Reactor Electrical Shock Prevention Cover with Movable Cable Guide
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Solution Overview
Problem
Existing reactors do not effectively prevent electrical shocks from current-carrying portions, particularly when cables of varying thicknesses are connected, as standard thickness requirements can allow thinner cables to expose these portions, posing a risk of contact.
Innovation Solution
A reactor design featuring a core body with magnetically connectable iron cores and coils, a terminal base with detachable plates or elastically deformable attachments to cover openings, and an electrical shock prevention cover that adjusts to cable thickness, ensuring finger protection regardless of cable size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical shock prevention cover is designed to cover the terminal base completely, then protection against electrical shock is improved, but cables cannot be connected to the terminal base
Solution Approach 1:
The electrical shock prevention cover is divided into multiple parts: a main cover body and a movable cable guide portion. The cable guide portion can be moved to different positions to accommodate cables of different thicknesses, allowing both protection and cable connection functions to be achieved simultaneously.
Solution Approach 2:
The cable guide portion is designed to be movable rather than fixed. It can be adjusted to different positions depending on the cable thickness, transforming the static cover into a dynamic structure that adapts to different operational requirements.
2Ease of operation
If the cover is cut away to allow cable passage, then cable connection is enabled, but gaps are formed that allow finger contact with current carrying portions
Solution Approach 1:
The cable guide portion acts as an intermediary element between the cover body and the terminal base. It fills the gap created by the cable passage and prevents finger contact with current carrying portions, while still allowing the cable to pass through.
Solution Approach 2:
The cable guide portion is specifically designed to fit around the cable and block access to current carrying portions only in the necessary areas, while maintaining overall cover protection. The local intervention preserves both cable access and safety.
3Adaptability or versatility
If the cover design is made to accommodate different cable thicknesses, then versatility is improved, but the structure becomes more complex
Solution Approach 1:
Instead of creating multiple static cover variants for different cable sizes, a single dynamic cover design is used where the cable guide portion can be moved to accommodate different cable thicknesses, reducing overall structural complexity.
Solution Approach 2:
The movable cable guide portion serves multiple functions: it guides cables of different thicknesses, maintains the protective barrier, and prevents finger contact. This single component performs what would otherwise require multiple different cover designs.
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
The solution effectively prevents finger contact with current-carrying portions across different cable thicknesses, conforming to protection standards like IP2X, ensuring safety regardless of cable thickness.
Implementation Method 1
a gap is formed between one of the iron cores and another of the iron cores adjacent to the one of the iron cores, so as to be magnetically connectable through the gap
Data Source
AI summary
A reactor includes a core body including an outer peripheral iron core, at least three iron cores contacting to an internal surface of the outer peripheral iron core, and coils wound on the iron cores. A gap is formed between one and another of the iron cores adjacent each other, so as to be magnetically connectable therethrough. The reactor has a terminal base connected to cables through current carrying portions, as well as connected to the coils, and an electrical shock prevention cover for covering the terminal base. The electrical shock prevention cover has openings for passing the cables connected to the terminals therethrough. The terminal base has a plate that blocks at least a part of each opening to prevent a finger from touching the current carrying portion while the cables are connected to the terminals and which is detachable in accordance with the thickness of the cables.