This multi-functionality allows the same component to fulfill multiple roles, eliminating the need for additional dedicated measurement devices that would consume valuable installation space.
2Measurement precision
If a current measurement sensor is installed between two modular devices on a rail, then electrical parameter measurement capability is improved, but electrical insulation safety deteriorates due to reduced clearance and presence of conductors
Solution Approach 1:
The insulating separating member acts as an intermediary element positioned between conductive parts and other conductors or grounded surfaces. This mediator provides the necessary electrical insulation and maintains safe clearances, allowing the current sensor to be installed in the limited space between modular devices without compromising electrical insulation safety or creating harmful electrical contacts.
Solution Approach 2:
The connection device applies insulation locally where needed through the insulating separating member, rather than requiring uniform insulation throughout the entire installation space. This localized approach to insulation provides targeted protection around the sensor and conductive tabs, ensuring electrical safety in the specific high-risk areas while maximizing the use of available space for measurement functionality.
3Adaptability or versatility
If the spar of the bridging bar is cut to insert the connection device, then integration of measurement function is improved, but connection reliability deteriorates due to severed bridging bar
Solution Approach 1:
The solution extracts only the specific portion of the spar that would interfere with the insertion of the connection device, rather than removing or damaging the entire bridging bar. By selectively removing only the necessary segment and positioning the connection device with its insulating separating member, the integrity of the remaining bridging bar structure is preserved, maintaining connection reliability while enabling measurement function integration.
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
Enables reliable measurement of electrical parameters, respects existing connections, ensures IP2X electrical insulation, and integrates seamlessly into the existing environment without occupying excessive space, ensuring safe and effective installation.
Implementation Method 1
a current sensor designed to measure the current flowing from one tab to the other
Data Source
Figure 1~2
Figure 3~4
AI summary
Electrical connection device for two electrical devices, for example modular devices (20, 21), mounted side-by-side on a rail-type mounting element allowing their arrangement in a row, said devices (20, 21) each having at least one upstream power supply connection terminal block capable of connecting at least one power supply conductor to a terminal of the device, at least one power supply conductor originating from a jumper bar consisting of a longitudinal member (3, 3') connected to a phase or neutral and rigid strips (6) spaced at a predetermined regular interval p, said strips (6) being designed to be individually connected to the terminal (9) of a device (20, 21) via one of said terminal blocks, the connection device comprising two electrically connected conductive tabs (5, 5') spaced at said interval p and a current sensor (11) designed to measure the current flowing from a tab (5, 5') to the other (5', 5).This device includes an electrically insulating separating element (2) positioned so that it takes the place of a portion of a longitudinal member between two successive slats (6) when the tabs (5, 5') are inserted into two adjacent terminal blocks of joined electrical devices (20, 21).